MacDon D1X Series Unloading And Assembly Instructions
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MacDon D1X Series Unloading And Assembly Instructions

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D1X and D1XL Series
Draper Header
Unloading and Assembly Instructions (North America)
215489 Revision A
Original Instruction
The Harvesting Specialists.

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  • Page 1 D1X and D1XL Series Draper Header Unloading and Assembly Instructions (North America) 215489 Revision A Original Instruction The Harvesting Specialists.
  • Page 2 © 2021 MacDon Industries, Ltd. The information in this publication is based on the information available and in effect at the time of printing. MacDon Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the...
  • Page 3 Introduction This instruction manual describes the unloading, setup, and predelivery requirements for MacDon D1X and D1XL Series Draper Headers for M1 Series Windrowers. NOTE: Confirm the windrower is equipped with a draper-ready header drive BEFORE connecting to the header: • All M1170 header drives are draper-ready.
  • Page 4 Summary of Changes At MacDon, we’re continuously making improvements, and occasionally these improvements affect product documentation. The following list provides an account of major changes from the previous version of this document. Section Summary of Change Internal Use Only Engineering 2.1 Unloading Header from...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction ..............................i Summary of Changes............................ ii Chapter 1: Safety ............................1 1.1 Signal Words ............................1 1.2 General Safety ............................2 1.3 Welding Precaution ..........................4 1.4 Safety Signs ............................5 Chapter 2: Unloading the Header ......................7 2.1 Unloading Header from Trailer........................7 2.2 Lowering Header to Field Position ......................9 2.2.1 Lowering Single-Reel Header......................9 2.2.2 Lowering Double-Reel Header ......................
  • Page 6 TABLE OF CONTENTS 6.5.2 Centering Single Reel ........................65 6.6 Reel Clearance to Cutterbar........................67 6.6.1 Measuring Reel Clearance ......................67 6.6.2 Adjusting Reel Clearance ....................... 69 6.7 Checking and Adjusting Draper Tension ....................71 6.8 Checking and Adjusting Draper Seal ......................73 6.9 Checking and Adjusting Skid Shoe Settings ....................

  • Page 7: Chapter 1: Safety

    Chapter 1: Safety Understanding and following safety procedures consistently will help to ensure the safety of machine operators and bystanders. 1.1 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words, IMPORTANT and NOTE, identify non-safety related information.

  • Page 8: General Safety

    SAFETY 1.2 General Safety Protect yourself when assembling, operating, and servicing machinery. CAUTION The following general farm safety precautions should be part of your operating procedure for all types of machinery. Wear all protective clothing and personal safety devices that could be necessary for the job at hand.
  • Page 9 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. •...

  • Page 10: Welding Precaution

    SAFETY 1.3 Welding Precaution To prevent damage to sensitive electronics, welding should never be attempted on the header while it is connected to a windrower. WARNING Severe damage to sensitive, expensive electronics can result from welding on the header while it is connected to the windrower.

  • Page 11: Safety Signs

    SAFETY 1.4 Safety Signs Safety signs are usually yellow decals placed on the machine where there is a risk of personal injury, or where the operator has to take extra precautions before operating controls. Operator manuals and technical manuals identify the location and meaning of all safety signs placed on the machine.

  • Page 13: Chapter 2: Unloading The Header

    Chapter 2: Unloading the Header Perform all procedures in this chapter in the order they are listed. 2.1 Unloading Header from Trailer In North America, headers are shipped on flat bed trailers. Following instructions carefully will help ensure headers make it from the trailer to the assembly area safely..
  • Page 14 UNLOADING THE HEADER 4. For D1XL: Approach one of the headers and slide forks (A) through four forklift brackets (B) underneath the shipping support, as far as possible without contacting the shipping support of second header (C). IMPORTANT: Avoid lifting the second header and ensure the forks do NOT interfere with the shipping frame.

  • Page 15: Lowering Header To Field Position

    UNLOADING THE HEADER 2.2 Lowering Header to Field Position The procedure for lowering the header varies depending on whether the header has a single or double reel. To lower the header, refer to the procedure according to the type of header: •...
  • Page 16 UNLOADING THE HEADER CAUTION Stand clear when lowering, as machine may swing. 3. Back up SLOWLY while lowering the forks until the header is just above the ground. Refer to the four positions in the illustration. Figure 2.4: Lowering the Header 215489 Revision A...
  • Page 17 UNLOADING THE HEADER 4. Place 150 mm (6 in.) blocks (A) under each end and at the center of the cutterbar, then lower the header onto the blocks. 5. Remove the chain and move the lifting vehicle to the rear of the header.

  • Page 18: Lowering Double-Reel Header

    UNLOADING THE HEADER 7. Lower the header stand by pulling pin (A), lowering stand (B), and releasing pin (A) to secure the stand in place. 8. If the ground is soft, place a block under the stand. 9. Lower the header onto the stand. Figure 2.7: Header Stand 2.2.2 Lowering Double-Reel Header Lower the header to field position to prepare it for assembly and setup.
  • Page 19 UNLOADING THE HEADER CAUTION Stand clear when lowering, as machine may swing. 3. Back up SLOWLY while lowering the forks until the header is just above the ground. Refer to the four positions in the illustration. Figure 2.10: Lowering the Header 215489 Revision A...
  • Page 20 UNLOADING THE HEADER 4. Place 150 mm (6 in.) blocks (A) under each end and at the center of the cutterbar, and then lower the header onto the blocks. 5. Remove the chain and move the lifting vehicle to the rear of the header.
  • Page 21 UNLOADING THE HEADER 7. Lower the header stand: pull pin (A), lower stand (B), and release pin (A) to secure the stand in place. 8. If the ground is soft, place a block under the stand. 9. Lower the header onto the stand. 10.

  • Page 22: Removing Shipping Supports

    UNLOADING THE HEADER 2.3 Removing Shipping Supports Shipping supports must be removed to prepare the header for assembly. NOTE: Unless otherwise specified, discard all shipping materials and hardware. 1. Cut the straps and remove draper header supports (A) from the shipping support. Set the draper header supports aside for installation.
  • Page 23 UNLOADING THE HEADER 4. Remove the bolts from locations (A) securing lower support (B) to the header legs. Remove support (B). Figure 2.17: Lower Support 5. Remove four bolts (A) from the shipping stands at both outboard header legs and remove the shipping stands. Figure 2.18: Outer Leg Shipping Support for D115X, D120X, and D125X Figure 2.19: Outer Leg Shipping Support for D130XL,...
  • Page 24 UNLOADING THE HEADER 6. Remove reel anti-rotation brace (A) from between the reel and endsheet. Figure 2.20: Anti-Rotation Brace 7. At the left side of the header, cut and remove wire (A) securing the endshield to the panel. Repeat at the opposite side.

  • Page 25: Chapter 3: Adding Ballast

    Table 3.1, page 19 lists the number of counterweight kits required for each D1XL and D1X Series configuration. Install them according to the instructions supplied with each kit BEFORE attaching the header to the windrower. Table 3.1 Available Ballast Kits for Different Header Types and Configurations...
  • Page 26 ADDING BALLAST Table 3.1 Available Ballast Kits for Different Header Types and Configurations (continued) Initial Rear Additional Rear Header Type Description Header Configuration Ballast Kit Ballast Kits 13.7 m (45 ft.) double reel, D145XL Transport double knife, untimed Transport, 13.7 m (45 ft.) double reel, D145XL Upper cross auger, double knife, untimed...

  • Page 27: Chapter 4: Attaching Header To Windrower

    Chapter 4: Attaching Header to Windrower Perform all the procedures in this chapter in the order in which they are listed. 4.1 Installing the Hydraulic Hose Management System The hydraulic hose management system must be moved from shipping position to working position. Lifting equipment is required to complete this task;...
  • Page 28 ATTACHING HEADER TO WINDROWER 4. 4.6 m (15 ft.) and 6.1 m (20 ft.) Headers: With the lifting device supporting the weight of hose management system (A), remove two bolts and nuts (C) securing shipping stand (B) to center anchor (D). Retain the hardware. NOTE: Sling not shown in the illustration at right.
  • Page 29 ATTACHING HEADER TO WINDROWER 8. 4.6 m (15 ft.) and 6.1 m (20 ft.) Headers: With the lifting device supporting the weight of hydraulic hose management system (A), remove two bolts and nuts (B) securing the hydraulic hose management system to outboard shipping support (C).
  • Page 30 ATTACHING HEADER TO WINDROWER 11. 12.2–13.7 m (40–45 ft.) Headers: With the lifting device supporting the weight of hydraulic hose management system, cut and remove wire (A) that secures the hydraulic hose management system to channel latch on top of header frame tube.
  • Page 31 ATTACHING HEADER TO WINDROWER 13. Secure plate support (A) to frame channel (B) using the four bolts and nuts previously removed. 14. Remove the sling from the hydraulic hose management system. Figure 4.9: Hydraulic Hose Management System Plate Support 15. 7.6–10.6 m (25–35 ft.) Headers: Remove two bolts (A) and shipping support (B) from coupler holder (C).
  • Page 32 ATTACHING HEADER TO WINDROWER 17. Connect harness connector (C) to the bulkhead on the header’s coupler holder. 18. Cut the cable tie securing the hoses in position (A), and secure the hoses with strap (B) bolted on the frame. IMPORTANT: Note the routing of the hoses in the hydraulic hose management system field position shown at right.

  • Page 33: Attaching Draper Header Supports

    ATTACHING HEADER TO WINDROWER 4.2 Attaching Draper Header Supports Draper header supports are required to attach a D1X or D1XL Series Draper Header to the windrower. DANGER To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.

  • Page 34: Connecting Center-Link

    ATTACHING HEADER TO WINDROWER 4.3 Connecting Center-Link The center-link hook on the windrower connects to a pin on the header, providing support and angle adjustment. The windrower may have an optional self-aligning hydraulic center-link that allows vertical position control of the center- link from the cab.
  • Page 35 ATTACHING HEADER TO WINDROWER 4. If lowering the header lift legs WITH a header or weight box attached, proceed to Step 8, page If lowering the header lift legs WITHOUT a header or weight box attached to the windrower, fully release the tension in header float springs (A): •...
  • Page 36 ATTACHING HEADER TO WINDROWER 8. For windrowers equipped with the self-aligning center-link kit: Press HEADER DOWN switch (E) on the ground speed lever (GSL) to fully retract the header lift cylinders. b. Press REEL UP switch (B) on the GSL to raise the center- link until the hook is above the attachment pin on the header.
  • Page 37 ATTACHING HEADER TO WINDROWER 12. For windrowers without the self-aligning center-link kit: Press the HEADER TILT UP or HEADER TILT DOWN cylinder switches on the GSL to extend or retract the center-link cylinder until the hook is aligned with the header attachment pin.
  • Page 38 ATTACHING HEADER TO WINDROWER 16. Install pin (B) through the header leg (engaging U-bracket in draper header support) on both sides and secure with a hairpin (A). 17. Raise header stand (D) to storage position by pulling spring pin (C) and lifting stand into uppermost position. Release spring pin.

  • Page 39: Connecting Hydraulics

    ATTACHING HEADER TO WINDROWER 4.4 Connecting Hydraulics Hydraulic connections power the reel, draper and knife functions of the header. IMPORTANT: To prevent contamination of the hydraulic system, use a clean rag to remove dirt and moisture from all (fixed and movable) hydraulic couplers.
  • Page 40 ATTACHING HEADER TO WINDROWER 7. Retrieve draper drive and reel control multicoupler (A) from the hydraulic hose management system. 8. Push knob (B) on the hydraulic receptacle and pull handle (C) fully away from the windrower. 9. Open cover (D) and position the coupler onto the receptacle.
  • Page 41 ATTACHING HEADER TO WINDROWER 18. Ensure hydraulic hose routing is as straight as possible and avoids potential rub/wear points. Figure 4.35: Hydraulic Multicouplers and Hose Routing 215489 Revision A...

  • Page 43: Chapter 5: Assembling The Header

    Chapter 5: Assembling the Header Perform all the procedures in this chapter in the order in which they are listed. 5.1 Positioning Transport Lights Transport lights are located on each outboard reel arm. They are shipped in an inverted position on the inboard sides of the reel arms.
  • Page 44 ASSEMBLING THE HEADER 3. D1X headers only: Position right light assembly (A) perpendicular to the right reel arm and attach it using retained lock nuts (B). NOTE: The light assembly should rotate with normal hand force yet maintain its position. Figure 5.3: Right Transport Light –...
  • Page 45 ASSEMBLING THE HEADER 6. Position left light assembly (B) perpendicular to the left reel arm and attach it using retained lock nuts (A). NOTE: The light assembly should rotate with normal hand force yet maintain its position. Figure 5.6: Left Transport Light 215489 Revision A...

  • Page 46: Attaching Reel Lift Cylinders

    ASSEMBLING THE HEADER 5.2 Attaching Reel Lift Cylinders You must set up the reel lift arms before assembling the header any further. CAUTION Tagged bolts (A) on the reel arms keep the reel from sliding forward. Ensure the fore-aft cylinders are attached before removing the bolts.
  • Page 47 ASSEMBLING THE HEADER NOTE: Some parts have been removed from the illustration for clarity. 1. Position sling (A) around reel tube (B) close to the outboard end of the reel and attach a sling to a forklift or an equivalent lifting device. 2.
  • Page 48 ASSEMBLING THE HEADER 4. Double-reel headers only: Support the reel with a lifting device, and remove two top bolts (A) from center reel arm shipping support (B) to allow the center reel arm to move. Figure 5.13: Center Reel Arm – Double Reel Only, D1XL Only 5.
  • Page 49 ASSEMBLING THE HEADER 8. Move reel safety props (A) to engaged position (B) on the outer arm. Figure 5.15: Reel Safety Props 9. For double reel only: Position sling (A) around the reel tube near the reel center support arm. b.
  • Page 50 ASSEMBLING THE HEADER 11. Reposition sling (A) around the reel tube near the opposite outboard reel arm. 12. Remove shipping wire and banding from the reel lift cylinder. Figure 5.18: Outboard Reel Arm 13. Lift the reel and remove the pins from endsheet (B) and reel arm (A).
  • Page 51 ASSEMBLING THE HEADER 16. Move reel safety props (A) to engaged position (B). Figure 5.20: Reel Safety Prop 17. Double reel only: Remove remaining bolt (A), disengage center reel arm shipping support (B) from the cutterbar, and remove the shipping support. Figure 5.21: Center Reel Arm Shipping Support 215489 Revision A...
  • Page 52 ASSEMBLING THE HEADER 18. Remove bolts (A) from reel arm support (B) at the endsheet and remove the support. Repeat at the other side. Figure 5.22: Outboard Reel Arm Supports – D1X Header Shown Figure 5.23: Outboard Reel Arm Supports – D1XL Header Shown 215489 Revision A...
  • Page 53 ASSEMBLING THE HEADER 19. Remove brace bolts and tags (A) locking the reel fore-aft position on the outer reel arms. IMPORTANT: Do NOT use hydraulic pressure to move the fore-aft cylinder to aid brace bolts removal. The cylinder could be damaged.
  • Page 54 ASSEMBLING THE HEADER 20. Double reel only: Remove remaining three bolts (A) locking the reel fore-aft position at the center reel arm and remove shipping channel (B). Figure 5.26: Center Reel Arm Shipping Channel – Double-Reel Only, D1XL Only 215489 Revision A...

  • Page 55: Installing Disc Segments Of Outboard Reel Endshields

    ASSEMBLING THE HEADER 5.3 Installing Disc Segments of Outboard Reel Endshields To meet the trucking load regulations for the maximum load width and height, two disc segments of reel endshields may have been removed from the right reel (tail end) and left reel (cam end). Reel endshield (A) with two disc segments removed for shipping.

  • Page 56: Attaching Cam Arms

    ASSEMBLING THE HEADER 5.4 Attaching Cam Arms Cam arms must be installed before operating the reel. To attach the reel cam arms, follow these steps: NOTE: On nine-bat reel headers, one cam arm assembly was removed and secured to the tine tube for shipping purposes. 1.
  • Page 57 ASSEMBLING THE HEADER 3. Rotate the reel manually until the tine bars with disconnected cam links are accessible. 4. Remove shipping wire (A) (if not already removed). Figure 5.32: Disconnected Cam Links and Shipping Wire 5. Remove bag of hardware (A) from tine bar. It contains hardware for cam links and endshields.

  • Page 58: Installing Crop Dividers

    ASSEMBLING THE HEADER 5.5 Installing Crop Dividers One crop divider and two divider rods are stored on the right inboard side of the endsheet; the other crop divider is stored on the left inboard side of the endsheet. 1. Loosen the bolt at location (A) on the lock tab securing divider rods (B) to storage bracket (C).
  • Page 59 ASSEMBLING THE HEADER 7. Lift the forward end of the divider up to the endsheet and install washer (A) and bolt (B). Figure 5.38: Installing Divider 8. Position divider rod (B) on the tip of the crop divider as shown and tighten bolt (A). Figure 5.39: Divider Rod on Crop Divider 9.

  • Page 60: Attaching Reel Height Sensor - D1Xl Headers

    ASSEMBLING THE HEADER 5.6 Attaching Reel Height Sensor – D1XL Headers On D1XL headers, the reel height sensor linkage (located toward the back of the right reel arm) is disconnected to prevent shipping damage. NOTE: This procedure does NOT apply to D1X headers because D1X headers are NOT factory-equipped with a reel height sensor. Reconnect the sensor using the following procedure: 1.
  • Page 61 ASSEMBLING THE HEADER 2. Attach reel height sensor plate (A) to reel arm with existing bolts and nuts (B). Torque to 8.2 Nm (6 lbf·ft). Figure 5.42: Reel Height Sensor 215489 Revision A...

  • Page 62: Installing Options

    ASSEMBLING THE HEADER 5.7 Installing Options Retrieve the kits supplied as options with the header, and install them according to the instructions supplied with each kit. 215489 Revision A...

  • Page 63: Chapter 6: Performing Predelivery Checks

    Chapter 6: Performing Predelivery Checks This machine has been set at the factory and should not require further adjustments; however, the following checks will ensure your machine provides maximum performance. If adjustments are necessary, follow the procedures in this chapter. WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before adjusting machine.

  • Page 64: Checking Wheel Bolt Torque - Transport And Stabilizer Wheels, Option For D1Xl Headers

    PERFORMING PREDELIVERY CHECKS 6.2 Checking Wheel Bolt Torque – Transport and Stabilizer Wheels, Option for D1XL Headers Check the torque on all transport and stabilizer wheel bolts to make sure the wheels are installed properly. Follow these steps to check the torque: 1.

  • Page 65: Checking Knife Drive Box

    PERFORMING PREDELIVERY CHECKS 6.3 Checking Knife Drive Box Single-knife headers have one knife drive box and double-knife headers have two knife drive boxes. To access the knife drive box(es), the endshield(s) must be fully opened. 1. Press down on latch (A) in the opening on the inboard side of the endsheet.

  • Page 66: Checking And Adjusting Knife Drive Belt Tension

    PERFORMING PREDELIVERY CHECKS 6.4 Checking and Adjusting Knife Drive Belt Tension Correct knife drive belt tension is necessary for the knife sections to stroke properly. Proceed to the section that applies to the header’s knife drive configuration: • 6.4.1 Checking and Tensioning Untimed Double-Knife Drive Belts, page 60 •...

  • Page 67: Tensioning Timed Double-Knife Drive Belts

    PERFORMING PREDELIVERY CHECKS 6.4.2 Tensioning Timed Double-Knife Drive Belts The procedure for tensioning timed double-knife drive belts is the same for both sides of the header. The illustrations shown are for the left side—the right side is opposite. IMPORTANT: To prolong belt and drive life, do NOT overtighten belt. IMPORTANT: Do NOT use the adjuster bolt at the drive pulley to adjust timing belt tension.
  • Page 68 PERFORMING PREDELIVERY CHECKS 4. Tighten nuts (A) on idler pulleys (B) to 217 Nm (160 lbf·ft). Figure 6.9: Left Knife Drive 5. Tighten jam nut (A) to prevent loosening of the adjuster bolt (B). Figure 6.10: Left Knife Drive 6. Ensure there is a clearance of 2.5–3.5 mm (3/32–1/8 in.) between lower belt (A) and lower guide (B).

  • Page 69: Tensioning Timed Knife Drive V-Belts

    PERFORMING PREDELIVERY CHECKS 6.4.3 Tensioning Timed Knife Drive V-Belts Correct knife drive belt tension is necessary for the knife sections to stroke properly. Double-knife timed headers have a third knife drive belt, which is a v-belt located on the left side of the header. Check the v-belt tension whenever checking the tension on the other two knife drive belts.

  • Page 70: Centering The Reel

    PERFORMING PREDELIVERY CHECKS 6.5 Centering the Reel A centered reel picks up crop evenly and prevents debris from accumulating at the ends of the reel. Refer to the topic for header type: • 6.5.1 Centering Double Reel, page 64 • 6.5.2 Centering Single Reel, page 65 6.5.1 Centering Double Reel A centered reel picks up crop evenly and prevents debris from accumulating at the ends of the reel.

  • Page 71: Centering Single Reel

    PERFORMING PREDELIVERY CHECKS 2. Loosen bolts (A) on each brace (B) located on both sides of reel center support arm (C). 3. Move the forward end of reel center support arm (C) laterally as required to center both reels. 4. Tighten bolts (A) and torque to 382 Nm (282 lbf∙ft). Figure 6.14: Reel Center Support Arm 6.5.2 Centering Single Reel A centered reel picks up crop evenly and prevents debris from accumulating at the ends of the reel.
  • Page 72 PERFORMING PREDELIVERY CHECKS 2. Loosen bolt (A) on brace (B) at both ends of the reel. 3. Move the forward end of reel support arm (C) laterally as required to center the reel. 4. Tighten bolt (A) and torque to 359 Nm (265 lbf∙ft). Repeat at opposite side.

  • Page 73: Reel Clearance To Cutterbar

    PERFORMING PREDELIVERY CHECKS Reel Clearance to Cutterbar The minimum clearance between the reel fingers and the cutterbar ensures that the reel fingers do not contact the cutterbar during operation. The clearance is set at the factory, but some adjustment may be necessary before operation. The finger to guard/cutterbar clearances with reels fully lowered are shown in the table below.
  • Page 74 PERFORMING PREDELIVERY CHECKS 4. Set the fore-aft position to the middle position (5) on fore- aft position decal (A). 5. Lower the reel fully. 6. Shut down the engine, and remove the key from the ignition. Figure 6.18: Fore-Aft Position 7.

  • Page 75: Adjusting Reel Clearance

    PERFORMING PREDELIVERY CHECKS Measurement locations (A) for Single and Double Reels: Outer ends of the reel (two places). Figure 6.20: Measurement Locations for Single and Double Reels – Single Reel Shown 8. Adjust the reel clearance, if required. For instructions, refer to 6.6.2 Adjusting Reel Clearance, page 6.6.2 Adjusting Reel Clearance Adjust the reel until there is enough clearance to prevent the reel fingers from contacting the cutterbar during operation.
  • Page 76 PERFORMING PREDELIVERY CHECKS 5. Double reel: adjust center arm lift cylinder stop (A) to change clearance at inboard ends of reels as follows: Loosen nut (B). NOTE: To make adjustment easier, lower reel onto the safety props after loosening nut (B). b.

  • Page 77: Checking And Adjusting Draper Tension

    PERFORMING PREDELIVERY CHECKS 6.7 Checking and Adjusting Draper Tension The drapers are tensioned at the factory and rarely need adjustment. If adjustment is required, tension the drapers just enough to prevent slipping and to keep the draper from sagging below the cutterbar. Adjust drapers on both sides of the header.
  • Page 78 PERFORMING PREDELIVERY CHECKS 6. Ensure idler roller (A) is between draper guides (B). Figure 6.25: Idler Roller IMPORTANT: Do NOT adjust nut (C). This nut is used for draper alignment only. 7. To loosen draper tension, turn adjuster bolt (A) counterclockwise.

  • Page 79: Checking And Adjusting Draper Seal

    PERFORMING PREDELIVERY CHECKS 6.8 Checking and Adjusting Draper Seal Maintain the deck height such that the draper runs just below the cutterbar. DANGER To avoid injury or death from unexpected start-up of machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason.
  • Page 80 PERFORMING PREDELIVERY CHECKS 6. Take measurement at deck supports (A) with the header in working position. Depending on the header size, there are between two and five supports per deck. 7. Loosen the draper tension. For instructions, refer to Checking and Adjusting Draper Tension, page Figure 6.28: Draper Deck Supports 8.
  • Page 81 PERFORMING PREDELIVERY CHECKS 12. Locate a gauge that is the same thickness as the draper belt, plus 1 mm (0.04 in.). Slide the thickness gauge along deck (A) under the cutterbar in order to properly set the gap. 13. To create a seal, adjust deck (A) so that clearance (B) between cutterbar (C) and deck is the same thickness as the draper belt plus 1 mm (0.04 in.).

  • Page 82: Checking And Adjusting Skid Shoe Settings

    PERFORMING PREDELIVERY CHECKS 6.9 Checking and Adjusting Skid Shoe Settings In addition to protecting the bottom of the header from damage during operation, skid shoes affect the cutting height. Raise or lower the skid shoes as required to optimize the cutterbar performance. 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 machine for any reason.

  • Page 83: Leveling The Header

    PERFORMING PREDELIVERY CHECKS 6.10 Leveling the Header The windrower linkages are factory-set to provide the proper level for the header and should not normally require adjustment. 1. If the header is not level, check the pressure of the windrower’s tires to ensure they are properly inflated (refer to your windrower operator’s manual).

  • Page 84: Checking And Adjusting Endshields

    PERFORMING PREDELIVERY CHECKS 6.11 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.
  • Page 85 Adjusting the endshield gap 1. Inside the endshield, loosen four bolts (A) on support tube bracket (B). NOTE: A D1X Series header is shown in illustration. A D1XL header is similar. Figure 6.39: Left Endshield Support Tube on D1X Series Header...
  • Page 86 5. Tighten four bolts (A) on support tube bracket (B) to 31 Nm (23 lbf·ft). NOTE: A D1X Series header is shown in illustration. A D1XL Series header is similar. Figure 6.41: Left Endshield Support Tube on D1X Series Header Closing the endshield 1.
  • Page 87 PERFORMING PREDELIVERY CHECKS 3. Swing the endshield in direction (A) into closed position. Engage the lock with a firm push. 4. Verify that the endshield is locked. Figure 6.43: Left Endshield 215489 Revision A...

  • Page 88: Lubricating Header

    PERFORMING PREDELIVERY CHECKS 6.12 Lubricating Header Two types of lubricant are used on the header. Table 6.5 Recommended Lubricant Specification Description High temperature, extreme pressure (EP2) performance with As required unless SAE multipurpose 1% max molybdenum disulphide (NLGI Grade 2) lithium base otherwise specified High temperature, extreme pressure (EP) performance with SAE multipurpose...

  • Page 89: Lubrication Points

    PERFORMING PREDELIVERY CHECKS 6.12.2 Lubrication Points Some components require additional lubrication instructions. Knifehead IMPORTANT: Overgreasing can cause the knife to bend and make contact with the guards closest to the knifehead. Check for signs of excessive heating on first few guards after greasing. If required, relieve some pressure by removing the grease fitting.
  • Page 90 PERFORMING PREDELIVERY CHECKS IMPORTANT: Reel U-joint (C) has an extended lubrication cross and bearing kit. Stop greasing when greasing becomes difficult or if U-joint stops taking grease. OVERGREASING WILL DAMAGE U-JOINT. Six to eight pumps is sufficient at first grease (factory).

  • Page 91: Checking Manuals

    PERFORMING PREDELIVERY CHECKS 6.13 Checking Manuals Check the manual case contents. The manual case is located inside the left endshield. 1. Open the left endshield. Remove the cable tie on manual case (A). 2. Confirm that the case contains the following manuals: •...

  • Page 92: Header System Calibration

    PERFORMING PREDELIVERY CHECKS 6.14 Header System Calibration The Harvest Performance Tracker (HPT) recognizes when a header is attached to the windrower and determines the systems that require calibration. The following sensors may be calibrated depending on header type: • Header height •...
  • Page 93 PERFORMING PREDELIVERY CHECKS 5. Scroll to WINDROWER SETTINGS icon (A) and press SELECT. 6. Scroll to CALIBRATION icon (B), and press SELECT to open the Calibration Selection screen. NOTE: The F3 shortcut button on the operator’s console will also open the WINDROWER SETTINGS menu. Figure 6.51: Windrower Settings Icon and Calibration Submenu Icon 7.
  • Page 94 PERFORMING PREDELIVERY CHECKS 10. Press the PLAY icon on the screen to begin the calibration process. The display on the screen will change to show that calibration has started. NOTE: If the engine speed is less than 1500 rpm prior to starting the calibration, the system will accelerate the engine speed to 1500 rpm.

  • Page 95: Calibrating Header Position Sensors On The Harvest Performance Tracker Display

    PERFORMING PREDELIVERY CHECKS NOTE: If an error message (A) appears when calibrating the knife drive system, follow the instructions in the message to fix the error. Press X (B) to exit the message. The following list is an example of items to check if the knife calibration fails: •...
  • Page 96 PERFORMING PREDELIVERY CHECKS 5. Scroll to WINDROWER SETTINGS icon (A) and press SELECT. 6. Scroll to CALIBRATION icon (B), and press SELECT to open the Calibration Selection screen. NOTE: The F3 shortcut button on the operator’s console will also open the WINDROWER SETTINGS menu. Figure 6.59: Windrower Settings Icon and Calibration Submenu Icon 7.
  • Page 97 PERFORMING PREDELIVERY CHECKS 8. When stage one of the calibration is complete, press PLAY icon (A) on the screen to continue with stage two of the calibration process. Figure 6.62: Calibration Screen 9. When stage two of the calibration is complete, press RESUME icon (A) on the screen to set HEADER FLOAT, or press HOME or BACK button (not shown) to exit without setting the float.

  • Page 99: Chapter 7: Running Up The Header

    Chapter 7: Running up the Header Operate the header and check for any problems. To run up the header, follow these steps: DANGER To avoid bodily injury or death from unexpected startup of machine, always stop the engine and remove the key before making adjustments to the machine.

  • Page 101: Chapter 8: Performing Post Run-Up Adjustments

    Chapter 8: Performing Post Run-Up Adjustments Stop engine and perform post run-up check as listed on the Predelivery Checklist (yellow sheet attached to this instruction Predelivery Checklist, page 115) to ensure machine is field-ready. WARNING To avoid bodily injury or death from the unexpected startup of the machine, always stop engine and remove the key before adjusting the machine.
  • Page 102 PERFORMING POST RUN-UP ADJUSTMENTS 5. Adjust guard tips downward by positioning tool as shown, and pushing down. Figure 8.3: Straightening Tool – Downward Adjustment 215489 Revision A...

  • Page 103: Chapter 9: Reference

    Chapter 9: Reference Use this section as a source for reference information. 9.1 Torque Specifications The following tables provide correct torque values for various bolts, cap screws, and hydraulic fittings. • Tighten all bolts to torque values specified in charts (unless otherwise noted throughout this manual). •...
  • Page 104 REFERENCE Table 9.2 SAE Grade 5 Bolt and Grade F Distorted Thread Nut Torque (Nm) Torque (lbf·ft) (*lbf·in) Nominal Size (A) Min. Max. Min. Max. 1/4-20 16.7 18.5 *149 *164 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 Figure 9.2: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...

  • Page 105: Metric Bolt Specifications

    REFERENCE Table 9.4 SAE Grade 8 Bolt and Grade 8 Free Spinning Nut Torque (Nm) Torque (lbf·ft) (*lbf·in) Nominal Size (A) Max. Max. Min. Min. 16.8 18.6 *150 *165 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 Figure 9.4: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...
  • Page 106 REFERENCE Table 9.6 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (lbf·ft) (*lbf·in) Torque (Nm) Nominal Size (A) Max. Max. Min. Min. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 8-1.25 18.8 20.8 *167 *185 Figure 9.6: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...

  • Page 107: Metric Bolt Specifications Bolting Into Cast Aluminum

    REFERENCE Table 9.8 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (lbf·ft) (*lbf·in) Torque (Nm) Nominal Size (A) Max. Max. Min. Min. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 10.7 11.8 *105 8-1.25 Figure 9.8: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5...

  • Page 108: Flare-Type Hydraulic Fittings

    REFERENCE 9.1.4 Flare-Type Hydraulic Fittings 1. Check flare (A) and flare seat (B) for defects that might cause leakage. 2. Align tube (C) with fitting (D) and thread nut (E) onto fitting without lubrication until contact has been made between flared surfaces.

  • Page 109: O-Ring Boss Hydraulic Fittings - Adjustable

    REFERENCE 9.1.5 O-Ring Boss Hydraulic Fittings – Adjustable Torque values are shown in following table below. 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Back off lock nut (C) as far as possible. Ensure that washer (D) is loose and is pushed toward lock nut (C) as far as possible.
  • Page 110 REFERENCE Table 9.11 O-Ring Boss (ORB) Hydraulic Fittings – Adjustable Torque Value SAE Dash Size Thread Size (in.) lbf·ft (*lbf·in) 5/16–24 6–7 *53–62 3/8–24 12–13 *106–115 7/16–20 19–21 14–15 1/2–20 21–33 15–24 9/16–18 26–29 19–21 3/4–16 46–50 34–37 7/8–14 75–82 55–60 1 1/16–12 120–132...

  • Page 111: O-Ring Boss Hydraulic Fittings - Non-Adjustable

    REFERENCE 9.1.6 O-Ring Boss Hydraulic Fittings – Non-Adjustable Torque values are shown in following table below. 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Check that O-ring (A) is NOT on the threads and adjust if necessary.

  • Page 112: O-Ring Face Seal Hydraulic Fittings

    REFERENCE 9.1.7 O-Ring Face Seal Hydraulic Fittings Torque values are shown in following table below. 1. Check the components to ensure that the sealing surfaces and fitting threads are free of burrs, nicks, scratches, and any foreign material. Figure 9.14: Hydraulic Fitting 2.

  • Page 113: Tapered Pipe Thread Fittings

    REFERENCE Table 9.13 O-Ring Face Seal (ORFS) Hydraulic Fittings (continued) Torque Value SAE Dash Size Thread Size (in.) Tube O.D. (in.) lbf·ft 80–88 59–65 115–127 85–94 1 3/16 – – Note 150–165 111–122 1 7/16 205–226 151–167 1 11/16 1 1/4 1–2 1 1/2 315–347...
  • Page 114 REFERENCE Table 9.14 Hydraulic Fitting Pipe Thread (continued) Tapered Pipe Thread Size Recommended TFFT Recommended FFFT 1.5–2.5 9–15 1–11 1/2 1.5–2.5 9–15 1 1/4–11 1/2 1.5–2.5 9–15 1 1/2–11 1/2 1.5–2.5 9–15 2–11 1/2 215489 Revision A...

  • Page 115: Header Specifications For Unloading And Assembly

    REFERENCE 9.2 Header Specifications for Unloading and Assembly Header dimensions and weight specifications are provided so that you can choose the correct equipment to lift or transport the header safely. DANGER To avoid injury to bystanders from being struck by machinery, do NOT allow people to stand in unloading area. DANGER Equipment used for unloading must meet or exceed the requirements specified below.
  • Page 116 REFERENCE Table 9.17 Header Dimensions – Fully Assembled and Attached to Shipping Stands IMPORTANT: These approximate dimensions are provided to help you choose the correct size of vehicle to lift or transport the header. These dimensions assume the header is assembled and attached to the shipping stands. Header Model Dimensions D115X...

  • Page 117: Conversion Chart

    REFERENCE 9.3 Conversion Chart Both SI units (including metric) and US customary units (sometimes referred to as standard units) of measurement are used in this manual. A list of those units along with their abbreviations and conversion factors is provided here for your reference.

  • Page 118: Definitions

    A hydraulic cylinder link between the header and machine used to change header angle CGVW Combined gross vehicle weight D1X Series Header MacDon D115X, D120X, and D125X rigid draper headers for M1 Series Windrowers MacDon D130XL, D135XL, D140XL, and D145XL rigid draper headers for M1 Series D1XL Series Header Windrowers...
  • Page 119 Definition Knife A cutting device which uses a reciprocating cutter (also called a sickle) M1 Series MacDon M1170 and M1240 Windrowers Not applicable North American header Header configuration typical in North America National Pipe Thread: A style of fitting used for low-pressure port openings. Threads on...
  • Page 120 REFERENCE Term Definition Windrower Power unit for a header Wide open throttle 215489 Revision A...

  • Page 121: Predelivery Checklist

    Predelivery Checklist Perform these checks prior to delivery to your Customer. Adjustments are normally not required as the machine is factory-assembled and adjusted. If adjustments are required, refer to the appropriate page number in this manual. The completed Checklist should be retained by either the Operator or the Dealer. CAUTION Carefully follow the instructions given.
  • Page 122 REFERENCE Table .19 Predelivery Checklist for D1X and D1XL Series Draper Headers – North America (continued) ü ü Item Reference — Check if reel lift cylinders extend fully. — Check if reel moves fully fore and aft. 8 Performing Post Run-Up Adjustments, page 95 Post run-up check.
  • Page 124 MacDon Industries Ltd. MacDon Brasil Agribusiness Ltda. 680 Moray Street Rua Grã Nicco, 113, Sala 404, B. 04 Winnipeg, Manitoba Mossunguê, Curitiba, Paraná Canada R3J 3S3 CEP 81200-200 Brasil t. (204) 885 5590 f. (204) 832 7749 t. +55 41 2101 1713 f. +55 41 2101 1699 MacDon, Inc.

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