MacDon D1 XL Series Assembly Instructions Manual
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MacDon D1 XL Series Assembly Instructions Manual

MacDon D1 XL Series Assembly Instructions Manual

Draper header for windrower
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D1 XL-Series
Draper Header for Windrowers
Unloading and Assembly Instructions (North America)
214017 Revision A
2016 Model Year
Original Instruction
The harvesting specialists.

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  • Page 1 D1 XL-Series Draper Header for Windrowers Unloading and Assembly Instructions (North America) 214017 Revision A 2016 Model Year Original Instruction The harvesting specialists.
  • Page 2 D1 XL-Series Draper Header for Self-Propelled Windrowers Published: April 2016...
  • Page 3 Introduction This instruction manual describes the unloading, setup, and predelivery requirements for the MacDon D1 XL-Series Draper Header for Self-Propelled Windrowers. To ensure the best performance of this product and the safety of your customers, carefully follow the unload and assembly procedure from the beginning through to completion.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction ............................i Safety ..............................1 Signal Words........................... 1 General Safety ..........................2 Safety Signs ............................ 4 Unloading Header..........................5 Unloading Header from Trailer ......................5 Lowering Header ..........................7 2.2.1 Lowering Single-Reel Header....................7 2.2.2 Lowering Double-Reel Header ....................9 Removing Shipping Supports ......................
  • Page 6 TABLE OF CONTENTS Reference ............................85 Torque Specifications ........................85 8.1.1 Metric Bolt Specifications ......................85 8.1.2 Metric Bolt Specifications Bolting into Cast Aluminum ............... 88 8.1.3 Flare-Type Hydraulic Fittings....................88 8.1.4 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)..............90 8.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) ............

  • Page 7: Safety

    1 Safety 1.1 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. The appropriate signal word for each situation has been selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

  • Page 8: General Safety

    SAFETY 1.2 General Safety CAUTION The following are general farm safety precautions that should be part of your operating procedure for all types of machinery. Protect yourself. • When assembling, operating, and servicing machinery, wear all the protective clothing and personal safety devices that could be necessary for the job at hand.
  • 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 the shaft and can telescope freely. •...

  • Page 10: Safety Signs

    • If original parts on which a safety sign was installed are replaced, be sure the repair part also bears the current safety sign. • Safety signs are available from MacDon Parts. Figure 1.7: Operator’s Manual Decal 214017 Revision A...

  • Page 11: Unloading Header

    2 Unloading Header Perform all procedures in this chapter in the order in which they are listed. 2.1 Unloading Header from Trailer The following procedure assumes that two headers were shipped on the trailer. CAUTION To avoid injury to bystanders from being struck by machinery, do not allow people to stand in unloading area.
  • Page 12 UNLOADING HEADER 3. Approach one of the headers and slide forks (A) underneath the shipping support (B) as far as possible without contacting the shipping support of opposite header (C). IMPORTANT: Avoid lifting the second header and ensure the forks do not interfere with the shipping frame.

  • Page 13: Lowering Header

    UNLOADING HEADER 2.2 Lowering Header The procedure for lowering the header from the trailer varies depending on whether the header has a single or double reel. Refer to the following: • 2.2.1 Lowering Single-Reel Header, page 7 • 2.2.2 Lowering Double-Reel Header, page 9 2.2.1 Lowering Single-Reel Header Reposition header in preparation for assembly and setup as follows:...
  • Page 14 UNLOADING HEADER CAUTION Stand clear when lowering, as machine may swing. 4. Back up SLOWLY while lowering forks until header is just above the ground. Refer to the four positions in the illustration. Figure 2.4: Lowering the Header 214017 Revision A...

  • Page 15: Lowering Double-Reel Header

    UNLOADING HEADER 5. Place 6 in. (150 mm) blocks (A) under each end and center of cutterbar, and then lower header onto blocks. 6. Remove chain and move lifting vehicle to rear of header. 7. Attach chain to center-link anchor on frame tube and raise rear of header so that stand can be lowered.
  • Page 16 UNLOADING HEADER 3. Attach a chain to shipping support (A) at center reel arm. IMPORTANT: Do NOT lift header at this location. This procedure is only for laying the machine over into working position. Figure 2.8: Shipping Support 214017 Revision A...
  • Page 17 UNLOADING HEADER CAUTION Stand clear when lowering, as machine may swing. 4. Back up SLOWLY while lowering forks until header is just above the ground. Refer to the four positions in the illustration. Figure 2.9: Lowering the Header 214017 Revision A...
  • Page 18 UNLOADING HEADER 5. Place 6 in. (150 mm) blocks (A) under each end and center of cutterbar, and then lower header onto blocks. 6. Remove chain and move lifting vehicle to rear of header. 7. Attach chain to center-link anchor on frame tube and raise rear of header so that stand can be lowered.

  • Page 19: Removing Shipping Supports

    UNLOADING HEADER 2.3 Removing Shipping Supports NOTE: Unless otherwise specified, discard all shipping materials and hardware. 1. Cut straps and remove draper header supports (A) from shipping support. Set draper header supports aside for reinstallation. Figure 2.12: Straps, Draper Header Supports, and Shipping Supports 2.
  • Page 20 UNLOADING HEADER 4. Remove six bolts (A) securing lower support (B) to header legs and remove support. Figure 2.15: Lower Support 5. Remove the four bolts (A) from the shipping stands at both outboard header legs and remove the shipping stands.
  • Page 21 UNLOADING HEADER 7. At the left-hand side of the header, cut and remove the wire (A) securing the endshield to the panel. Repeat at the opposite side. 8. Loosen the two nuts (B) securing the shipping support to the endsheet. 9.

  • Page 23: Attaching Header To Windrower

    3 Attaching Header to Windrower Perform all the procedures in this chapter in the order in which they are listed. 3.1 Installing the Hydraulic Hose Management Arm The hydraulic hose management arm should be properly installed from shipping position to working position. Lifting equipment is required to complete this task;...
  • Page 24 ATTACHING HEADER TO WINDROWER 4. Remove the two bolts and nuts (A) securing the base of the hose management arm (B) to the frame channel (C). 5. Remove the other two bolts and nuts (D) from the plate support (E). 6.
  • Page 25 ATTACHING HEADER TO WINDROWER 8. 40–45 Foot Headers: With the sling supporting the hose management arm, cut and remove the wire (A) that secure it to channel latch on top of header frame tube. Figure 3.5 9. With the help of the sling, position the hose management arm (A) as shown.
  • Page 26 ATTACHING HEADER TO WINDROWER 10. Secure the plate support (A) to the frame channel (B) using the four bolts and nuts previously removed. 11. Remove sling from the hose management arm. Figure 3.7: Hose Management Arm Plate Support 12. 30–35 Foot Headers: Remove the two bolts (A) and shipping support (B) from the coupler holder (C).
  • Page 27 ATTACHING HEADER TO WINDROWER 14. Retrieve the latch support assembly (A) removed in Step 3, page 15. Remove the three nuts (B) from the latch support assembly (A). Figure 3.10: Latch Support Assembly 16. Align the bolts (A) on the latch support assembly (B) to the holes on the support channel (C) of the windrower’s outer leg, and secure with the three nuts removed earlier.

  • Page 28: Attaching Draper Header Supports

    ATTACHING HEADER TO WINDROWER 3.2 Attaching Draper Header Supports WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine. 1. Remove hairpin and clevis pin (B) from the draper header support (A).

  • Page 29: Connecting Center-Link

    ATTACHING HEADER TO WINDROWER 3.3 Connecting Center-Link The procedure for connecting the center-link varies depending on the type of center-link installed on the machine. Refer to the applicable topic: • 3.3.1 Hydraulic Link without Self-Alignment Kit, page 23 • 3.3.2 Hydraulic Link with Optional Self-Alignment Kit, page 27 3.3.1 Hydraulic Link without Self-Alignment Kit The following connection procedure applies to M1240 windrowers with a hydraulic center-link and without the self-alignment kit.
  • Page 30 ATTACHING HEADER TO WINDROWER CAUTION To prevent damage to the header lift linkages when lowering header lift legs without a header or weight box attached to the windrower, ensure the float springs tension is fully released. Figure 3.16: Float Springs 5.
  • Page 31 ATTACHING HEADER TO WINDROWER 8. Drive the windrower slowly forward until the draper header supports (A) enter the header legs (B). Continue driving slowly forward until lift linkages contact the support plates in the header legs and the header nudges forward. 9.
  • Page 32 ATTACHING HEADER TO WINDROWER CAUTION Check to be sure all bystanders have cleared the area. 14. Start engine and press the HEADER UP switch (A) on the GSL to raise header to maximum height. 15. Stop engine and remove the key from the ignition. Figure 3.22: GSL 16.

  • Page 33: Hydraulic Link With Optional Self-Alignment Kit

    ATTACHING HEADER TO WINDROWER 19. Disengage safety prop by turning lever (A) downward to raise prop until lever locks into vertical position. NOTE: If safety prop will not disengage, raise header to release the prop. 20. Repeat for opposite side. Figure 3.25: Cylinder Safety Prop CAUTION Check to be sure all bystanders have cleared the area.
  • Page 34 ATTACHING HEADER TO WINDROWER 2. Remove hairpins (A) from pins (B), and remove pins from both header legs. CAUTION Check to be sure all bystanders have cleared the area. 3. Start engine. Figure 3.27: Header Leg CAUTION To prevent damage to the header lift linkages when lowering header lift legs without a header or weight box attached to the windrower, ensure the float springs tension is fully released.
  • Page 35 ATTACHING HEADER TO WINDROWER 6. Press soft key 3 (A) to remove float. Figure 3.30: HPT Display CAUTION Check to be sure all bystanders have cleared the area. 7. Press HEADER DOWN switch (A) on the ground speed lever (GSL) to fully retract header lift cylinders. 8.
  • Page 36 ATTACHING HEADER TO WINDROWER GSL switches: • REEL DOWN (A) to lower the center-link • REEL UP (B) to raise the center-link • HEADER TILT DOWN (C) to extend the center-link • HEADER TILT UP (D) to retract the center-link Figure 3.33: GSL 11.
  • Page 37 ATTACHING HEADER TO WINDROWER 16. Engage safety prop on the windrower’s lift cylinder as follows: a. Pull lever (A) and rotate toward header to release, and lower safety prop onto cylinder. b. Repeat for opposite lift cylinder. IMPORTANT: Ensure the safety props engage over cylinder piston rods.
  • Page 38 ATTACHING HEADER TO WINDROWER CAUTION Check to be sure all bystanders have cleared the area. 21. Start engine and press HEADER DOWN switch (A) on GSL to fully lower header. 22. Stop engine and remove key. Figure 3.39: GSL 214017 Revision A...

  • Page 39: Connecting Hydraulics

    ATTACHING HEADER TO WINDROWER 3.4 Connecting Hydraulics IMPORTANT: To prevent contamination of the hydraulic system, use a clean rag to remove dirt and moisture from all (fixed and movable) hydraulic couplers. 1. Move arm (A) toward left cab-forward side of windrower.
  • Page 40 ATTACHING HEADER TO WINDROWER 5. Retrieve draper drive and reel control multicoupler (A) from hose management arm. 6. Push knob (B) on hydraulic receptacle and pull handle (C) fully away from windrower. 7. Open cover (D) and position coupler onto receptacle. Align pins in coupler with slots in handle (C) and push handle toward windrower so that coupler is locked onto receptacle and knob (B) snaps out.
  • Page 41 ATTACHING HEADER TO WINDROWER 14. Ensure hydraulic hose routing is as straight as possible and avoids potential rub/wear points. Figure 3.46: Hydraulic Multicouplers and Hose Routing 214017 Revision A...

  • Page 43: Assembling The Header

    4 Assembling the Header Perform all the procedures in this chapter in the order in which they are listed. 4.1 Attaching Reel Lift Cylinders CAUTION Bolts (A) (with tags) on reel arms keep the reel from sliding forward. Ensure fore-aft cylinders are attached before removing bolts.
  • Page 44 ASSEMBLING THE HEADER 1. Position sling (A) around the reel tube (B) close to the outboard end of reel and attach sling to a forklift (or equivalent). 2. Remove shipping wire/banding from the reel lift cylinder. Figure 4.3: Reel Tube 3.
  • Page 45 ASSEMBLING THE HEADER 5. Lift reel and remove pins from the endsheet and the reel arm. 6. Align the reel lift cylinder mounting holes until they line up with the lug on endsheet and the hole in the reel arm. 7.
  • Page 46 ASSEMBLING THE HEADER NOTE: Step 9, page 40 to Step 16, page 40 apply ONLY to double-reel headers; for single-reel headers, go to Step 17, page 9. Double reel only: Position sling (A) around the reel tube near the reel center support arm. 10.
  • Page 47 ASSEMBLING THE HEADER 19. Lift reel and remove pins from the endsheet and the reel arm. 20. Align the reel lift cylinder mounting holes until they line up with the lug on endsheet and the hole in the reel arm. 21.
  • Page 48 ASSEMBLING THE HEADER 23. Double reel only: Remove the remaining bolt (A), disengage center reel arm shipping support (B) from cutterbar, and remove shipping support. Figure 4.13: Center Reel Arm Shipping Support 24. Remove bolts (A) from reel arm support at endsheet and remove support.
  • Page 49 ASSEMBLING THE HEADER 25. Remove brace bolts and tags (A) locking the reel fore-aft position at outer reel arms. Figure 4.15: Right Reel Arm Top Image - Single Reel Bottom Image - Double Reel Figure 4.16: Left Reel Arm 214017 Revision A...
  • Page 50 ASSEMBLING THE HEADER 26. Double reel only: Remove the remaining three bolts (A) locking the reel fore-aft position at the center reel arm and remove shipping channel (B). Figure 4.17: Center Reel Arm Shipping Channel (Double-Reel Header Only) 214017 Revision A...

  • Page 51: Installing Disc Segments Of Outboard Reel Endshields

    ASSEMBLING THE HEADER 4.2 Installing Disc Segments of Outboard Reel Endshields To meet the trucking load regulations for the maximum load width and height, two disc segments of the reel endshields (A) may have been removed from the right-hand reel (tail end) and left-hand reel (cam end). Check if reel endshields are completely installed.

  • Page 52: Attaching Cam Arms

    ASSEMBLING THE HEADER 4.3 Attaching Cam Arms To attach the reel cam arms, follow these steps: 1. Rotate the reel manually until the tine bars with disconnected cam links are accessible. 2. Remove shipping wire (A) (if not already removed). Figure 4.21: Disconnected Cam Links and Shipping Wire 3.

  • Page 53: Installing Crop Dividers

    ASSEMBLING THE HEADER 4.4 Installing Crop Dividers One crop and two rod dividers 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. Remove the two shipping wire (A) and loosen the bolt (B) on the lock tab securing the divider rods (C) to the bracket storage.
  • Page 54 ASSEMBLING THE HEADER 7. Lift forward end of divider up to endsheet and install washer (A) and bolt (B). Figure 4.27: Installation Hardware 8. Position divider rod (B) on tip of crop divider as shown and tighten bolt (A). Figure 4.28: Divider Rod on Crop Divider 9.

  • Page 55: Positioning Transport Lights

    ASSEMBLING THE HEADER 4.5 Positioning Transport Lights Transport lights are located on each of the outboard reel arms. 1. Position lights (A) perpendicular to header. Figure 4.30: Transport Light Perpendicular to Header 214017 Revision A...

  • Page 56: Installing Options

    ASSEMBLING THE HEADER 4.6 Installing Options Retrieve the kits supplied as options with the header and install them according to the instructions supplied with each kit. 214017 Revision A...

  • Page 57: Adding Tire Ballast

    ASSEMBLING THE HEADER 4.7 Adding Tire Ballast When using large headers on the windrower, adding fluid ballast to the rear caster tires will improve machine stability. Machine stability is also affected by different attachments, windrower options, terrains, and driving techniques. Ballast capability per tire is at a maximum fill of 75% or when the fluid is level with the valve stem when the stem is positioned at the 12 o’clock position.

  • Page 59: Performing Predelivery Checks

    5 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 making adjustments to machine.

  • Page 60: Checking Wheel Bolt Torque

    PERFORMING PREDELIVERY CHECKS 5.2 Checking Wheel Bolt Torque Perform the following procedure to ensure that transport and stabilizer wheel bolts are correctly torqued: 1. Check wheel bolt torque is 80–90 ft·lbf (110–120 N·m). Refer to bolt tightening sequence illustration at right. Figure 5.1: Bolt Tightening Sequence 214017 Revision A...

  • Page 61: Checking Knife Drive Box

    PERFORMING PREDELIVERY CHECKS 5.3 Checking Knife Drive Box To access the knife drive box(es), endshield(s) must be fully opened. WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine. 1.
  • Page 62 PERFORMING PREDELIVERY CHECKS IMPORTANT: The knife drive box breather is shipped in position (A) (forward) to prevent oil loss during transport. The breather plug MUST be repositioned to location (B) to prevent oil loss during normal operation. Failure to do so can result in damage to the knife drive box.

  • Page 63: Checking And Adjusting Knife Drive Belt Tension

    PERFORMING PREDELIVERY CHECKS 5.4 Checking and Adjusting Knife Drive Belt Tension Proceed to the section that applies to the header’s knife drive configuration: • 5.4.1 Tensioning Non-Timed Knife Drive Belts, page 57 • 5.4.2 Tensioning Timed Knife Drive Belts, page 58 •...

  • Page 64: Tensioning Timed Knife Drive Belts

    PERFORMING PREDELIVERY CHECKS 5.4.2 Tensioning Timed Knife Drive Belts The procedure for tensioning timed 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 over-tighten belt. IMPORTANT: Do NOT use the adjuster bolt at the drive pulley to adjust timing belt tension.
  • Page 65 PERFORMING PREDELIVERY CHECKS 5. Tighten hex nuts (A) on idler pulleys (B). Figure 5.9: LH Knife Drive 6. Loosen flange nut (A) until adjuster bolt (B) is just snug, then tighten jam nut (C) to prevent loosening of the adjuster bolt. NOTE: If flange nut and adjuster bolt is not loosened, the lower guide will not be parallel to the belt.

  • Page 66: Tensioning Timed Knife Drive V-Belts

    PERFORMING PREDELIVERY CHECKS 5.4.3 Tensioning Timed Knife Drive V-Belts 1. Loosen the two bolts (A). 2. Turn drawbolt clockwise tighten counterclockwise to loosen belts (C) tension. NOTE: Tension is checked at mid-span of the belts. The belts should deflect 5/32 in. (4 mm) with 12–17 lbf (52–77 N) of force applied to each belt.

  • Page 67: Centering The Reel

    PERFORMING PREDELIVERY CHECKS 5.5 Centering the Reel If the reel is not centered between the endsheets, refer to the topic for the header type: WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine.

  • Page 68: Centering Single Reels

    PERFORMING PREDELIVERY CHECKS 5.5.2 Centering Single Reels 1. Measure the clearance at locations (A) between the reel and endsheets. The clearances should be the same if the reel is centered. If not centered, continue on the next step. Figure 5.15: Single Reel Measurement Locations 2.

  • Page 69: Adjusting Draper Tension

    PERFORMING PREDELIVERY CHECKS 5.6 Adjusting Draper Tension WARNING 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. NOTE: If adjustment is required, tension the drapers just enough to prevent slipping and to keep the draper from sagging below the cutterbar.
  • Page 70 PERFORMING PREDELIVERY CHECKS 5. Ensure the idler roller (A) is between the draper guides (B). Figure 5.19: Idler Roller IMPORTANT: Do NOT adjust nut (C). This nut is used for draper alignment only. 6. Turn the adjuster bolt (A) counterclockwise to loosen. The white indicator bar (B) will move outboard in the direction of arrow (D) to indicate that the draper is loosening.

  • Page 71: Checking And Adjusting Draper Seal

    PERFORMING PREDELIVERY CHECKS 5.7 Checking and Adjusting Draper Seal Maintain the deck height such that the draper runs just below the cutterbar. IMPORTANT: With a new header or newly installed draper, set the gap between the draper (A) and cutterbar (B) to 1/8 in. (3 mm).
  • Page 72 PERFORMING PREDELIVERY CHECKS 4. Loosen two lock nuts (A) only one-half-turn on deck support (B). 5. Tap deck (C) to lower deck relative to supports and achieve the recommended setting. Tap support (B) using a punch to raise deck relative to supports. 6.

  • Page 73: Checking And Adjusting Skid Shoe Settings

    PERFORMING PREDELIVERY CHECKS 5.8 Checking and Adjusting Skid Shoe Settings Check skid shoes and adjust, if necessary. WARNING 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. DANGER Engage header safety props and reel props before working under header or reel.

  • Page 74: Levelling The Header

    PERFORMING PREDELIVERY CHECKS 5.9 Levelling 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’s operator’s manual).

  • Page 75: Measuring And Adjusting Reel Clearance To Cutterbar

    PERFORMING PREDELIVERY CHECKS 5.10 Measuring and Adjusting Reel Clearance to Cutterbar The minimum clearance between the reel fingers and the cutterbar ensures that the reel fingers do not contact the cutterbar during operation. The clearance is adjusted at the factory, but some adjustment may be necessary before operation.
  • Page 76 PERFORMING PREDELIVERY CHECKS 5. Measure the clearance (X) between points (B) and (C) at the ends of each reel (A). NOTE: The reel is factory-set to provide more clearance at the center of the reel than at the ends (frown) to compensate for reel flexing.

  • Page 77: Adjusting Reel Clearance

    PERFORMING PREDELIVERY CHECKS 5.10.2 Adjusting Reel Clearance DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under header for any reason. 1. Stop the engine and remove the key. 2.

  • Page 78: Checking And Adjusting Endshields

    PERFORMING PREDELIVERY CHECKS 5.11 Checking and Adjusting Endshields Endshields are subject to expansion or contraction caused by large temperature variations. The position of the top pin and lower catch can be adjusted to compensate for dimensional changes. 1. Check gap (X) between front end of shields and header frame and compare to the values in Table 5.3 Endshield Gap at Various Temperatures, page...
  • Page 79 PERFORMING PREDELIVERY CHECKS 4. Pull endshield at handle depression (A). Endshield is retained by a hinge tab (B) and will open in direction (C). Figure 5.36: Left Endshield 5. Pull the endshield free of hinge tab (A) if additional clearance is required, and swing shield towards the rear of the header.
  • Page 80 PERFORMING PREDELIVERY CHECKS 8. Loosen the three bolts (A) on latch assembly (B). 9. Adjust latch assembly to achieve the desired gap between the front end of shield and header frame in accordance with Table 5.3 Endshield Gap at Various Temperatures, page 10.

  • Page 81: Lubricating The Header

    PERFORMING PREDELIVERY CHECKS 5.12 Lubricating the Header Table 5.4 Recommended Lubricant Specification Description High temperature, extreme pressure (EP2) performance As required unless with 1% max molybdenum disulphide (NLGI Grade 2) otherwise specified lithium base SAE multipurpose High temperature, extreme pressure (EP) performance with 10% max molybdenum disulphide (NLGI Grade 2) Driveline slip-joints lithium base...
  • Page 82 PERFORMING PREDELIVERY CHECKS 1. Wipe grease fitting with a clean cloth before greasing to avoid injecting dirt and grit. 2. Inject grease through fitting with grease gun until grease overflows fitting (except where noted). 3. Leave excess grease on fitting to keep out dirt. 4.

  • Page 83: Lubrication Points

    PERFORMING PREDELIVERY CHECKS 5.12.2 Lubrication Points 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 84 PERFORMING PREDELIVERY CHECKS IMPORTANT: The 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). As U-joint wears and requires more than six pumps, grease the joint more often. Figure 5.45: Reel Shaft Bearings A - Reel Shaft Right-Hand Bearing (One Place) B - Reel Center Bearing (One Place)

  • Page 85: Checking Manuals

    PERFORMING PREDELIVERY CHECKS 5.13 Checking Manuals Check manual case contents. The manual case is located inside the left-hand endshield. 1. Open the left-hand endshield and remove the cable tie on the manual case. Figure 5.46: Manual Case 2. Confirm that the case contains the following manuals: •...

  • Page 87: Running Up The Header

    6 Running up the Header To run up the header, follow these steps: 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. CAUTION Before investigating an unusual sound or attempting to correct a problem, shut off engine, engage parking brake, and remove key.

  • Page 89: Performing Post Run-Up Adjustments

    7 Performing Post Run-Up Adjustments Perform post run-up check as listed on the Predelivery Checklist (yellow sheet attached to this instruction Predelivery Checklist, page 101) to ensure machine is field-ready. WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine.
  • Page 90 PERFORMING POST RUN-UP ADJUSTMENTS 5. Adjust guard tips downward by positioning tool as shown and pushing down. Figure 7.3: Guard Tips – Downward Adjustment 214017 Revision A...

  • Page 91: Reference

    8 Reference 8.1 Torque Specifications The following tables provide the correct torque values for various bolts, cap screws, and hydraulic fittings. • Tighten all bolts to the torque values specified in the charts (unless otherwise noted throughout this manual). • Replace hardware with the same strength and grade of bolt. •...
  • Page 92 REFERENCE Table 8.2 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 8-1.25 *167 *185 18.8 20.8 Figure 8.2: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...
  • Page 93 REFERENCE Table 8.4 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 *105 10.7 11.8 8-1.25 Figure 8.4: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5...

  • Page 94: Metric Bolt Specifications Bolting Into Cast Aluminum

    REFERENCE 8.1.2 Metric Bolt Specifications Bolting into Cast Aluminum Table 8.5 Metric Bolt Bolting into Cast Aluminum Bolt Torque Nominal 10.9 Size (A) (Cast Aluminum) (Cast Aluminum) N·m N·m ft·lbf ft·lbf – – – – – – – Figure 8.5: Bolt Grades –...
  • Page 95 REFERENCE Table 8.6 Flare-Type Hydraulic Tube Fittings Torque Value Flats from Finger Tight (FFFT) SAE Dash Size Thread Size (in.) Swivel Nut or ft·lbf N·m Tube Hose — — 5/16–24 3–4 4–5 — — 3/8–24 5–6 7–8 7/16–20 13–14 18–19 2-1/2 1/2–20 14–15...

  • Page 96: O-Ring Boss (Orb) Hydraulic Fittings (Adjustable)

    REFERENCE 8.1.4 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Back off the lock nut (C) as far as possible. Ensure that washer (D) is loose and is pushed toward the lock nut (C) as far as possible.
  • Page 97 REFERENCE Table 8.7 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) Torque Value SAE Dash Size Thread Size (in.) ft·lbf (*in·lbf) N·m 5/16–24 *53–62 6–7 3/8–24 *106–115 12–13 7/16–20 14–15 19–21 1/2–20 15–24 21–33 9/16–18 19–21 26–29 3/4–16 34–37 46–50 7/8–14 55–60 75–82 1-1/16–12 88–97...

  • Page 98: O-Ring Boss (Orb) Hydraulic Fittings (Non-Adjustable)

    REFERENCE 8.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) 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. 3. Apply hydraulic system oil to the O-ring. 4.

  • Page 99: O-Ring Face Seal (Orfs) Hydraulic Fittings

    REFERENCE 8.1.6 O-Ring Face Seal (ORFS) Hydraulic Fittings 1. Check components to ensure that the sealing surfaces and fitting threads are free of burrs, nicks, scratches, or any foreign material. Figure 8.10: Hydraulic Fitting 2. Apply hydraulic system oil to the O-ring (B). 3.
  • Page 100 REFERENCE Table 8.9 O-Ring Face Seal (ORFS) Hydraulic Fittings Torque Value SAE Dash Size Thread Size (in.) Tube O.D. (in.) ft·lbf N·m Note 3/16 – – 9/16 18–21 25–28 Note – – 5/16 11/16 29–32 40–44 13/16 41–45 55–61 59–65 80–88 1-3/16 85–94...

  • Page 101: Tapered Pipe Thread Fittings

    REFERENCE 8.1.7 Tapered Pipe Thread Fittings The proper method of assembling a pipe thread fitting is: 1. Check components to ensure that fitting and port threads are free of burrs, nicks and scratches, or any form of contamination. 2. Apply pipe thread sealant (paste type) to the external pipe threads. 3.

  • Page 102: Lifting Equipment Requirements

    REFERENCE 8.2 Lifting Equipment Requirements The following topic describes the minimum equipment requirements for lifting headers. CAUTION To avoid injury to bystanders from being struck by machinery, do not allow people to stand in unloading area. CAUTION Equipment used for loading and unloading must meet or exceed the minimum specified requirements. Using inadequate equipment may result in vehicle tipping, machine damage, or chain breakage.

  • Page 103: Conversion Chart

    REFERENCE 8.3 Conversion Chart Table 8.13 Conversion Chart Inch-Pound Units SI Units (Metric) Quantity Factor Unit Name Abbreviation Unit Name Abbreviation Area acres acres x 0.4047 = hectares US gallons Flow x 3.7854 = liters per minute L/min per minute Force pounds force x 4.4482 =...

  • Page 104: Definitions

    Center-link It is used to change header angle CGVW Combined vehicle gross weight MacDon D130 XL, D135 XL, D140 XL, and D145 XL rigid draper headers for D1 XL-Series header windrowers from the D1 XL model number series Double knife...
  • Page 105 REFERENCE Term Definition An internally threaded fastener that is designed to be paired with a bolt N-DETENT The slot opposite the NEUTRAL position on operator’s console North American header Header configuration typical in North America National Pipe Thread: A style of fitting used for low pressure port openings Threads on NPT fittings are uniquely tapered for an interference fit O-ring boss: A style of fitting commonly used in port opening on manifolds, pumps, and motors...
  • Page 106 REFERENCE Term Definition Unsynchronized motion applied at the cutterbar to two separately driven knives Untimed knife drive 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, Washer load distribution element, or a locking mechanism Windrower...

  • Page 107: 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 108 PREDELIVERY CHECKLIST  Item Reference Check if reel lift cylinders extend fully. — Check if reel moves fully fore and aft. — Post run-up check. Stop engine. 5.4 Checking and Adjusting Knife Drive Belt Check belt drives for heated bearings. Tension, page 57 Check knife sections for discoloration caused by 7.1 Adjusting Knife, page 83...
  • Page 110 10708 N. Pomona Avenue Kansas City, Missouri United States 64153-1924 t. (816) 891-7313 f. (816) 891-7323 MacDon Australia Pty. Ltd. A.C.N. 079 393 721 P.O. Box 243, Suite 3, 143 Main Street Greensborough, Victoria, Australia 3088 t. 03 9432 9982 f.

This manual is also suitable for:

D130 xlD135 xlD140 xlD145 xl

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