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215651

127

Revision B

5.4

Electrical System

The electrical system for the header is powered by the windrower. The header has various lights and sensors that
require power.

5.4.1

How It Works

Understanding how the electrical system works will help you identify situations where it is not working properly and help
you determine the cause of any problems.

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Figure 5.14: Wire Identification Label

Wire identification

Electrical wires are identified by a two letter wire location (A),
four digit identification number (B), one digit branch wire
location (C), one letter for color (D), and two digit wire size (E).
The wire identification is printed on each wire covering.

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Figure 5.15: Wire Identification

–

Location,

Identification Number, Branch location

Wire example, CH1234B XXX: The location (A) is the chassis
harness. The identification number (B) is 1234. The branch wire
location (C) is B. This means that there is one splice point before
you reach CH1234B.

Table 5.1 D1XL Series Wire Prefix Identification

Prefix

System

HM

D1XL main harness

DS

Header deck shift

HA

Auger/draper adapter

HR

Reel extend

HT

Transport lights

IDA

Header identification

(D130XL)

IDB

Header identification

(D135XL)

IDC

Header identification

(D140XL and D145XL)

XL

Draper speed (left)

XR

Draper speed (right)

Table 5.2 D1X Series Wire Prefix Identification

Prefix

System

DS

D1 Series main harness

DX

D1 Series reel extension

harness

MAINTENANCE AND SERVICING

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Summary of Contents for D115X

Page 1: ...D1X and D1XL Series Draper Headers for M1 Series Windrowers Operator s Manual 215651 Revision B Original Instruction The Harvesting Specialists ...

Page 2: ...s 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 information in this publication MacDon Industries Ltd reserves the right to make changes at any time without notice ...

Page 3: ...EŽŵďƌĞ Ǉ ŵŽĚĞůŽ ϯ EƷŵĞƌŽƐ ĚĞ ƐĞƌŝĞ ϰ ĐƵŵƉůĞ ĐŽŶ ƚŽĚĂƐ ůĂƐ ĚŝƐƉŽƐŝĐŝŽŶĞƐ ƉĞƌƟŶĞŶƚĞƐ ĚĞ ůĂ ĚŝƌĞĐƚƌŝǌ ϮϬϬϲ ϰϮ Ğ ƵƟůŝǌĂƌŽŶ ŶŽƌŵĂƐ ĂƌŵŽŶŝǌĂĚĂƐ ƐĞŐƷŶ ůŽ ĚŝƐƉƵĞƐƚŽ ĞŶ Ğů ĂƌơĐƵůŽ ϳ ϮͿ E K ϰϮϱϰ ϭ ϮϬϭϯ E K ϰϮϱϰ ϳ ϮϬϬϵ ƵŐĂƌ Ǉ ĨĞĐŚĂ ĚĞ ůĂ ĚĞĐůĂƌĂĐŝſŶ ϱ ĚĞŶƟĚĂĚ Ǉ ĮƌŵĂ ĚĞ ůĂ ƉĞƌƐŽŶĂ ĨĂĐƵůƚĂĚĂ ƉĂƌĂ ĚƌĂǁ ƌĞĚĂĐƚĂƌ ůĂ ĚĞĐůĂƌĂĐŝſŶ ϲ EŽŵďƌĞ Ǉ ĚŝƌĞĐĐŝſŶ ĚĞ ůĂ ƉĞƌƐŽŶĂ ĂƵƚŽƌŝǌĂĚĂ ƉĂƌĂ ĞůĂďŽƌĂƌ Ğů ĞǆƉĞĚŝĞŶƚĞ ƚĠĐŶŝĐŽ ĞŶĞĚ...

Page 4: ...ĞŶƟƚĂƚĞĂ ƕŝ ƐĞŵŶĉƚƵƌĂ ƉĞƌƐŽĂŶĞŝ ŠŵƉƵƚĞƌŶŝĐŝƚĞ ƉĞŶƚƌƵ ŠŶƚŽĐŵŝƌĞĂ ĚĞĐůĂƌĂƜŝĞŝ ϲ EƵŵĞůĞ ƕŝ ƐĞŵŶĉƚƵƌĂ ƉĞƌƐŽĂŶĞŝ ĂƵƚŽƌŝǌĂƚĞ ƉĞŶƚƌƵ ŠŶƚŽĐŵŝƌĞĂ ĐĉƌƜŝŝ ƚĞŚŶŝĐĞ ĞŶĞĚŝŬƚ ǀŽŶ ZŝĞĚĞƐĞů DĂŶĂŐĞƌ ĞŶĞƌĂů DĂĐ ŽŶ ƵƌŽƉĞ ŵď ĂŐĞŶĂƵĞƌ ƚƌĂƘĞ ϱϵ ϲϱϮϬϯ tŝĞƐďĂĚĞŶ ĞƌŵĂŶŝĂͿ ďǀŽŶƌŝĞĚĞƐĞůΛŵĂĐĚŽŶ ĐŽŵ s sŝ ϭ ŶƚǇŐĂƌ ĂƩ ƉƌŽĚƵŬƚĞŶ DĂƐŬŝŶƚǇƉ Ϯ EĂŵŶ ŽĐŚ ŵŽĚĞůů ϯ ĞƌŝĞŶƵŵŵĞƌ ϰ ƵƉƉĨǇůůĞƌ ĂůůĂ ƌĞůĞǀĂŶƚĂ ǀŝůůŬŽƌ ŝ ĚŝƌĞŬƟǀĞƚ ϮϬϬϲ ϰϮ ĂƌŵŽŶŝ...

Page 5: ...es 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 Failure to use the machine equipment component or part in accordance with the manufacturer s instructions This manual is...

Page 6: ...his manual handy for frequent reference or to pass on to new Operators or Owners A manual storage case A is located inside the left endshield Call your MacDon Dealer if you need assistance information or additional copies of this manual 215651 iv Revision B ...

Page 7: ...ns Publications 2 3 Specifications page 28 Corrected header model numbers Publications 3 7 7 Knife Speed Information page 66 Corrected header model numbers Publications Adjusting Reel Cam page 70 Revised topic to show D1X and D1XL content erroneously included content for the wrong header model Product Support Replacing Reel Endshield Supports page 223 Revised procedure for clarity Publications 215...

Page 8: ...s below Figure 2 Header Serial Number Plate Location Header Model Serial Number Model Year Header serial number plate A is located on the upper corner on the left endsheet Figure 3 Transport Stabilizer Wheel Location Transport Stabilizer Wheel Option Serial Number Model Year Transport serial number plate A is located on the right axle assembly 215651 vi Revision B ...

Page 9: ...25 2 2 Component Identification 27 2 3 Specifications 28 2 4 Dimensions 31 Chapter 3 Operation 33 3 1 Owner Operator Responsibilities 33 3 2 Operational Safety 34 3 2 1 Header Safety Props 34 3 2 2 Reel Safety Props 35 Engaging Reel Safety Props 35 Disengaging Reel Safety Props 36 3 2 3 Header Endshields 37 Opening Endshields 37 Closing Endshields 38 Removing Endshields 39 Installing Endshields 39...

Page 10: ... Option from Header 71 Installing Crop Dividers with Latch Option onto Header 72 Installing Crop Dividers without Latch Option onto Header 73 3 7 12 Crop Divider Rods 75 Removing Crop Divider Rods 75 Installing Crop Divider Rods 76 3 8 Delivery Opening 77 3 8 1 Manually Adjusting Delivery Opening on Header 77 3 8 2 Adjusting Delivery Opening on Header using Hydraulic Deck Shift 78 3 9 Double Windr...

Page 11: ...eparing Machine for Servicing 113 5 2 Maintenance Specifications 114 5 2 1 Installing a Roller Chain 114 5 2 2 Installing Sealed Bearing 114 5 3 Maintenance Requirements 116 5 3 1 Maintenance Schedule Record 116 5 3 2 Break In Inspection 117 5 3 3 Preseason Servicing 118 5 3 4 End of Season Service 118 5 3 5 Checking Hydraulic Hoses and Lines 119 5 3 6 Lubrication 120 Lubricating Header 120 Lubric...

Page 12: ...ling Drapers 175 5 7 3 Checking and Adjusting Draper Tension 177 5 7 4 Adjusting Draper Tracking 179 5 7 5 Adjusting Deck Height 181 5 7 6 Replacing Draper Clips Option 186 5 7 7 Draper Roller Maintenance 187 Inspecting Draper Roller Bearing 187 Draper Deck Idler Roller 187 Draper Deck Drive Roller 191 5 7 8 Draper Deflectors 195 Removing Narrow Draper Deflectors 195 Installing Narrow Draper Defle...

Page 13: ...hain Using the Reel Drive Method 235 Replacing Chain Using the Breaking the Chain Method 237 5 9 7 Replacing Single Reel Header Drive Chain 238 5 10 Transport System Option 239 5 10 1 Checking Wheel Bolt Torque 239 5 10 2 Checking Axle Bolt Torque 239 5 10 3 Checking Tire Pressure 240 Chapter 6 Options and Attachments 243 6 1 Reel 243 6 1 1 Multi Crop Rapid Reel Conversion Kit 243 6 1 2 Reel Arm E...

Page 14: ...rive 255 Chapter 7 Unloading and Assembly 257 Chapter 8 Troubleshooting 259 8 1 Crop Loss 259 8 2 Cutting Action and Knife Components 261 8 3 Reel Delivery 264 8 4 Header and Drapers 266 8 5 Cutting Edible Beans 268 8 6 Windrow Formation 271 Chapter 9 Reference 273 9 1 Torque Specifications 273 9 1 1 SAE Bolt Torque Specifications 273 9 1 2 Metric Bolt Specifications 275 9 1 3 Metric Bolt Specific...

Page 15: ...Safety Alert Symbols The safety alert symbol indicates important safety messages in this manual and on safety signs on the machine Figure 1 1 Safety Symbol 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 ...

Page 16: ...ided 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 IMPORTANT Indicates a situatio...

Page 17: ...vy gloves Wet weather gear Respirator or filter mask Figure 1 3 Safety Equipment In addition take the following precautions Be aware that exposure to loud noises can cause hearing impairment Wear suitable hearing protection devices such as earmuffs or earplugs to help protect against loud noises Figure 1 4 Safety Equipment Provide a first aid kit in case of emergencies Keep a properly maintained f...

Page 18: ...ctionality and or safety of the machine It may also shorten the machine s service life To avoid injury or death from the 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 Figure 1 7 Safety around Equipment Keep the machine service area clean and dry Wet and or oily floors are slippery Wet spots can be dan...

Page 19: ...vicing and or disconnecting the machine Ensure that all components are tight and that steel lines hoses and couplings are in good condition before applying pressure to hydraulic systems Keep hands feet clothing and hair away from all moving and or rotating parts Clear the area of bystanders especially children when carrying out any maintenance repairs or adjustments Install the transport lock or p...

Page 20: ...hydraulic system operates under extremely high pressure Makeshift repairs can fail suddenly and create hazardous conditions Figure 1 12 Hydraulic Pressure Hazard Wear proper hand and eye protection when searching for high pressure hydraulic fluid leaks Use a piece of cardboard as a backstop instead of your hands to isolate and identify a leak If injured by a concentrated high pressure stream of hy...

Page 21: ...connected to the windrower It can be impossible to know what effect high current could have with regard to future malfunctions or shorter lifespan It is very important that welding on the header is not attempted while the header is connected to the windrower If it is unfeasible to disconnect the header from the windrower before welding contact your MacDon Dealer for welding precautions detailing a...

Page 22: ... which a safety sign was installed is replaced ensure that the repair part displays the current safety sign Replacement safety signs are available from your MacDon Dealer Parts Department 1 7 1 Installing Safety Decals If a safety decal is damaged it should be replaced 1 Decide exactly where you are going to place the decal 2 Clean and dry the installation area 3 Remove the smaller portion of the ...

Page 23: ...Safety decals are installed in several locations on the header Replace any missing or damaged decals on the machine with identical parts Figure 1 15 Upper Cross Auger Optional A MD 279085 Figure 1 16 Slow Speed Transport Optional A MD 220799 SAFETY ...

Page 24: ...215651 10 Revision B Figure 1 17 Slow Speed Transport Tow Bar Optional A MD 220797 B MD 220798 Figure 1 18 Vertical Knife Optional A MD 174684 SAFETY ...

Page 25: ... Revision B Figure 1 19 Endsheets Reel Arms and Backsheet A MD 184422 Four Places B MD 131393 Three Places on Single Reel C MD 174632 D MD 166466 Two Places E MD 131392 Double Reel F MD 131391 Two Places SAFETY ...

Page 26: ...215651 12 Revision B Figure 1 20 Backtube D115X Draper Header A MD 184422 B MD 184372 C MD 131391 SAFETY ...

Page 27: ...215651 13 Revision B Figure 1 21 Backtube D120X Draper Header A MD 184372 B MD 166466 C MD 131391 SAFETY ...

Page 28: ...215651 14 Revision B Figure 1 22 Backtube D125X Draper Header A MD 184372 B MD 166466 C MD 131391 SAFETY ...

Page 29: ...215651 15 Revision B Figure 1 23 Backtube D135XL Draper Header D130XL Draper Header Similar A MD 184372 B MD 166466 C MD 131391 D MD 131392 D135XL Double Reel Only SAFETY ...

Page 30: ...215651 16 Revision B Figure 1 24 Backtube D140XL Draper Header D145XL Draper Header Similar A MD 184372 B MD 166466 C MD 131391 D MD 131392 SAFETY ...

Page 31: ...ff of the machine Keep all the shields in place and stay clear of the moving parts Disengage the header drive put the transmission in Neutral and wait for all movement to stop before leaving the operator s position Stop the engine and remove the key from the ignition before servicing adjusting lubricating cleaning or unplugging the machine Engage the safety locks to prevent lowering of a raised un...

Page 32: ...ngage the mechanical safety lock on each reel support arm before working on or under the reel Figure 1 29 MD 166466 MD 166466 High pressure oil hazard WARNING High pressure hydraulic fluid can penetrate human skin which can cause serious injury such as gangrene which can be fatal To prevent this Do NOT go near hydraulic fluid leaks Do NOT use a finger or skin to check for hydraulic fluid leaks Low...

Page 33: ... can cause serious injury gangrene or death If injured seek emergency medical help Immediate surgery is required to remove oil Figure 1 31 MD 174632 MD 174632 Reel entanglement hazard DANGER To prevent injury from entanglement with the rotating reel Stand clear of the header while the machine is running Figure 1 32 MD 174682 MD 174682 Auger entanglement hazard DANGER To prevent injury Stop the eng...

Page 34: ...safety instructions with all machine Operators every year Ensure that all safety signs are installed and are legible Make certain that bystanders are clear of the header before starting the engine and during operation of the header Keep riders off of the machine Keep all shields in place Stay clear of moving parts Disengage the header drive put the transmission into Neutral and wait for all moveme...

Page 35: ...hields in place Figure 1 36 MD 193147 MD 193147 Loss of control hazard DANGER To prevent injury or death from loss of control Ensure the tow bar lock mechanism is locked Figure 1 37 MD 220797 MD 220797 Transport tipping hazard DANGER To prevent serious injury or death from the transport tipping Read the operator s manual for more information on potential tipping or rollover of the header while tra...

Page 36: ...on Figure 1 39 MD 220799 MD 220799 Loss of control hazard WARNING To prevent serious injury or death from loss of control Ensure the tow bar lock mechanism is locked Figure 1 40 MD 279085 MD 279085 Auger entanglement hazard DANGER To prevent injury from the rotating auger Stand clear of the auger while the machine is running Stop the engine and remove the key before servicing the auger Do NOT reac...

Page 37: ... Header crushing hazard WARNING To prevent injury or death from the fall of a raised header Do NOT lift the header at the marked locations Only use locations marked for this purpose to lower the header from the vertical to the horizontal position SAFETY ...

Page 38: ......

Page 39: ...tion of travel Export header The header configuration typical outside North America FFFT Flats from finger tight Finger tight Finger tight is a reference position in which the given sealing surfaces or components are making contact with each other and the fitting has been tightened by hand to a point where the fitting is no longer loose and cannot be tightened further by hand GSL Ground speed leve...

Page 40: ...ng materials compress or relax over a period of time spm Strokes per minute SR Single reel Tension An axial load placed on a bolt or screw usually measured in Newtons N or pounds lb This term can also be used to describe the force a belt exerts on a pulley or sprocket TFFT Turns from finger tight Timed knife drive Synchronized motion applied at cutterbar to two separately driven knives from a sing...

Page 41: ...3 4 5 Figure 2 1 Windrower Header Components A Reel Cam B Reel Tines C Draper D Center Reel Arm Prop Handle E Hydraulic Connections F Transport Light G Reel Safety Prop H Endshield J Reel Lift Cylinder K Skid Shoe L Reel Fore Aft Cylinder M Knife Drive Box N Crop Divider P Crop Divider Rod Q Reel Endshield R Hydraulic Hose Management System PRODUCT OVERVIEW ...

Page 42: ...imed hydraulic motors with cogged belts to two heavy duty knife drive boxes S Knife stroke 76 mm 3 in S Double knife speed strokes per minute 1 D115X 1500 1900 spm S Double knife speed strokes per minute 1 D120X 1500 1900 spm S Double knife speed strokes per minute 1 D125X 1400 1700 spm S Double knife speed strokes per minute 1 D130XL 1200 1600 spm S Double knife speed strokes per minute 1 D135XL ...

Page 43: ...ting decks 4 6 m 15 ft 1540 1770 mm 60 5 8 69 11 16 in S Delivery opening width center delivery variable by shifting decks 6 1 13 7 m 20 45 ft 1720 1950 mm 67 1 8 76 11 16 in S PR15 Pick Up Reel Quantity of tine tubes 5 6 or 9 Center tube diameter 10 7 m 35 ft single reel only 254 mm 10 in Center tube diameter All reel sizes except 10 7 m 35 ft single reel 203 mm 8 in Finger tip radius Factory set...

Page 44: ... Weight Estimated weight range with base header variances are due to different package configurations D115X 4 6 m 15 ft header 1479 1538 kg 3260 3390 lb D120X 6 0 m 20 ft header 1678 1640 kg 3615 3700 lb D125X 7 6 m 25 ft header 1753 kg 3872 lb D130XL 9 1 m 30 ft header 2318 kg 5110 lb D135XL 10 7 m 35 ft header 2562 2730 kg 5649 6018 lb D140XL 12 2 m 40 ft header 2823 kg 6224 lb D145XL 13 7 m 45 ...

Page 45: ...sport Mode Reel Fore Aft Fully Retracted D1XL Series headers B 2 long dividers installed 2845 mm 112 in S D1XL Series headers A 2 long dividers removed 2667 mm 105 in S D1X Series headers B 2 long dividers installed 2636 mm 104 in S D1X Series headers A 2 long dividers removed 2452 mm 97 in S Header Height Transport Mode Reel Fore Aft Fully Retracted D1X Series headers C 2 long dividers installed ...

Page 46: ......

Page 47: ...e people around you Before allowing someone 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 ...

Page 48: ...sion in gear when travelling downhill Never attempt to get on or off a moving machine Do NOT leave the operator s station while the engine is running To avoid bodily injury or death from the 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 indicat...

Page 49: ...To prevent damage to the reel support arms do NOT transport the header with the reel safety props engaged Engaging Reel Safety Props Engage the reel safety props anytime you are going to work on or around a raised reel When engaged the reel safety props prevent the reel from unexpectedly lowering Figure 3 3 Engaged Reel Safety Prop Left Shown 1 Raise the reel fully 2 Move reel safety props A to th...

Page 50: ... arm cylinder mounts and the center arm pins Disengaging Reel Safety Props Disengage the reel safety props once you have completed working on or around a raised reel to ensure the proper operation of the reel and header Figure 3 5 Left Reel Safety Prop 1 Raise the reel to its maximum height 2 Move reel safety prop A back inside the reel arm 3 Repeat the previous step on the opposite end of the ree...

Page 51: ...f the header Opening Endshields The endshields can be opened to access serviceable components or stored items This procedure details the steps necessary to open the left endshield the procedure for opening the right endshield is opposite Figure 3 7 Left Endshield 1 Locate the endshield 2 From the back of the header push release lever A to unlock the endshield 3 Pull the endshield open using handle...

Page 52: ...d pull the endshield free of hinge tab A and swing the endshield toward the rear of the header 6 Engage safety latch B on the hinge arm to secure the endshield in the fully open position Closing Endshields Close and lock the endshields before moving the header Figure 3 10 Left Endshield 1 Disengage latch B to allow the endshield to move 2 Insert the front of the endshield behind hinge tab A and in...

Page 53: ...ocedure provided here NOTE A D1X Series Draper Header is shown in the illustration A D1XL Series Draper Header is similar Figure 3 12 Left Endshield on D1X Series Draper Header 1 Fully open the endshield For instructions refer to Opening Endshields page 37 2 Engage lock A to prevent endshield movement 3 Remove self tapping screw B 4 Slide the endshield upwards and remove it from hinge arm C Instal...

Page 54: ...nstructions refer to Checking and Adjusting Endshields page 40 Checking and Adjusting Endshields The header s endshields are made from molded plastic and are therefore subject to expansion or contraction caused by variations in the ambient temperature The position of the top pin and that of the lower latch can be adjusted to compensate for dimensional changes in the endshield Checking the endshiel...

Page 55: ...e desired gap between the front end of the endshield and the header frame Refer to Table 3 1 page 40 for the recommended endshield gap at various ambient temperatures 5 Tighten three bolts A on the latch assembly to 27 Nm 20 lbf ft Figure 3 17 Left Endshield Support Tube on D1X Series Header 6 Tighten four bolts A on support tube bracket B to 31 Nm 23 lbf ft NOTE A D1X Series Draper Header is show...

Page 56: ... day Do NOT take chances Personal safety devices that may be needed include 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 1 Check the machine for leaks and any parts that are missing brok...

Page 57: ... correct a problem shut off the engine and remove the key from the igniation After attaching the header to the windrower for the first time follow these steps 1 Operate the machine with the reels drapers and knives running slowly for 5 minutes Watch and listen FROM THE OPERATOR S SEAT for binding or interfering parts NOTE The reels and side drapers will not operate until oil flow fills the lines 2...

Page 58: ...op the engine and remove the key from the ignition before leaving the operator s seat for any reason To shut down the windrower do the following 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 Shut down the engine and remove the key from the ignition 7 Wait for all movement t...

Page 59: ...re clear of the machine before starting the engine or engaging any header drives For instructions refer to your windrower 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 OPERATION ...

Page 60: ...ional attachments can be ordered and installed by your MacDon Dealer Refer to 6 Options and Attachments page 243 for descriptions of available items 3 6 2 Header Settings The following tables provide guidelines for setting up D1X or D1XL Series Draper Headers for different crops and crop conditions however the suggested settings can be changed to suit crops and conditions not covered in the tables...

Page 61: ...ON 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 Force required to lift header at ends Refer to your windrower operator s manual for adjustment procedures 5 Set header angle as shallow as possible setting A with center link and skid shoes while maintaining cutting height Refer to 3 7 3 Header Angle page 63 ...

Page 62: ...ON 11 Stabilizer wheels are used to limit the side to side movement when cutting off the ground in rolling terrain and to minimize bouncing 12 Force required to lift header at ends Refer to your windrower operator s manual for adjustment procedures 13 Set header angle as shallow as possible setting A with center link and skid shoes while maintaining cutting height Refer to 3 7 3 Header Angle page ...

Page 63: ... 19 Stabilizer wheels are used to limit the side to side movement when cutting off the ground in rolling terrain and to minimize bouncing 20 Force required to lift header at ends Refer to your windrower operator s manual for adjustment procedures 21 Set header angle as shallow as possible setting A with center link and skid shoes while maintaining cutting height Refer to 3 7 3 Header Angle page 63...

Page 64: ...ION 27 Stabilizer wheels are used to limit the side to side movement when cutting off the ground in rolling terrain and to minimize bouncing 28 Force required to lift header at ends Refer to your windrower operator s manual for adjustment procedures 29 Set header angle as shallow as possible setting A with center link and skid shoes while maintaining cutting height Refer to 3 7 3 Header Angle page...

Page 65: ...ATION 35 Stabilizer wheels are used to limit the side to side movement when cutting off the ground in rolling terrain and to minimize bouncing 36 Force required to lift header at ends Refer to your windrower operator s manual for adjustment procedures 37 Set header angle as shallow as possible setting A with center link and skid shoes while maintaining cutting height Refer to 3 7 3 Header Angle pa...

Page 66: ...uired OPERATION 43 Stabilizer wheels are used to limit the side to side movement when cutting off the ground in rolling terrain and to minimize bouncing 44 Force required to lift header at ends Refer to your windrower operator s manual for adjustment procedures 45 Set header angle as shallow as possible setting A with center link and skid shoes while maintaining cutting height Refer to 3 7 3 Heade...

Page 67: ...RATION 51 Stabilizer wheels are used to limit the side to side movement when cutting off the ground in rolling terrain and to minimize bouncing 52 Force required to lift header at ends Refer to your windrower operator s manual for adjustment procedures 53 Set header angle as shallow as possible setting A with center link and skid shoes while maintaining cutting height Refer to 3 7 3 Header Angle p...

Page 68: ...uired OPERATION 59 Stabilizer wheels are used to limit the side to side movement when cutting off the ground in rolling terrain and to minimize bouncing 60 Force required to lift header at ends Refer to your windrower operator s manual for adjustment procedures 61 Set header angle as shallow as possible setting A with center link and skid shoes while maintaining cutting height Refer to 3 7 3 Heade...

Page 69: ...quired OPERATION 67 Stabilizer wheels are used to limit the side to side movement when cutting off the ground in rolling terrain and to minimize bouncing 68 Force required to lift header at ends Refer to your windrower operator s manual for adjustment procedures 69 Set header angle as shallow as possible setting A with center link and skid shoes while maintaining cutting height Refer to 3 7 3 Head...

Page 70: ...the reel at each cam or finger pitch setting as well as the reel position relative to the ground at different positions on the reel arm Refer to 3 6 2 Header Settings page 46 for the applicability of each finger pattern and reel position Table 3 11 Recommended Reel Settings Cam Setting Number Finger Speed Gain Reel Position Number Reel Finger Pattern 1 0 6 or 7 2 20 3 or 4 OPERATION ...

Page 71: ...nd 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 ...

Page 72: ...the ground Cutting height will vary depending on a range of factors including crop type and crop conditions Cutting off the Ground 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 an even stubble height and greatly reduces operato...

Page 73: ...e ground as shown NOTE This reduces the weight of the assembly and makes adjusting the wheel position easier 6 Lift the left wheel slightly to support the weight of the wheel and pull handle C upwards to release the lock 7 Lift the left wheel to the desired height and engage the support channel into slot D in the upper support 8 Push down on handle C to lock 9 Lift the right wheel back into field ...

Page 74: ...tor s manual for details 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 46 for recommended use in specific crops and crop conditions DANGER To prevent injury or death from the unexpected start up of the machine always stop the e...

Page 75: ...an result in damage to the suspension system 9 Adjust the header angle to the desired working angle with the windrower header angle controls If header angle is not critical set it to mid position 10 Use the Harvest Performance Tracker HPT controls to automatically maintain cutting height Refer to your windrower operator s manual for details Cutting on the Ground Cutting on the ground is performed ...

Page 76: ...rops before going under the header for any reason 1 Raise the header fully 2 Engage the header s safety props 3 Shut down the engine and remove the key from the ignition 4 Raise the stabilizer wheels or slow speed transport wheels fully if installed For instructions refer to the following Adjusting Stabilizer Slow Speed Transport Wheels page 58 Adjusting Stabilizer Wheels page 60 Figure 3 26 Inner...

Page 77: ...justments 3 7 3 Header Angle Header angle is the angle between the header and the ground The header angle is adjustable to accommodate different crop conditions and or soil types and can be adjusted using the center link between the windrower and the header For in cab adjustment details refer to the windrower operator s manual Figure 3 28 Header Angle The header angle A controls the distance B bet...

Page 78: ...articular crop conditions refer to 3 6 2 Header Settings page 46 Adjusting Header Angle Header angle can be adjusted using the center link between the windrower and the header Refer to the windrower operator s manual for adjustment details 3 7 4 Reel Speed Reel speed is one of the factors that determines how crop is moved from the cutterbar onto the drapers The reel performs best when it appears t...

Page 79: ...l cleanly cut crop and evenly distribute crop material in uniform windrows For effects of ground speed on windrow formation refer to 3 10 Windrow Types page 80 Reduce ground speed in difficult cutting conditions to reduce loads on cutting components and drives Use lower ground speeds in very light crops e g short soybeans to allow the reel to pull in short plants Start at 4 8 5 8 km h 3 0 3 5 mph ...

Page 80: ... 1400 NOTE Refer to your windrower operator s manual for information about using the HPT 3 7 8 Reel Height The reel operating position depends on the type of crop and cutting conditions You can create preset reel height positions using the Headland Management feature on an M1 Series Windrower To set up this feature refer to your windrower operator s manual Set the reel height and fore aft position...

Page 81: ...r angle Refer to 3 7 3 Header Angle page 63 for adjustment instructions Adjust reel position only if header angle adjustments are not satisfactory For recommended reel positions in specific crops and crop conditions refer to 3 6 2 Header Settings page 46 NOTE In crops that are difficult to pick up such as rice or severely lodged crops that require full forward positioning of the reel set the reel ...

Page 82: ...s The following outlines the function of each cam position and provides set up guidelines for various crop conditions The setting numbers are visible above the slots on the cam disc For instructions refer to Adjusting Reel Cam page 70 Figure 3 33 Finger Profile Position 1 Cam Position 1 Reel Position 6 or 7 delivers the most even crop flow onto the drapers without fluffing or disturbing the materi...

Page 83: ...5 faster than the reel speed Figure 3 37 Finger Profile Position 4 Cam Position 4 Header Angle at Maximum and Reel Fully Forward provides the maximum amount of reel reach below the cutterbar to pick up lodged crops This position leaves a significant amount of stubble when cutting height is set to approximately 203 mm 8 in In damp materials such as rice it is possible to double the ground speed bec...

Page 84: ...c transparent view shown in the illustration for improved clarity 4 Turn latch pin A clockwise to engage and lock the cam disc IMPORTANT Ensure the cam is secured into position before operating the machine 5 For double reel headers repeat the above procedure for the next reel 3 7 11 Crop Dividers Crop dividers are used to help divide the crop when harvesting They are removable to allow installatio...

Page 85: ...Dividers without Latch Option from Header To correctly remove crop dividers without the latch option follow the recommended removal procedure provided here DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine remove the key and engage the safety props before going under the header for any reason 1 Lower the reel fully For instruct...

Page 86: ...remove the key and engage the safety props before going under the header for any reason 1 Lower the reel fully For instructions refer to your windrower operator s manual 2 Raise the header fully For instructions refer to your windrower operator s manual 3 Shut down the engine and remove the key from the ignition 4 Engage the safety props For instructions refer to your windrower operator s manual 5...

Page 87: ...er to Closing Endshields page 38 Installing Crop Dividers without Latch Option onto Header To correctly install crop dividers without the latch option follow the recommended installation procedure provided here DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine remove the key and engage the safety props before going under the he...

Page 88: ...from the endsheet Figure 3 46 Crop Divider 7 Position the crop divider as shown by inserting lugs A into the holes in the endsheet Figure 3 47 Crop Divider 8 Lift the forward end of the crop divider and install bolt A and special stepped washer B step towards divider Tighten the bolt 9 Pull on the tip of the crop divider to ensure there is no lateral movement If necessary adjust bolts C to tighten...

Page 89: ...vider Rods Without Divider Rods Alfalfa Lodged cereal Edible beans Canola Peas Milo Flax Soybeans Rice Grass seed Sudan grass Soybeans Lentils Winter forage Standing cereal Removing Crop Divider Rods To remove the crop divider rods and place them in their storage position perform the removal procedure provided here Figure 3 48 Crop Divider Rod 1 Loosen bolt A and remove crop divider rod B from bot...

Page 90: ...on procedure provided here Figure 3 50 Right Endsheet 1 Remove crop divider rods A from their storage location on the inboard of the side endsheet Figure 3 51 Divider Rod on Crop Divider 2 Position crop divider rod B on the tip of the crop divider as shown and tighten bolt A 3 Repeat procedure at opposite end of header OPERATION ...

Page 91: ...Weather conditions Available drying time Refer to 3 10 Windrow Types page 80 for the pros and cons of various windrow configurations with respect to these factors and also refer to 3 9 Double Windrowing page 79 3 8 1 Manually Adjusting Delivery Opening on Header Both draper decks can be moved manually to adjust the delivery opening between 1720 mm and 1950 mm 67 1 8 in and 76 11 16 in Figure 3 52 ...

Page 92: ...nboard to increase the maximum opening size IMPORTANT Ensure that the deck shift stops are sufficiently adjusted to prevent the decks from contacting each other 3 Install two 1 4 in hex head bolts A and nuts and tighten them Adjusting outboard deck shift stop Figure 3 54 Outboard Hydraulic Deck Shift Stops 4 Remove two 1 4 in hex head bolts A and nuts 5 Slide stop B inboard to move decks away from...

Page 93: ...ion Refer to your windrower operator s manual for identification and operation of the deck shift control Laying a double windrow Figure 3 55 Left and Right End Crop Delivery 1 Use the deck shift control in the windrower cab to position the decks at the left end of the header and deliver crop from right end A or shift the decks to the right end of the header and deliver crop from left end B Figure ...

Page 94: ...eads are distributed across full width of windrow This windrow can be formed by center delivery only Good Good Excellent Reel and ground speed approximately equal Medium draper speed Center delivery Fantail The stalks are crossed in the center and the heads are in line along outside edges This windrow can be formed by center delivery only Fair Fair Fair Low draper speed Low header angle Center del...

Page 95: ...r delivery if the crop is leaning to one side Poor Fair Poor Low reel speed Less aggressive tine pitch If crop is leaning end delivery or center delivery 75 diagonal The stalks are closer to parallel than the 45 windrow Stalk tips are lined along one edge with heads opposite 75 to windrow perpendicular This windrow can be formed by end delivery or by center delivery if the crop is leaning to one s...

Page 96: ...sture drops below 45 If ground is wet due to frequent rains cut when weather allows and let the forage lie on wet ground until it dries to the moisture level of the ground Cut hay will dry only to the moisture level of the ground beneath it so consider moving the windrow to drier ground 3 11 3 Weather and Topography Weather conditions and topography can greatly affect haying Cut as much hay as pos...

Page 97: ... that the machine can straddle NOTE Driving on the windrow in high yield crops may be unavoidable if a full width windrow is necessary 3 11 6 Raking and Tedding Raking or tedding speeds up drying however the resulting leaf loss may outweigh the benefits There is little or no advantage to raking or tedding if the ground beneath the windrow is dry Large windrows on damp or wet ground should be turne...

Page 98: ...oat springs are NOT used to level the header If the header is not level check the pressure of the windrower s tires to ensure proper inflation refer to your windrower operator s manual If the windrower s tires are properly inflated and the header is still not level adjust the windrower linkages as required refer to the appropriate section in the windrower operator s manual OPERATION ...

Page 99: ...r handling knives IMPORTANT Lowering a rotating reel on a plugged cutterbar will damage the reel components To unplug the cutterbar reverse the windrower If the cutterbar is still plugged do the following 1 Stop the forward movement of the machine and disengage the header drives 2 Raise the header to prevent it from filling with dirt and engage the header drive clutch 3 If the plug does NOT clear ...

Page 100: ... A improves delivery of very bulky crops across the header Figure 3 57 Upper Cross Auger The UCA is available as an optional kit For more information refer to 6 4 3 Upper Cross Auger page 253 NOTE Optional wide draper deflectors are NOT compatible with the UCA OPERATION ...

Page 101: ...e field Before driving windrower on a roadway be sure flashing amber lamps red tail lamps and head lamps are clean and working properly Pivot amber lamps for best visibility by approaching traffic Always use lamps when travelling on roads to provide adequate warning to other vehicles Do NOT use field lamps on roads they may confuse other drivers Before driving on a roadway clean slow moving vehicl...

Page 102: ...ransporting Connect hitch to towing vehicle using a proper hitch pin with a spring locking pin or other suitable fastener Attach the hitch safety chain to the towing vehicle Adjust the safety chain length to provide only enough slack to permit turning Connect the header seven pole plug wiring harness to the mating receptacle on the towing vehicle the seven pole receptacle is available from your Ma...

Page 103: ...p of the machine always stop the engine and remove the key before making adjustments to the machine 1 Shut down the engine and remove the key from the ignition Figure 3 58 Tow Bar Assembly 2 Block the tires to prevent the header from rolling and unhook the header from the towing vehicle 3 Disconnect electrical connector A on the tow bar 4 Remove pin B from the tow bar and disassemble outer section...

Page 104: ...7 Push latch B and lift tow bar C from the hook Release latch 8 Install clevis pin A Storing Tow Bar Perform the following procedure to store the tow bar Figure 3 61 Tow Bar Assembly The tow bar consists of two sections an inner half A and an outer half B this makes storage and handling easier OPERATION ...

Page 105: ...pport B on the endsheet using hitch pin C Secure with a lynch pin 3 Install rubber strap D on cradle A Figure 3 63 10 7 m and 12 2 m 35 ft and 40 ft Header 4 At the right end of the 10 7 m and 12 2 m 35 ft and 40 ft header a Place the inner end of the inner half of the tow bar in cradle A on header backtube b Secure tube end in support B with clevis pin C Secure with hairpin c Install rubber strap...

Page 106: ... the windrower operator s manual 7 Place the transport wheels into field position For instructions refer to the following Moving Front Left Wheels into Field Position page 92 Moving Rear Right Wheels into Field Position page 94 Moving Front Left Wheels into Field Position Perform the following procedure to move the front left wheels into field position DANGER To prevent bodily injury or death from...

Page 107: ... the rear of the header Store the pin in hole C at the top of the leg 6 Pull handle D upwards to release and lower the linkage into the vertical support Figure 3 66 Front Wheels 7 Align lift hook A with lug B and lift the wheel assembly to engage the pin in the lift hook Ensure latch C is engaged 8 Install clevis pin D and secure to the center of the axle with hairpin OPERATION ...

Page 108: ... right wheels into field position DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine remove the key and engage the safety props before going under the header for any reason 1 Raise the header fully 2 Shut down the engine and remove the key from the ignition 3 Engage the header s safety props Figure 3 68 Rear Wheel Right Side 4 P...

Page 109: ...nnel into slot D in the vertical support 8 Push down on handle C to lock Figure 3 70 Rear Wheel Right Side 9 Pull pin A on brace B on the right wheel in front of the cutterbar Disengage the brace from the cutterbar and lower the brace against axle C 10 Remove pin D lower support E onto axle and reinsert the pin into the support 11 Swing axle C clockwise towards the rear of the header OPERATION ...

Page 110: ...bar Figure 3 72 Field Position 16 Complete the conversion by ensuring left wheels A and right wheels B are in the position shown 3 15 4 Converting from Field to Transport Position To convert from field position to transport position follow all the recommended procedures provided here Moving Front Left Wheels into Transport Position Perform the following procedure to move the front left wheels into...

Page 111: ...ully 3 Shut down the engine and remove the key from the ignition 4 Engage the header s safety props Figure 3 74 Left Front Wheels 5 Remove the hairpin and clevis pin A 6 Pull the latch handle B to release suspension linkage C and pull the suspension linkage away from spindle D 7 Lower the wheels slowly Figure 3 75 Suspension Linkage 8 Lower handle A to lock OPERATION ...

Page 112: ...Perform the following procedure to move the rear right wheels into transport position Figure 3 77 Separating Axles 1 Remove hairpin A from latch B 2 Lift latch B disengage right axle C and lower to the ground CAUTION Stand clear of the wheels and release the linkage carefully the wheels will drop suddenly once the mechanism is released 3 Pull handle D carefully to release the spring and lower the ...

Page 113: ...the pin to lock 7 Pull pin D swivel wheel C counterclockwise 90 degrees and release the pin to lock Figure 3 79 Left Wheel in Transport Position 8 Ensure the left wheel is in the transport position as shown Figure 3 80 Right Rear Wheel 9 Pull the pin A and swivel the right rear wheel B clockwise 90 degrees OPERATION ...

Page 114: ...es the tube on the axle 12 Swing the brace C into the position shown and insert the brace into the slot D behind the cutterbar Position the brace so that pin E engages the hole in the bracket F The right wheel is now in transport position 13 Disengage the header cylinder lift stops 14 Detach the header s hydraulic and electrical connections from the windrower Refer to 4 Header Attachment Detachmen...

Page 115: ...of the header 2 Remove clevis pin C and detach the tube end from support B 3 Reinstall clevis pin C 4 Lift the inner half of the tow bar off the header and place it near the left side of the header Figure 3 84 Tow Bar Removal Left Side 5 Unhook rubber strap D from cradle A on the left side of the header 6 Remove hitch pin C from support B and remove the tow bar 7 Reinstall rubber strap D on cradle...

Page 116: ...bar to inner half A Figure 3 86 Tow Bar Assembly 9 Lift outer half B and insert it into inner half A Figure 3 87 Tow Bar Assembly 10 Secure the two halves together with L pin A and then turn to lock Secure the L pin with ring B 11 Connect the electrical harness to connector C OPERATION ...

Page 117: ...ar A onto the axle and push against latch B until the tow bar pins drop into hooks C 13 Check that latch B has engaged the tow bar 14 Install clevis pin D and secure with hairpin Figure 3 89 Harness Connection 15 Connect electrical harness A at the front wheel OPERATION ...

Page 118: ......

Page 119: ... two shield mount plates A MD 307045 from the forming shield before attaching the draper header to the windrower 4 1 Attaching Header to M1 Series Windrowers DANGER To prevent bodily injury or death from the 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 1 Shut down the engine and remove the key from t...

Page 120: ...Header 4 D115X Draper Headers Pull hydraulic hose management system A towards the left outboard end of the header disengage ball stud B from the cradle in support C Figure 4 5 Windrower Left Outer Leg 5 Connect hydraulic hose management system A to the left outer leg of the windrower by pushing ball stud B into ball stud latch C NOTE The hydraulic hoses have been removed from the illustration for ...

Page 121: ...emove the cover from electrical connector E push the electrical connector onto the receptacle and secure by turning the collar on the electrical connector clockwise Figure 4 7 Knife Reel Drive Multicoupler 11 Retrieve knife and reel drive multicoupler A from the hydraulic hose management system 12 Push knob B on the hydraulic receptacle and pull handle C fully away from the windrower 13 Open cover...

Page 122: ...215651 108 Revision B Figure 4 9 Hydraulic Multicouplers and Hose Routing 15 Ensure the hydraulic hose routing is as straight as possible and avoid potential rub wear points HEADER ATTACHMENT DETACHMENT ...

Page 123: ...ulticoupler A Pressure may cause the handle to kick back with force 4 Push lock button B and pull handle C to disengage multicoupler A and disconnect the hydraulics from the windrower knife reel drive receptacle 5 Remove any debris that may have accumulated on the receptacle and close cover D 6 Route the hose bundle with multicoupler A back to the storage position on the hydraulic hose management ...

Page 124: ...tration for clarity Figure 4 13 Hydraulic Hose Management System All Headers Except D115X 12 All draper headers except D115X Pull arm B towards latch D on the left side of the header Align pin C to the latch opening Push arm B so lever A can secure the pin Figure 4 14 Hydraulic Hose Management System D115X Header 13 D115X Draper Headers Pull hose management system A inboard and toward the center o...

Page 125: ...rower Platform 14 Swing the left windrower platform forwards For instructions refer to the windrower operator s manual 15 Detach the header from the windrower For instructions refer to the windrower operator s manual HEADER ATTACHMENT DETACHMENT ...

Page 126: ......

Page 127: ...hedule Record page 116 to keep track of your scheduled maintenance 5 1 Preparing Machine for Servicing Observe all safety precautions before beginning service on the machine DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine and remove the key before leaving the operator s seat and always engage the safety props before going und...

Page 128: ...e spring clip C over the face of the aft pin E until it slips into the groove Do NOT press the spring clip lengthwise from the closed end 8 Ensure the spring clip C is seated into the grooves of the front pin D and the aft pin E 5 2 2 Installing Sealed Bearing A typical sealed bearing is shown here but the same steps apply to any sealed bearing DANGER To prevent injury or death from the unexpected...

Page 129: ...215651 115 Revision B 7 Loosen the flangette bolts on the mating bearing one turn and then retighten This will allow the bearing to properly line up MAINTENANCE AND SERVICING ...

Page 130: ... Inspection page 117 End of Season Refer to 5 3 4 End of Season Service page 118 10 Hours or Daily ü Hydraulic Hoses and Lines Refer to 5 3 5 Checking Hydraulic Hoses and Lines page 119 NOTE Keep a record of daily maintenance as evidence of a properly maintained machine however daily maintenance records are not required to meet normal warranty conditions ü Knife Sections Guards and Hold Downs Refe...

Page 131: ...pection Break in inspection involves checking belts fluids and performing general machine inspections for loose hardware or other areas of concern Break in inspections ensure that all components can operate for an extended period without requiring service or replacement The break in period is the first 50 hours of operation after the machine s initial start up Inspection Interval Item Refer to 5 H...

Page 132: ...aterials may be toxic and or flammable CAUTION Cover cutterbar and knife guards to prevent injury from accidental contact 1 Clean the header thoroughly 2 Bring the machine for storage in a dry and protected place if possible If storing outside always cover the machine with a waterproof canvas or other protective material NOTE If storing the machine outside remove the drapers and store them in a da...

Page 133: ...sure Keep hands and body away from pin holes and nozzles which eject fluids under high pressure If any fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result Figure 5 4 Testing for Hydraulic Leaks Use a piece of cardboard or paper to search for leaks IMPORTANT Keep hydraulic coupler tips and connectors c...

Page 134: ...e 5 6 Grease Point Location Decal 1 Open the driveshields at the ends of the header to access greasing points For instructions refer to Opening Endshields page 37 2 Refer to the grease point location decal for the locations of the greasing points on the header For service intervals refer to Lubrication Service Intervals page 121 3 Wipe each grease fitting with a clean cloth before lubricating to a...

Page 135: ... 10 Hours A Drive Roller Bearing IMPORTANT When greasing the drive roller bearing clear any debris and excess grease from around the bearing and bearing housing Inspect the condition of the bearing and bearing housing Grease the feed draper drive roller bearing until grease comes out of the seal Wipe any excess grease from area after greasing B Idler Roller Bearing Both Sides IMPORTANT When greasi...

Page 136: ...ew guards after greasing If required relieve the pressure by pressing the check ball in the grease fitting IMPORTANT Overgreasing the knifehead puts pressure on the knife causing it to rub against the guards resulting in excessive wear from binding Do NOT overgrease the knifehead Apply only one to two pumps using a mechanical grease gun do NOT use an electric grease gun If more than six to eight p...

Page 137: ... with 1 max molybdenum disulphide NLGI Grade 2 lithium base unless otherwise specified Figure 5 10 Every 100 Hours A Knife Drive Box Check Oil Level with Top of Knife Drive Box in Horizontal Position B Dipstick Level between Lower Hole and End of Dipstick C Upper Cross Auger Bearing D Reel Drive Chain E Hydraulic Couplers Use WD40 or Equivalent MAINTENANCE AND SERVICING ...

Page 138: ...nt75 B Upper Cross Auger Bearing Two Places 76 MAINTENANCE AND SERVICING 75 U joint has an extended lubrication cross and bearing kit Stop greasing when greasing becomes difficult or if U joint stops taking grease Overgreasing will damage U joint Six to eight pumps are sufficient at first grease done at factory Decrease grease interval as U joint wears and requires more than six pumps 76 Use High ...

Page 139: ...heel Pivot B Frame Wheel Pivot Both Sides C Double Reel U Joint77 MAINTENANCE AND SERVICING 77 U joint has an extended lubrication cross and bearing kit Stop greasing when greasing becomes difficult or if U joint stops taking grease Overgreasing will damage U joint Six to eight pumps are sufficient at first grease done at factory Decrease grease interval as U joint wears and requires more than six...

Page 140: ...se stated NOTE Use High Temperature Extreme Pressure EP2 Performance with 1 max molybdenum disulphide NLGI Grade 2 lithium base unless otherwise specified Figure 5 13 Every 500 Hours A Reel Right Side Bearing C Wheel Bearings Four Places B Reel Center Bearing D Reel Left Bearing MAINTENANCE AND SERVICING ...

Page 141: ...wire identification is printed on each wire covering Figure 5 15 Wire Identification Location Identification Number Branch location Wire example CH1234B XXX The location A is the chassis harness The identification number B is 1234 The branch wire location C is B This means that there is one splice point before you reach CH1234B Table 5 1 D1XL Series Wire Prefix Identification Prefix System HM D1XL...

Page 142: ... DN Brown Dark brown LN Brown Light brown U Blue Blue DU Blue Dark blue LU Blue Light blue G Green Green DG Green Dark green LG Light green Light green P Purple Purple R Red Red W White White Y Yellow Yellow O Orange Orange S Slate Slate gray K Pink Pink V Violet Violet 5 4 2 Replacing Light Bulbs To replace the light bulbs on the header perform the recommended replacement procedure provided here ...

Page 143: ...auto reel height sensor can be checked from inside the windrower or manually at the sensor For in cab instructions refer to the windrower operator s manual DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key before making adjustments to the machine WARNING To prevent bodily injury from the fall of a raised reel always engag...

Page 144: ...ointer behind it IMPORTANT To measure the output voltage of the reel height sensor the windrower engine needs to be running and supplying power to the sensor Always engage the windrower parking brake and stay away from the reel Table 5 4 Reel Height Sensor Voltage Limits Power Unit Voltage Range X Voltage Y Voltage M1 Series Windrower 0 5 0 9 V 4 1 4 5 V To check the voltage range manually follow ...

Page 145: ...age the reel safety props For instructions refer to Engaging Reel Safety Props page 35 13 Start the engine 14 Use the windrower display or a voltmeter if measuring the sensor manually to measure voltage range X Refer to Table 5 4 page 130 for range requirements Figure 5 21 Reel Height Sensor Right Reel Arm with Reel Up 15 If using a voltmeter measure the voltage between the ground Pin 2 wire and t...

Page 146: ...k and are not worn or damaged worn and damaged sections leave behind uncut plants Worn or damaged sections can be replaced without removing the knife from the cutterbar DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key before making adjustments to the machine WARNING To prevent bodily injury from the fall of a raised reel...

Page 147: ...nuts B NOTE If replacing screws ensure they are fully inserted Do NOT use nuts to draw screws into the knife bar 10 Torque nuts to 9 5 Nm 7 lbf ft 5 5 2 Spare Knife A spare knife contains all the parts required to replace the entire knife on the cutterbar A spare knife can be ordered when you order a new header Figure 5 24 Spare Knife A spare knife can be stored in the header frame backtube A at t...

Page 148: ...round the knifehead 6 Remove grease fitting B from the pin NOTE Removing the grease fitting will make it easier to reinstall the knifehead pin later 7 Remove bolt and nut A 8 Use a screwdriver or chisel in slot C to release the load on the knifehead pin 9 Use a screwdriver or chisel to pry the pin upwards in the pin groove until the pin is clear of the knifehead 10 Push the knife assembly inboard ...

Page 149: ...eter as pin A Tap seal B bearing C plug D and O ring E from the underside of the knifehead NOTE Seal B can be replaced without removing the bearing When changing the seal check the pin and needle bearing for wear and replace if necessary 5 5 5 Installing Knifehead Bearing The knifehead bearing allows the knifehead pin to rotate within the knifehead as the drive arm strokes the knife back and forth...

Page 150: ...ngage the reel safety props before going under the raised reel for any reason WARNING Stand to the rear of the knife during removal to reduce the risk of injury from cutting edges Wear heavy gloves when handling the knife 1 Raise the reel fully 2 Shut down the engine and remove the key from the ignition 3 Engage the reel safety props For instructions refer to Engaging Reel Safety Props page 35 Fig...

Page 151: ... are aligned and the knife sections are contacting the shear surfaces of the knife guards Depending on your cutting needs you may be using either pointed guards or stub guards Adjusting Pointed Knife Guards To adjust pointed knife guards perform the recommended adjustment procedure provided here DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the en...

Page 152: ...erform the recommended replacement procedure provided here DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key before making adjustments to the machine 1 Shut down the engine and remove the key from the ignition Figure 5 32 Pointed Guards 2 Stroke the knife manually until the knife sections are spaced midway between the gua...

Page 153: ... adjust the clearance between the hold downs and the knife For instructions refer to Checking and Adjusting Hold Downs with Pointed Guards page 141 7 Torque nuts B to 88 Nm 65 lbf ft Replacing Stub Knife Guards Stub knife guards complete with top guides and adjuster plates are designed to cut tough crops and are factory installed at the outer ends of specific headers DANGER To prevent bodily injur...

Page 154: ... top guide C to the cutterbar 4 Remove guard B the plastic wearplate if installed top guide C and adjuster bar D Figure 5 36 Stub Knife Guards A Drive Side Guard B Standard Guard with Ledger Plate IMPORTANT The first four outboard guards A on the drive sides of the header do NOT have ledger plates Ensure the proper replacement guards are installed at these locations MAINTENANCE AND SERVICING ...

Page 155: ...between the hold downs and knife sections For checking and adjusting instructions refer to the following procedures Checking and Adjusting Hold Downs with Pointed Guards page 141 Checking and Adjusting Hold Down at Double Knife Center Pointed Guard page 142 Checking and Adjusting Hold Down with Stub Guards page 143 NOTE Align guards prior to adjusting the hold downs For instructions refer to Adjus...

Page 156: ...il finger tight b Turn three adjuster bolts E clockwise to raise the front of the hold down and increase clearance or counterclockwise to lower the front of the hold down and decrease clearance c When all the adjustments are complete and the specified clearances are achieved torque nuts D to 88 Nm 65 lbf ft WARNING Check to be sure all bystanders have cleared the area 6 Complete the hold down adju...

Page 157: ...t low engine speed and listen for noise caused by insufficient clearance IMPORTANT Insufficient hold down clearance will result in overheating of the knife and guards readjust as necessary Figure 5 41 Center Guard 6 Manually stroke knives until sections A are under hold down B as shown 7 Loosen nuts C and back off bolts D until they don t contact cutterbar 8 Lightly clamp hold down B to guard E wi...

Page 158: ...ifehead shield attaches to the endsheet and reduces the knifehead opening to prevent cut crop from accumulating in the knifehead cutout Part numbers for knifehead shields knife opening covers and mounting hardware are listed in the header parts catalog IMPORTANT Remove the shields when using the cutterbar on the ground in muddy conditions Mud may pack into the cavity behind the shield which could ...

Page 159: ...ofile of the knifehead and or hold downs 5 Bend knifehead shield A along the slit to conform to the endsheet 6 Align the mounting holes and secure with two 3 8 x 1 2 in Torx head bolts B 7 Tighten bolts B just enough to hold knifehead shield A in place while allowing it to be adjusted as close to the knifehead as possible 8 Manually rotate the knife drive box pulley to move the knife and check for...

Page 160: ...knife Double knife drive systems have two knife drive boxes one at each end of the header CAUTION To avoid personal injury before servicing machine or opening drive covers refer to 5 1 Preparing Machine for Servicing page 113 Figure 5 44 Left Knife Drive Box Shown Right Similar There is a knife drive box A at each end of the header Checking Knife Drive Box Mounting Bolts Check the torque on the fo...

Page 161: ...procedure is the same for both ends of a timed double knife header Images shown are for the left end the right end is opposite 1 Shut down the engine and remove the key from the ignition 2 Open the endshield For instructions refer to Opening Endshields page 37 For timed headers Figure 5 46 Timed Double Knife Drive 3 Loosen the two nuts A enough to allow idler pulleys B to pivot Figure 5 47 Timed D...

Page 162: ... counterclockwise For both timed and untimed headers Figure 5 49 Access Cover 9 To provide clearance between the knife drive box pulley and the endsheet open access cover A on the endsheet behind the cutterbar Figure 5 50 Knife Drive 10 Remove belt A from drive pulley B 11 Slip belt A over and behind knife drive box pulley C Use the notch in the pulley to assist with belt removal MAINTENANCE AND S...

Page 163: ... B to the knife drive box output shaft 21 Remove knife drive arm B from the knife drive box output shaft 22 Remove the four knife drive box mounting bolts C and D NOTE If shims are set on bolts C between the knife drive box and housing mark the location of the shims for later reinstallation NOTE Do NOT remove bolt E it is factory set to properly position the knife drive box in the correct fore aft...

Page 164: ...ocedure provided here Figure 5 54 Knife Drive Box 1 Ensure the splines and bores in the pulley and drive arm are free of paint oil and solvents 2 Apply two bands A of medium strength threadlocker Loctite 243 or equivalent around the shaft as shown at right Apply one band at the end of the spline and the second band in the middle 3 Press pulley B onto the shaft until flush with the end of the shaft...

Page 165: ...e 8 hex head bolts A on the side and two 5 8 x 2 1 4 in grade 8 hex head bolts B on the bottom NOTE If shims were removed from bolts A in Step 22 page 149 install them again in the same place between the knife drive box and housing 3 Tighten knife drive box side bolts A slightly then tighten bottom bolts B to ensure proper contact with the vertical and horizontal mounting surfaces Do NOT torque th...

Page 166: ...orque output arm bolt A to 217 Nm 160 lbf ft Figure 5 60 Knifehead 9 Slide the knife into place and align the knifehead with the output arm 10 Install knifehead pin A through output arm C and into the knifehead NOTE Remove the grease fitting from the knifehead pin for easier installation of knifehead pin 11 Position the pin so that groove B is 1 5 mm 1 16 in above output arm C 12 Secure pin with 5...

Page 167: ...esn t contact the front of the first guard If the knife drive box requires adjustment contact your MacDon Dealer 18 Install and tension the knife drive belts For untimed headers refer to Checking and Tensioning Untimed Double Knife Drive Belts page 160 For timed double knife headers refer to Tensioning Timed Double Knife Drive Belts page 167 For timed double knife headers also check the knife timi...

Page 168: ...5 65 U Shaped Shim 6 Manufacture a U shaped shim A to fit under the side bolts securing the knife drive box to the frame Place the shim between the header mount and the knife drive box Shim the drive box as required to align the pulley 7 For bolt installation instructions refer to Installing Knife Drive Box page 151 8 Tighten bolts and recheck squareness 9 For belt tensioning instructions refer to...

Page 169: ... refer to Opening Endshields page 37 Figure 5 66 Timed Double Knife Drive 4 Loosen two nuts A enough to allow idler pulleys B to pivot Figure 5 67 Timed Double Knife Drive 5 Loosen jam nut C 6 Turn flange nut A counterclockwise on adjuster bolt B to relieve knife drive belt tension Figure 5 68 Knife Drive Box 7 Loosen four bolts A securing the knife drive box to the mount 8 Loosen bolt C securing ...

Page 170: ... the knife bar makes contact with the rear of the guard move the knife drive box forwards Figure 5 70 Knife Drive Box 10 Tighten bolt A securing knife drive box locating tab B Figure 5 71 Knife Drive Box 11 Tighten knife drive box side bolts A first then tighten bottom bolts B Torque to 271 Nm 200 lbf ft 12 Install and tension the knife drive belts For non timed belts refer to Checking and Tension...

Page 171: ... plug B 5 Allow the oil to drain from the knife drive box and into the container placed below it 6 Reinstall drain plug B 7 Add oil to the knife drive box Refer to the inside back cover for recommended fluids and lubricants 8 Reinstall breather dipstick A 9 Close the endshield For instructions refer to Closing Endshields page 38 5 6 2 Knife Drive Belts Untimed Double Knife Drive Belts D1XL Only Th...

Page 172: ...ng Endshields page 37 Figure 5 74 Untimed Double Knife Drive 3 Loosen two bolts A securing the motor assembly to the header endsheet 4 Loosen the belt tension by turning tensioning bolt B counterclockwise Figure 5 75 Access Cover 5 To provide clearance between the knife drive box pulley and the endsheet open access cover A on the endsheet behind the cutterbar MAINTENANCE AND SERVICING ...

Page 173: ...es of the header DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key before making adjustments to the machine 1 Shut down the engine and remove the key from the ignition Figure 5 77 Knife Drive 2 Route knife drive belt A around knife drive box pulley C and knife drive pulley B Use the notch in the pulley to assist with the ...

Page 174: ...e key before making adjustments to the machine IMPORTANT To ensure the service life of the belt and the knife drive NEVER overtighten a drive belt 1 Shut down the engine and remove the key from the ignition 2 Open the left endshield For instructions refer to Opening Endshields page 37 Figure 5 79 Knife Drive Motor and Adjuster 3 Check the tension on knife drive belt C A properly tensioned drive be...

Page 175: ...of the header Timing is achieved using cogged belts on both sides of the header Removing Timed Drive V Belts Matching V belts transfer power from the knife drive motor to the pulley that drives the knife drive belt DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key before making adjustments to the machine 1 Shut down the e...

Page 176: ... drive motor is fully forward Do NOT pry the belts over the pulley 3 Turn adjuster bolt B clockwise to tighten the V belts A properly tensioned V belt should deflect 4 mm 5 32 in when a force of 52 77 N 12 17 lbf is applied at midspan IMPORTANT To prolong the life of V belts and drives do NOT overtighten the V belts 4 Tighten two bolts A on the endsheet 5 Close the endshield For instructions refer...

Page 177: ... remove the key before making adjustments to the machine 1 Shut down the engine and remove the key from the ignition Figure 5 83 Knife Drive 2 Open the endshield For instructions refer to Opening Endshields page 37 3 Loosen two nuts A enough to allow idler pulleys B to pivot Figure 5 84 Timed Double Knife Drive 4 Loosen the jam nut C 5 To relieve knife drive belt tension turn flange nut A counterc...

Page 178: ...endsheet behind the cutterbar to provide clearance between the knife drive box pulley and the endsheet 9 Remove the knife drive belt Installing Timed Knife Drive Belt The procedure for installing timed knife drive belts is the same for both sides of the header DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key before makin...

Page 179: ...ll V belts C onto the pulleys NOTE Ensure the drive motor is fully forward do NOT pry the belts over the pulley 4 Turn adjuster bolt B clockwise to tighten the V belts A properly tensioned V belt should deflect 4 mm 5 32 in when a force of 52 77 N 12 17 lbf is applied at the midspan IMPORTANT To prolong the life of V belts and drives do NOT overtighten the V belts NOTE If the belt is out of alignm...

Page 180: ...re timed before tightening the belt For instructions refer to Adjusting Timed Double Knife Timing page 169 2 Slide pulley A up the slot on support bracket B to take up the slack in the timing belt and tighten adjuster nut C NOTE Ensure idler pulley A is as high as possible in the support bracket slot 3 Tighten nut D to 212 234 Nm 157 173 lbf ft NOTE If the belt is out of alignment refer to Adjusti...

Page 181: ...1 Shut down the windrower and remove the key from the ignition 2 Open the left endshield For instructions refer to Opening Endshields page 37 Figure 5 92 Left Knife Drive Pulleys 3 Check the tension on the knife drive belt A properly tensioned drive belt should deflect 20 mm 3 4 in when 89 N 20 lbf of force is applied at the midspan of the belt 4 Loosen two nuts A Figure 5 93 Left Knife Drive Belt...

Page 182: ...2 1 8 in between lower belt A and lower guide B 9 If necessary loosen three bolts C and adjust lower guide B then tighten the bolts again 10 Check that upper belt D and upper guide E have a clearance of 1 5 2 5 mm 1 16 3 32 in If necessary loosen the two bolts F and adjust upper guide E then tighten the bolts again 11 Close the left endshield Refer to Closing Endshields page 38 12 Repeat this proc...

Page 183: ...page 37 3 Remove the right belt For instructions refer to Removing Timed Knife Drive Belt page 163 Figure 5 97 Adjusting Timing Left Side 4 Rotate the left knife drive box driven pulley clockwise until left knife A is at the center of inboard stroke B moving towards the center of the header NOTE The center stroke is when knife sections C are centered between the guard points Figure 5 98 Adjusting ...

Page 184: ... Side 7 Slide idler pulley A up by hand to remove most of the belt slack Tighten nut B Figure 5 101 Knife Drive Left Side Right Side Opposite 8 Pull idler pulley A as high as possible by hand 9 Thread flange nut B down adjuster bolt C to achieve final tension NOTE Tension is checked at midspan of the belts The belts should deflect 18 22 mm 11 16 7 8 in with 89 N 20 lbf of force applied MAINTENANCE...

Page 185: ...er belt tracking with ensure longer belt life Belts that are not tracking properly are subject to premature failure ensure the pulleys are aligned and parallel Two people are required for this procedure one to operate the windrower and header and the other to observe and adjust the belt tracking IMPORTANT Cogged timing belts should be centered on the knife drive box pulley and positioned at least ...

Page 186: ...oceed to Step 8 page 173 6 If the belt is tracking towards the outboard side of the drive pulley the likely cause is a toe in problem C and D If the belt tends to move towards the high tension outboard side of the pulley proceed to Step 8 page 173 Figure 5 104 Knife Drive Belt 7 If belt A is tracking to one side of the knife drive box pulley B the likely cause is an out of position idler pulley C ...

Page 187: ...acking problems continue proceed to Step 10 page 174 Figure 5 106 Knife Drive Left Side 9 Correct a tracking problem on the knife drive box pulley by adjusting idler positions as follows a Loosen jam nuts A b Loosen jam nut and adjuster bolt B to relieve belt tension c Turn bolts C and D clockwise to move belt inboard or counterclockwise to move belt outboard NOTE Bolts must touch the endsheet to ...

Page 188: ...rive pulley location d To correct toe in problems turn the adjuster bolt D clockwise to enable the belt to track inboard e To correct toe out problems turn the adjuster bolt D counterclockwise to enable the belt to track outboard f Tighten the nuts C at the drive pulley location g Tension the belt For instructions refer to Tensioning Timed Double Knife Drive Belts page 167 h Operate the header che...

Page 189: ...6 Engage the header safety props 7 Engage the reel safety props For instructions refer to Engaging Reel Safety Props page 35 8 Release the tension on the draper For instructions refer to 5 7 3 Checking and Adjusting Draper Tension page 177 Figure 5 109 Draper Connector 9 Remove screws A and tube connectors B at the draper joint 10 Pull the draper from the deck 5 7 2 Installing Drapers DANGER To pr...

Page 190: ...terbar 9 Insert the draper into the deck at the outboard end under the rollers Pull the draper into the deck while feeding it at the end 10 Feed in the draper until it can be wrapped around the drive roller 11 Insert the opposite end of the draper into the deck over the rollers Pull the draper fully into the deck Figure 5 111 Draper Seal 12 Loosen mounting bolts B on rear deck deflector A this may...

Page 191: ...phite lubricant makes contact and adheres to the draper seal surfaces 5 7 3 Checking and Adjusting Draper Tension The header s drapers are tensioned at the factory and rarely need adjustment If adjustment is required tension the drapers just enough so that the drapers do not slip when in operation and so that the draper does not sag below the cutterbar ensure that the draper is adjusted similarly ...

Page 192: ...ent is required Proceed to Step 3 page 178 WARNING Check to be sure all bystanders have cleared the area 3 Start the engine 4 Fully raise the header 5 Shut down the engine and remove the key from the ignition 6 Engage the header safety props Refer to the windrower operator s manual for instructions Figure 5 116 Drive Roller 7 Ensure that the draper guide the rubber track on the underside of the dr...

Page 193: ...o indicate that the tension on the draper has increased Continue to turn adjuster bolt A clockwise until the white indicator bar is at the halfway point in the window IMPORTANT To prevent premature failure of the draper draper rollers and or tightener components do NOT operate the draper if the white bar is not visible in the inspection window IMPORTANT To prevent the header from scooping soil whi...

Page 194: ...Backward Increase drive roller C Tighten adjuster nut C Forward Decrease drive roller C Loosen adjuster nut C Backward Increase idler roller D Tighten adjuster nut C Forward Decrease idler roller D Loosen adjuster nut C Figure 5 120 Left Deck Drive Roller Right Side Opposite 2 Refer to Table 5 5 page 180 and adjust drive roller either by increasing or decreasing its alignment as follows a Loosen n...

Page 195: ...t up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason WARNING To prevent bodily injury from the fall of a raised reel always engage the reel safety props before going under the raised reel for any reason IMPORTANT The draper seal is set to 0 3 mm 0 00 0 12 in at the factory to prevent material from entering into the side d...

Page 196: ...the stored position when not in use but can be engaged using hand force 4 Repeat the previous step on the opposite reel arm Figure 5 123 Reel Safety Prop Center Arm 5 Use handle A to move the lock rod to inboard position B which engages pin C under the prop 6 Lower the reel until the safety props contact the outer arm cylinder mounts and the center arm pins 7 Shut down the engine and remove the ke...

Page 197: ...ce between the draper and the cutterbar at deck supports A Depending on the header size there are between two and five supports per deck 10 Reduce the tension on the draper For instructions refer to 5 7 3 Checking and Adjusting Draper Tension page 177 Figure 5 126 Deck Adjustment 11 Lift the front edge of draper A past cutterbar B to expose the deck support MAINTENANCE AND SERVICING ...

Page 198: ...k Support 15 Locate a feeler gauge of the same thickness as the draper belt plus 1 mm 0 04 in 16 Slide the feeler gauge along deck A under the cutterbar in order to properly set the gap 17 To create a seal adjust deck A so that clearance B between cutterbar C and the deck is the same thickness as the draper belt plus 1 mm 0 04 in NOTE When checking the clearance at either roller measure the gap be...

Page 199: ...bystanders have cleared the area 23 Start the engine Figure 5 130 Left Reel Safety Prop 24 Raise the reel to its maximum height 25 Move reel safety prop A back inside the reel arm 26 Repeat the previous step on the opposite end of the reel Figure 5 131 Reel Safety Prop Center Arm 27 Use handle B on double reel headers to move lock rod A to the outboard position 28 Lower the reel fully 29 Shut down...

Page 200: ... down the engine and remove the key from the ignition NOTE Views are from the left end of the header Figure 5 132 Draper Clips 6 Remove the existing draper clips A from the draper 7 Clean the area with water and a rag Coat the installation surface of the clip with a small amount of dish soap to allow the clip to slide on easier Figure 5 133 Clip Installation 8 Rotate the draper until the cleat is ...

Page 201: ... and C on each deck Ensure the temperature does not exceed 44 C 80 F above the ambient temperature Draper Deck Idler Roller Removing Draper Idler Roller DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine and remove the key before leaving the operator s seat and always engage the safety props before going under the machine for an...

Page 202: ...rs B and nuts from the draper joint to uncouple the draper 10 Pull the draper off the idler roller Figure 5 137 Idler Roller 11 Remove bolt A and washer from the idler roller at the back of the header deck 12 Remove bolt B and washer from the idler roller at the front of the header deck 13 Spread roller arms C and D and remove the idler roller MAINTENANCE AND SERVICING ...

Page 203: ...lide hammer to remove bearing assembly B and seal C from the roller Figure 5 139 Idler Roller IMPORTANT When installing the new bearing do NOT place the end of the roller directly onto the ground Bearing assembly A protrudes past roller tube B and placing the end on the ground will push the bearing farther into the tube Figure 5 140 Idler Roller 4 Cut a relief A into a block of wood 5 Place the en...

Page 204: ...142 Idler Roller Bearing 7 Install new seal A by pressing on the inner and outer race of the seal until it is 3 4 mm 1 8 3 16 in B from the outside edge of the tube NOTE The seal can be oriented in either direction 8 Reinstall idler roller For instructions refer to Installing Draper Idler Roller page 190 Installing Draper Idler Roller Figure 5 143 Idler Roller 1 Install idler roller A between idle...

Page 205: ...fer to 5 7 4 Adjusting Draper Tracking page 179 if additional adjustment is necessary Draper Deck Drive Roller Removing Draper Drive Roller DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine and remove the key before leaving the operator s seat and always engage the safety props before going under the machine for any reason WARN...

Page 206: ...nuts from the draper joint 10 Pull the draper off the drive roller Figure 5 148 Drive Roller 11 Align the set screws with hole A in the guard Remove the two set screws holding the motor onto the drive roller NOTE The set screws are 1 4 turn apart 12 Remove four bolts B securing the motor to the drive roller arm NOTE It may be necessary to remove plastic shield C to gain access to the top bolt MAIN...

Page 207: ...r drive roller assembly For instructions refer to Removing Draper Drive Roller page 191 Figure 5 150 Drive Roller Bearing 2 Remove bearing assembly A and seal B from roller tube C as follows a Attach slide hammer D to threaded shaft E in bearing assembly b Tap out bearing assembly A and seal B 3 Clean inside of roller tube C Check tube for wear or damage and replace if necessary MAINTENANCE AND SE...

Page 208: ...s on the bearing assembly A Seal C is properly positioned when a dimension of 3 mm 1 8 in D is achieved Installing Draper Drive Roller Figure 5 152 Drive Roller 1 Position drive roller B between the roller support arms 2 Install bolt A to secure the drive roller to the arm closest to the cutterbar Torque bolt to 95 Nm 70 lbf ft 3 Grease the motor shaft and insert into the end of drive roller B Fig...

Page 209: ...ional adjustment is necessary refer to 5 7 4 Adjusting Draper Tracking page 179 5 7 8 Draper Deflectors Narrow draper deflectors can reduce bunching at the ends of the header when decks are set for center delivery Removing Narrow Draper Deflectors DANGER To prevent bodily injury or death from the unexpected start up or fall of a raised machine always stop the engine and remove the key before leavi...

Page 210: ...ised machine always stop the engine and remove the key before leaving the operator s seat and always engage the safety props before going under the machine for any reason DANGER Never start or move the machine until you are sure that all bystanders have cleared the area 1 Raise the reel to its full height and lower the header to the ground 2 If hydraulic deck shift is installed shift the decks to ...

Page 211: ...btain the best fit 7 Install two 3 8 x 5 8 in self tapping screws A and tighten all four screws Figure 5 159 Rear Deflector Left Side 8 Position aft deflector C as shown and install three 3 8 x 3 4 in carriage bolts B and lock nuts 9 Install two Torx head screws A and lock nuts with the heads facing down 10 Tighten all fasteners 11 Repeat for the opposite end of the header NOTE The draper deflecto...

Page 212: ...lues when the reels are fully lowered are shown in the table below Figure 5 160 Finger Clearance Table 5 6 Finger to Guard Cutterbar Clearance Header Model X 3 mm 1 8 in at Reel Ends Single Reel Double Reel D115X 20 mm 3 4 in D120X 20 mm 3 4 in D125X 25 mm 1 in D130XL 55 mm 2 11 64 in 25 mm 1 in D135XL 70 mm 2 3 4 in 25 mm 1 in D140XL 25 mm 1 in D145XL 25 mm 1 in Measuring Reel Clearance Measure t...

Page 213: ...rement locations For the clearance specifications refer to Table 5 7 page 199 For the measurement locations refer to Figure 5 163 page 200 NOTE When measuring the reel clearance at the center of a double reel header measure the lowest reel Table 5 7 Finger to Guard Cutterbar Clearance Header Model Clearance at Reel Ends 3 mm 1 8 in Single Reel Double Reel D115X 20 mm 3 4 in D120X 20 mm 3 4 in D125...

Page 214: ...ety props before going under the header for any reason 1 Start the engine 2 Engage the reel safety props For instructions refer to Engaging Reel Safety Props page 35 3 Shut down the engine and remove the key from the ignition Figure 5 164 Outside Reel Arm 4 Single reel headers Adjust the outboard reel arm lift cylinders to set the clearance at the outboard ends of the reel as follows a Loosen bolt...

Page 215: ...e cleared the area 7 Start the engine 8 Move the reel back to ensure that the steel end fingers do NOT contact the deflector shields 9 If contact between the steel end fingers and the deflector shields occurs adjust the reel upward to maintain the reel to cutterbar clearance at all reel fore aft positions If contact between the steel end fingers and the deflector shields still occurs after adjusti...

Page 216: ...l than at the ends to compensate for reel flexing DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key before making adjustments to the machine Figure 5 168 Fore Aft Position Decal 1 Position the reel over the cutterbar between 4 and 5 on fore aft position decal A to provide adequate clearance at all reel fore aft positions ...

Page 217: ...g the current reel endsheet clearance on each side of the header and adjusting the center reel support arm DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key before making adjustments to the machine 1 Shut down the engine and remove the key from the ignition Figure 5 170 Double Reel Measurement Locations 2 Measure clearanc...

Page 218: ... measuring the current reel to endsheet clearance on each side of the header DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key before making adjustments to the machine 1 Shut down the engine and remove the key from the ignition Figure 5 172 Single Reel Measurement Locations 2 Measure clearance A at locations B Clearance A...

Page 219: ...nsure the tine tube is supported at all times to avoid damaging it and other components 1 Lower the header fully 2 Raise the reel fully 3 Shut down the engine and remove the key from the ignition 4 Engage the reel safety props For instructions refer to Engaging Reel Safety Props page 35 5 Remove the tine tube bushings from the applicable tine tube at the center and left reel discs For instructions...

Page 220: ...from the machine For instructions about removing fingers refer to Removing Steel Fingers page 205 Figure 5 175 Tine Tube 1 Slide the new finger and tine tube arm A onto the end of the tube 2 Install the tine tube bushings For instructions refer to Installing Bushings onto Reels page 214 3 Attach the fingers to the tine tube with bolts and nuts B Removing Plastic Fingers WARNING To prevent bodily i...

Page 221: ...event injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason WARNING To prevent bodily injury from the fall of a raised reel always engage the reel safety props before going under the raised reel for any reason NOTE This procedure assumes a finger has been removed from the machine For...

Page 222: ...tall screw A using a Torx Plus 27 IP socket wrench and torque to 8 5 9 0 Nm 75 80 lbf in 5 8 5 Tine Tube Bushings Removing Bushings from Reels Bushing are located where the reel tine connects to the reel disc WARNING To prevent bodily injury from the fall of a raised reel always engage the reel safety props before going under the raised reel for any reason IMPORTANT Ensure the tine tube is support...

Page 223: ...sure bolts A are reinstalled at the original locations Figure 5 181 Bushing Clamp 7 Release bushing clamps A using a small screwdriver to separate the serrations Pull the clamp off the tine tube Figure 5 182 Bushing 8 Rotate tine tube arm A until clear of the disc and slide the arm inboard off of bushing B 9 Remove bushing halves B If required remove the next steel or plastic finger so the arm can...

Page 224: ...upport C from the tail end of the reel at the applicable tine tube location NOTE There are no endshields on the center disc 12 Remove bolts A securing tine tube arms B to the tail and center discs Tine tube reinforcing kit option Figure 5 185 Tine Tube Supports 13 Release the bushing clamps or disconnect the support channels from the tine tube support if installed depending on which tine tube is b...

Page 225: ...l screwdriver to separate the serrations Move the clamps off the bushings Figure 5 188 Cam End 16 Slide tine tube A outboard to expose bushing B 17 Remove bushing halves B If required remove the next steel or plastic finger so the arm can slide off the bushing Refer to the following procedures if necessary Removing Plastic Fingers page 206 Removing Steel Fingers page 205 MAINTENANCE AND SERVICING ...

Page 226: ...ew E and remove finger D if it is too close to the support to allow access to the bushing For instructions refer to Removing Plastic Fingers page 206 or Removing Steel Fingers page 205 Figure 5 190 Bushing Clamp 21 Release bushing clamps A using a small screwdriver to separate the serrations Figure 5 191 Tine Tube Reinforcing Kit Bushing Clamp Option 22 Move clamps A off the bushings MAINTENANCE A...

Page 227: ...ff bushing halves B Figure 5 193 Tine Tube Reinforcing Kit Opposite Support Option 24 On each reel there are two left facing supports A Rotate the supports until the flanges clear the channels before moving them off bushing B Move the tube slightly away from the reel if necessary 25 Remove bushing halves B from the tine tubes MAINTENANCE AND SERVICING ...

Page 228: ...tall bushing clamps C Secure pliers in a vise and grind a notch B into the end of each arm to fit the clamp as shown Cam end bushings Figure 5 195 Cam End 1 Position bushing halves B on tine tube A with the flangeless end adjacent to the tine tube arm and position the lug in each bushing half into the hole in the tine tube 2 Slide tine tube A towards the tail end of the reel to insert bushing B in...

Page 229: ...ush when the clamp is fit into the groove on the bushing and the lock tabs are engaged Figure 5 197 Installing Clamp 6 Tighten clamp A using modified channel lock pliers B until finger pressure will NOT move the clamp IMPORTANT Overtightening clamp may result in breakage Figure 5 198 Cam End 7 Line up tine tube B with the cam arm and install bolt A Torque bolt to 165 Nm 120 lbf ft MAINTENANCE AND ...

Page 230: ...t the cam end 11 Reinstall the reel endshields For instructions refer to Replacing Reel Endshields page 220 Center disc and tail end bushings Figure 5 201 Cam End 12 Position bushing halves B on tine tube A with the flangeless end adjacent to the tine tube arm and position the lug in each bushing half into the hole in the tine tube 13 Slide tine tube A onto bushing B and position against the disc ...

Page 231: ...ngaged Figure 5 203 Installing Clamp 17 Tighten clamp A using modified channel lock pliers B until finger pressure will NOT move the clamp IMPORTANT Overtightening clamp may result in breakage Figure 5 204 Tail End 18 Install bolts A securing tine tube arm B to the center disc 19 Install tine tube arm B and endshield support C to the tail end of the reel at the applicable tine tube location and se...

Page 232: ...nforcing Kit Support Option 21 On each reel there are three right facing supports A Slide the support onto bushing B Figure 5 207 Tine Tube Reinforcing Kit Opposite Support Option 22 On each reel there are two left facing supports A Rotate support A until its flanges clear channels C before moving the support onto bushing B NOTE If necessary move tine tube D slightly away from the reel to allow th...

Page 233: ...5 Tighten clamp A using modified channel lock pliers B until finger pressure will NOT move the clamp IMPORTANT Overtightening clamp may result in breakage Figure 5 210 Tine Tube Reinforcing Kit Support Option 26 Reattach channels C to the three right facing supports A on each reel with screws B and nuts Torque screws to 43 Nm 32 lbf ft 27 Using screws E reinstall any fingers D that were previously...

Page 234: ...Slightly dented or deformed endshields and supports are repairable but it s necessary to replace severely damaged components You can attach reel endshields to either end of the reel Replacing Reel Endshields DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 St...

Page 235: ...emoved 8 Remove the reel endshield from the supports Figure 5 215 Reel Endshields 9 Slightly lift the end of reel endshield A off of support tabs B 10 Install new reel endshield C behind reel endshield A 11 Reattach reel endshield C then A onto support tabs B 12 Reinstall three bolts D 13 Tighten all hardware MAINTENANCE AND SERVICING ...

Page 236: ...d remove the key from the ignition 2 Rotate the reel manually until the reel endshield A requiring replacement is accessible 3 Remove six bolts B Retain hardware Figure 5 217 Reel Endshields 4 Lift end of reel endshield A off endshield E and rotate down 5 Remove bolt B steel tine C and bushing D Retain hardware 6 Remove the reel endshield E Figure 5 218 Reel Endshields 7 Install new reel endshield...

Page 237: ...emove the key from the ignition before leaving the operator s seat for any reason 1 Lower the header fully 2 Lower the reel fully 3 Shut down the engine and remove the key from the ignition Figure 5 220 Reel Endshield Supports 4 Rotate the reel manually until the reel endshield support requiring replacement is accessible 5 Remove bolt B from support A 6 Remove bolts C from support A and two adjace...

Page 238: ...el endshields A Ensure the tabs engage both reel endshields 9 Secure support B to the disc sector with bolt C and nut Do NOT tighten 10 Secure reel endshields A to support B with bolt D and nut Do NOT tighten 11 Reattach the supports with bolts E and nuts 12 Check the clearance between the tine tube and reel endshield support and adjust if necessary 13 Torque nuts to 27 Nm 20 lbf ft MAINTENANCE AN...

Page 239: ...tected by a removable cover DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Shut down the engine and remove the key from the ignition Single reel drive Figure 5 222 Drive Cover Single Reel 2 Remove four bolts A securing cover B to the reel drive Double reel ...

Page 240: ... or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Shut down the engine and remove the key from the ignition Single reel drive Figure 5 225 Drive Cover Single Reel 2 Position drive cover B onto the reel drive and secure with four bolts A Torque bolts to 12 13 2 Nm 9 10 lbf ft MAINTENA...

Page 241: ... Reel Drive Chain The reel drive chain transfers power from the hydraulically driven reel motor to the sprockets that rotate the reels Loosening Reel Drive Chain DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key before making adjustments to the machine 1 Lower the header fully 2 Adjust the reel to full forward position fo...

Page 242: ...ve Viewed from Underside of Reel Tightening Reel Drive Chain DANGER To prevent bodily injury or death from the unexpected start up of the machine always stop the engine and remove the key before making adjustments to the machine 1 Lower the header fully 2 Adjust the reel to full forward position for easier access to the work area 3 Shut down the engine and remove the key from the ignition 4 Remove...

Page 243: ...to 73 Nm 54 lbf ft 8 Install the drive cover For instructions refer to Installing Reel Drive Cover page 226 Figure 5 232 Single Reel Drive Viewed from Underside of Reel 5 9 3 Reel Drive Sprocket The reel drive sprocket is attached to the reel drive motor For Case IH and New Holland combine models configure the combine according to the reel sprocket size in order to optimize the auto reel to ground...

Page 244: ...o Loosening Reel Drive Chain page 227 4 Remove reel drive chain A from reel drive sprocket B Figure 5 234 Reel Drive Sprocket 5 Remove cotter pin A slotted nut B and flat washer C from the motor shaft 6 Remove reel drive sprocket D Ensure the key remains in the shaft IMPORTANT To avoid damaging the motor use a puller if the drive sprocket D does not come off by hand Do NOT use a pry bar and or ham...

Page 245: ...nstalling Reel Drive Cover page 226 5 9 4 Double Reel Drive U Joint The double reel drive U joint allows each reel to move independently Lubricate the U joint according to the specifications For instructions refer to 5 3 6 Lubrication page 120 Replace the U joint if severely worn or damaged For instructions refer to Removing Double Reel Drive U Joint page 231 Removing Double Reel Drive U Joint DAN...

Page 246: ... center tube support the reel as close to the end disc as possible Figure 5 238 U Joint 4 Remove four bolts A securing the reel tube to U joint flange B and move the reel sideways Figure 5 239 U Joint 5 Remove six bolts A attaching U joint flange B to driven sprocket C 6 Remove the U joint NOTE It may be necessary to move the right reel sideways so that the U joint can clear the tube MAINTENANCE A...

Page 247: ... that the U joint can clear the reel tube Figure 5 241 U Joint 3 Position the right reel tube against the reel drive and engage the stub shaft into the U joint pilot hole 4 Rotate the reel until the holes in the end of the reel tube and U joint flange B line up 5 Apply medium strength threadlocker Loctite 243 or equivalent to four 1 2 in bolts A and secure in the flange 6 Torque the ten bolts to 1...

Page 248: ...e sprocket For instructions refer to Removing Reel Drive Sprocket page 230 Figure 5 243 Reel Motor and Hoses 4 Mark hydraulic lines A and their connections on motor B to ensure correct reinstallation NOTE Before disconnecting the hydraulic lines clean the motor s ports and exterior surfaces 5 Disconnect hydraulic lines A at motor B Cap or plug open ports and lines 6 Remove four nuts and bolts C an...

Page 249: ...rive chain For instructions refer to Tightening Reel Drive Chain page 228 5 9 6 Replacing Double Reel Header Drive Chain Refer to the following two methods for replacing the drive chain on a double reel drive Replacing Chain Using the Reel Drive Method page 235 Replacing Chain Using the Breaking the Chain Method page 237 Both procedures are acceptable but disconnecting the reel drive method is pre...

Page 250: ...d disc as possible Figure 5 248 U Joint 4 Remove four bolts A securing the reel tube to U joint flange B Figure 5 249 Replacing Chain 5 Move the right reel sideways to separate reel tube A from U joint B 6 Remove drive chain C 7 Route new chain C over U joint B and position it on the sprockets 8 Position right reel tube A against the reel drive and engage the stub shaft into the U joint pilot hole...

Page 251: ...ure 5 251 Supporting Reel 12 Remove temporary reel support A Replacing Chain Using the Breaking the Chain Method Figure 5 252 Reel Drive 1 Grind off the head of a link rivet on chain A punch out the rivet and remove the chain 2 Grind off the head of a link rivet on the new chain punch out the rivet and separate the chain 3 Position the ends of the new chain onto sprocket B MAINTENANCE AND SERVICIN...

Page 252: ...eed to be replaced DANGER To prevent injury or death from the unexpected start up of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Shut down the engine and remove the key from the ignition 2 Remove the reel drive cover For instructions refer to Removing Reel Drive Cover page 225 3 Loosen the drive chain For instructions ...

Page 253: ...making adjustments to the machine 1 Shut down the engine and remove the key from the ignition Figure 5 255 Bolt Tightening Sequence 2 Follow the bolt tightening sequence shown and torque the wheel bolts to 110 120 Nm 80 90 lbf ft IMPORTANT Whenever a wheel is removed and reinstalled check the wheel bolt torque after 1 hour of operation and every 100 hours thereafter 5 10 2 Checking Axle Bolt Torqu...

Page 254: ...ning WARNING A tire can explode during inflation which could cause serious injury or death Do NOT stand over tire Use a clip on chuck and extension hose Do NOT exceed maximum inflation pressure indicated on tire label or sidewall Replace tires that have defects Replace wheel rims that are cracked worn or severely rusted Never weld a wheel rim Never use force on an inflated or partially inflated ti...

Page 255: ...ent and experience to perform the job Take the tire and rim to a qualified tire repair shop 1 Check the tire pressure Refer to Table 5 8 page 241 2 Make sure the tire is correctly seated on the rim before inflating a If the tire is not correctly positioned on the rim take the tire to a qualified tire repair shop 3 If inflation is required use a clip on chuck and an extension hose to inflate the ti...

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Page 257: ...urbance The kit also allows the reel fore aft cylinders to be quickly moved to the normal operating location Figure 6 1 Center Arm Left and Right Arms Similar MD B6590 6 1 2 Reel Arm Extension Kit North American Configured Headers Only Figure 6 2 Right Arm Center and Left Arms Similar This kit provides extensions for the outer reel support arms These extensions provide the additional reel arm leng...

Page 258: ...der the following bundles according to your header size and type D115X Steel Fingers MD B6514 D115X Plastic Fingers MD B6516 D120X Steel Fingers MD B6515 D120X Plastic Fingers MD B6517 D125X Steel Fingers MD B5656 D125X Plastic Fingers MD B5937 D130XL Plastic Fingers MD B6029 NOTE You must also order additional endshields when converting the reel 6 1 5 Reel Endshield Kit Figure 6 4 Reel Endshields...

Page 259: ...remely heavy crops Installation instructions are provided in the kit Five Bat Reels MD B5825 Six Bat Reels MD B5826 6 1 7 Reel Drop Rate Adjuster Kit Figure 6 6 Draper Reel Multicoupler The reel drop rate adjuster kit A permits adjustment of the reel drop rate via a flow control valve that gets installed in the reel lift circuit Installation instructions are included in the kit See your MacDon Dea...

Page 260: ... Wearplates Order one of the following bundles based on header size 4 6 m 15 ft MD B4864 6 1 m 20 ft MD B4865 7 6 m 25 ft MD B4838 6 2 2 Knife Cutout Cover Figure 6 8 Knife Cutout Cover Knife cutout covers attach to the endsheets and prevent cut crop particularly severely lodged crop from passing through the knifehead opening and accumulating in the knife drive box and endsheet Order the following...

Page 261: ...one of the following bundles according to your header size 4 6 m 15 ft MD B5009 6 1 m 20 ft MD B5010 7 6 m 25 ft MD B5011 9 1 m 30 ft MD B5012 10 7 m 35 ft MD B5013 6 2 5 Vertical Knife Mounts Figure 6 11 Vertical Knife Mount The vertical knife mounts allow the installation of vertically oriented knives onto both ends of the header The vertical knives themselves are not sold by MacDon and must be ...

Page 262: ... includes hardware and some plumbing This mount requires installation of MD B6609 Right MD B6609 includes flow control template hardware and some plumbing This mount can be installed individually or with MD B6608 OPTIONS AND ATTACHMENTS ...

Page 263: ...eet divider cones and if required reduce the transport width of the header Installation instructions are included in the kit MD B6158 6 3 2 Stabilizer Wheels Figure 6 13 Stabilizer Wheel Stabilizer wheels help stabilize the header in field conditions that would otherwise cause the header to bounce resulting in uneven cutting heights Installation and adjustment instructions are included in the kit ...

Page 264: ... The Stabilizer Wheels and Transport Package help to stabilize the header in field conditions that would otherwise cause the header to bounce resulting in uneven cutting heights This system is similar to the Stabilizer Wheel MD C1986 option For instructions refer to 6 3 2 Stabilizer Wheels page 249 The Stabilizer Wheels and Transport Package are also used to convert the header into transport mode ...

Page 265: ...e ground Installation instructions are included in the kits MD B5615 Inboard Skid Shoes MD B4963 Outboard Skid Shoes 6 3 6 Steel Skid Shoes Steel skid shoes offer extra abrasion resistance Figure 6 17 Steel Skid Shoe IMPORTANT Not recommended for wet mud or conditions prone to sparking Installation instructions are included with the kit MD B9053 OPTIONS AND ATTACHMENTS ...

Page 266: ...uctions are included with the kit IMPORTANT The wide draper deflector is NOT compatible with the Lodged Crop Reel Finger MD B4831 option NOTE Required for double swathing only leaves a gap between the standing crop and the swath for the divider to run through MD B6551 for D1X includes extra parts for various cutterbar layouts MD B6552 for D1XL 6 4 2 Draper Clips Draper clips offer additional wear ...

Page 267: ...flector option is NOT compatible with the upper cross auger option 6 4 4 Rice Divider Rods Figure 6 21 Rice Divider Rod Rice divider rods attach to the left and right crop dividers and divide tall and tangled rice crops in a similar manner to standard crop divider rods performing in standing crops Installation instructions are included in the kit MD B5609 6 4 5 Double Draper Drive Kit The Double D...

Page 268: ... forming rods form windrows so the heads are in the center and protected from shatter Swath forming rods are mainly used for grass seed cutting applications Installation and adjustment instructions are included with the kit MD B4803 6 4 8 Swath Rods Figure 6 23 Swath Deflector End delivery deflector rods are used for double swathing with end delivery only The deflector rods help prevent delivered ...

Page 269: ...ydraulic Deck Shift This system allows Operators to shift the decks using the in cab console when double swathing Installation and adjustment instructions are included with the kit Available on 7 6 12 2 m 25 40 ft headers MD B5664 6 4 11 Upper Cross Auger Hydraulic Kit for Double Draper Drive This kit is required to provide hydraulic power to the upper cross auger UCA on headers with both UCA and ...

Page 270: ......

Page 271: ...structions for unloading assembly and setup procedures that are included with your shipment Table 7 1 Unloading and Assembly Instructions Shipping Destination Header Description North America D1X and D1XL Series Draper Header for Windrowers Export D1X Series Draper Header for Windrowers ...

Page 272: ......

Page 273: ...ciently Install crop lifters See your MacDon Dealer Symptom Heads shattering or breaking off Reel speed too fast Reduce reel speed 3 7 4 Reel Speed page 64 Reel too low Raise reel 3 7 8 Reel Height page 66 Ground speed too fast Reduce ground speed 3 7 5 Ground Speed page 65 Crop too ripe Operate at night when humidity is higher Symptom Material accumulating in gap between cut out in endsheet and k...

Page 274: ...bridging the guards Replace 3 4 end guards with stub guards 5 5 7 Knife Guards page 137 6 2 4 Stub Guard Conversion Kit page 247 See your MacDon Dealer Symptom Bushy or tangled crop flows over divider rod builds up on endsheets Divider rods providing insufficient separation Install long divider rods 3 7 11 Crop Dividers page 70 Symptom Cut grain falling ahead of cutterbar Ground speed too slow Inc...

Page 275: ...nd or finger pitch 3 7 9 Reel Fore Aft Position page 67 3 7 10 Reel Tine Pitch page 68 Cutterbar too high Lower cutting height 3 7 1 Cutting Height page 58 Header angle too flat Steepen header angle 3 7 3 Header Angle page 63 Bent knife causing binding of cutting parts Straighten bent knife and align guards 5 5 7 Knife Guards page 137 Cutting edge of guards not close enough or parallel to knife se...

Page 276: ...bar or adjust frown 5 8 2 Reel Frown page 202 Float is set too heavy Adjust springs for lighter float 3 7 2 Header Float page 63 Mud or dirt build up on cutterbar Raise cutterbar by lowering skid shoes Cutting on the Ground page 61 Mud or dirt build up on cutterbar Install cut out sections See your MacDon Dealer Mud or dirt build up on cutterbar Flatten header angle Adjusting Header Angle page 64 ...

Page 277: ...ten cutterbar See your MacDon Dealer Symptom Excessive breakage of knife sections or guards Knife hold downs not properly adjusted Adjust knife hold downs 5 5 8 Knife Hold Downs page 141 Cutterbar operating too low in stony conditions Raise cutterbar using skid shoes Cutting on the Ground page 61 Float is set too heavy Adjust springs for lighter float 3 7 2 Header Float page 63 Bent or broken guar...

Page 278: ...forward Move reel back 3 7 9 Reel Fore Aft Position page 67 Symptom Reel will not lift Reel lift couplers are incompatible or defective Change quick coupler Symptom Reel will not turn Control set at 0 Activate reel speed control 3 7 4 Reel Speed page 64 Quick couplers not properly connected Connect couplers 4 Header Attachment Detachment page 105 Reel drive chain disconnected Connect reel drive ch...

Page 279: ...into ground with reel speed slower than ground speed Move reel aft 3 7 9 Reel Fore Aft Position page 67 Symptom Plastic fingers bent forward at tip Reel digging into ground with reel speed faster than ground speed Raise header 3 7 1 Cutting Height page 58 Reel digging into ground with reel speed faster than ground speed Decrease header tilt 3 7 3 Header Angle page 63 Reel digging into ground with ...

Page 280: ...sen draper and clean rollers 5 7 3 Checking and Adjusting Draper Tension page 177 Slat or connector bar jammed by frame or material Loosen draper and clear obstruction 5 7 3 Checking and Adjusting Draper Tension page 177 Roller bearing seized Replace roller bearing 5 7 7 Draper Roller Maintenance page 187 Low hydraulic oil Fill windrower hydraulic oil reservoir to full level Refer to the windrower...

Page 281: ...de or under front edge of draper Deck height improperly adjusted Adjust deck height 5 7 5 Adjusting Deck Height page 181 Symptom Material accumulating on end deflectors and releasing in bunches End deflectors too wide For headers with manual deck shift only trim deflector or replace with narrow deflector MD 172381 3 13 Unplugging the Cutterbar page 85 TROUBLESHOOTING ...

Page 282: ...o slow Adjust reel speed to be marginally faster than ground speed 3 7 4 Reel Speed page 64 Ground speed too fast Lower ground speed 3 7 5 Ground Speed page 65 Skid shoes too low Raise skid shoes to highest setting Cutting on the Ground page 61 Dirt packs on bottom of cutterbar and raises cutterbar off the ground Install plastic wear strips on bottom of cutterbar and skid shoes Dirt packing on bot...

Page 283: ... clearance to cutterbar setting too high Adjust minimum reel height with cylinders fully retracted 5 8 1 Reel to Cutterbar Clearance page 198 Reel too far forward Reposition reel 3 7 9 Reel Fore Aft Position page 67 Symptom Crop wrapping around reel Reel too low Raise reel 3 7 8 Reel Height page 66 Symptom Reel shattering pods Reel too far forward Reposition reel 3 7 9 Reel Fore Aft Position page ...

Page 284: ...n draper and cutterbar Raise header fully at each end of field or as required and shift decks back and forth to help clean out cutterbar Symptom Reel occasionally carries over plants in same location Steel fingers bent and hooking plants from drapers Straighten fingers steel Dirt accumulation on end of fingers preventing plants from falling off fingers onto drapers Raise reel 3 7 8 Reel Height pag...

Page 285: ...gle 3 7 6 Draper Speed page 66 Draper speed too fast or header angle too steep Reduce draper speed and or decrease header angle 3 7 3 Header Angle page 63 Ground speed too fast Reduce ground speed 3 7 5 Ground Speed page 65 Crop too green Allow crop to mature All heads to one side Crop leaning to one side and reel too slow Increase reel speed to re orient crop parallel to draper slats and or incre...

Page 286: ......

Page 287: ... nuts Jam nuts require less torque than nuts used for other purposes When applying torque to finished jam nuts multiply the torque applied to regular nuts by 0 65 to obtain the modified torque value Self tapping screws Use the standard torque values when installing self tapping screws Do NOT install self tapping screws on structural or otherwise critical joints 9 1 1 SAE Bolt Torque Specifications...

Page 288: ...de G Distorted Thread Nut Nominal Size A Torque Nm Torque lbf ft lbf in Min Max Min Max 1 4 20 16 8 18 6 150 165 5 16 18 24 26 18 19 3 8 16 42 46 31 34 7 16 14 67 74 50 55 1 2 13 102 113 76 84 9 16 12 148 163 109 121 5 8 11 204 225 151 167 3 4 10 362 400 268 296 7 8 9 583 644 432 477 1 8 874 966 647 716 Figure 9 4 Bolt Grades A Nominal Size B SAE 8 C SAE 5 D SAE 2 Table 9 4 SAE Grade 8 Bolt and Gr...

Page 289: ...0 5 1 4 1 6 13 14 3 5 0 6 2 2 2 5 20 22 4 0 7 3 3 3 7 29 32 5 0 8 6 7 7 4 59 66 6 1 0 11 4 12 6 101 112 8 1 25 28 30 20 23 10 1 5 55 60 40 45 12 1 75 95 105 70 78 14 2 0 152 168 113 124 16 2 0 236 261 175 193 20 2 5 460 509 341 377 24 3 0 796 879 589 651 Figure 9 6 Bolt Grades Table 9 6 Metric Class 8 8 Bolts and Class 9 Distorted Thread Nut Nominal Size A Torque Nm Torque lbf ft lbf in Min Max Mi...

Page 290: ...132 145 97 108 14 2 0 210 232 156 172 16 2 0 326 360 242 267 20 2 5 637 704 472 521 24 3 0 1101 1217 815 901 Figure 9 8 Bolt Grades Table 9 8 Metric Class 10 9 Bolts and Class 10 Distorted Thread Nut Nominal Size A Torque Nm Torque lbf ft lbf in Min Max Min Max 3 0 5 1 3 1 5 12 13 3 5 0 6 2 1 2 3 19 21 4 0 7 3 1 3 4 28 31 5 0 8 6 3 7 56 62 6 1 0 10 7 11 8 95 105 8 1 25 26 29 19 21 10 1 5 51 57 38 ...

Page 291: ...c Fitting 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 3 Torque fitting nut E to specified number of flats from finger tight FFFT or to a given torque value in Table 9 10 page 277 4 Use two wrenches to prevent fitting D from rotating Place one...

Page 292: ... 12 1 1 9 1 5 O Ring Boss Hydraulic Fittings Adjustable The standard torque values are provided for adjustable hydraulic fittings If a procedure specifies a different torque value for the same type and size of fitting found in this topic use the value specified in the procedure instead Figure 9 11 Hydraulic Fitting 1 Inspect O ring A and seat B for dirt or obvious defects 2 Back off lock nut C as ...

Page 293: ...D and O ring A contact part face E 6 Position the angle fittings by unscrewing no more than one turn 7 Turn lock nut C down to washer D and tighten it to the torque value indicated in the table Use two wrenches one on fitting B and the other on lock nut C 8 Check the final condition of the fitting REFERENCE ...

Page 294: ...que values are provided for non adjustable hydraulic fittings If a procedure specifies a different torque value for the same type and size of fitting found in this topic use the value specified in the procedure instead Torque values are shown in following table below Figure 9 13 Hydraulic Fitting 1 Inspect O ring A and seat B for dirt or obvious defects 2 Check that O ring A is NOT on the threads ...

Page 295: ...298 199 220 32 2 1 2 12 332 365 245 269 9 1 7 O Ring Face Seal Hydraulic Fittings The standard torque values are provided for O ring face seal hydraulic fittings If a procedure specifies a different torque value for the same type and size of fitting found in this topic use the value specified in the procedure instead Torque values are shown in following table below Figure 9 14 Hydraulic Fitting 1 ...

Page 296: ...5 28 18 21 5 Note85 5 16 6 11 16 3 8 40 44 29 32 8 13 16 1 2 55 61 41 45 10 1 5 8 80 88 59 65 12 1 3 16 3 4 115 127 85 94 14 Note85 7 8 16 1 7 16 1 150 165 111 122 20 1 11 16 1 1 4 205 226 151 167 24 1 2 1 1 2 315 347 232 256 32 2 1 2 2 510 561 376 414 9 1 8 Tapered Pipe Thread Fittings The standard torque values are provided for tapered pipe thread fittings If a procedure specifies a different to...

Page 297: ... excess thread conditioner with an appropriate cleaner 6 Assess the final condition of the fitting Pay special attention to the possibility of cracks in the port opening 7 Mark the final position of the fitting If a fitting leaks disassemble the fitting and check it for damage NOTE The failure of fittings due to overtorquing may not be evident until the fittings are disassembled and inspected Tabl...

Page 298: ...ter m x 3 2808 foot ft Power kilowatt kW x 1 341 horsepower hp Pressure kilopascal kPa x 0 145 pounds per square inch psi Pressure megapascal MPa x 145 038 pounds per square inch psi Pressure bar Non SI bar x 14 5038 pounds per square inch psi Torque Newton meter Nm x 0 7376 pound feet or foot pounds lbf ft Torque Newton meter Nm x 8 8507 pound inches or inch pounds lbf in Temperature degrees Cels...

Page 299: ...ing single reel drive 238 tightening 228 combines transporting header towing the header 87 88 attaching to towing vehicle 88 component identification 27 conversion chart 284 crop delivery options 252 crop divider rods 75 installing 76 removing 75 crop dividers 70 installing on header with latch option 72 installing on header without latch option 73 removing from header with latch option 70 removin...

Page 300: ...moving drive roller 191 removing idler roller 187 replacing drive roller bearing 193 replacing idler roller bearing 189 drive rollers side drapers installing 194 removing 191 removing drive roller bearing 193 drying agents 83 DWA definition 25 E electrical system how it works 127 maintaining electrical system 127 replacing light bulbs 128 endshields adjusting 40 checking 40 closing 38 installing 3...

Page 301: ...lic deck shifts 79 package 255 hydraulics fittings flare type 277 O ring boss ORB adjustable 278 O ring boss ORB non adjustable 280 O ring face seal ORFS 281 tapered pipe thread fittings 282 hoses and lines 119 hydraulic safety 6 I idler rollers replacing idler roller bearing 189 side draper decks installing idler roller 190 removing idler roller 187 inspections break in inspections 117 maintenanc...

Page 302: ...operating variables headers 58 operations 33 options 243 crop delivery 252 double draper drive DDD kit 253 draper deflector wide 252 draper extension kit 254 HC10 hay conditioner 255 swath forming rods center delivery 254 swath rods center delivery 254 end delivery 254 upper cross auger UCA 86 253 hydraulic kit for DDD 255 cutterbars 246 cutterbar wearplates 246 knife cutout cover 246 rock retarde...

Page 303: ...203 reel clearance 198 reel endshields 220 replacing endshield supports 223 replacing right reel on double reel header 222 reel speed 64 preseason servicing 118 product overview 25 R raking 83 recommended fluids and lubricants 293 recommended setting 46 recommended settings reels 56 reel arm extension kit North American configured headers 243 reel clearance adjusting 200 reel drive chains loosenin...

Page 304: ...See maintenance and servicing setting up the header 257 shutting down procedures 44 skid shoes adjusting 62 soft joints definition 25 spare knives 133 specifications D1X 28 D1XL 28 dimensions D1X 31 D1XL 31 torque specifications 273 speeds ground speed 65 reel speed 64 side draper speed 66 spm definition 25 sprockets 225 226 229 adjusting reel drive chain tension 227 installing reel drive sprocket...

Page 305: ...sition 96 converting from transport to field 89 moving wheels front left wheels to field position 92 rear right wheels to field position 94 removing tow bar 89 storing tow bar 90 header on windrower 87 tire inflation pressures 240 tow bars attaching 101 transporting header 87 towing the header 87 attaching to towing vehicle 88 wheel bolt torques 239 troubleshooting 259 crop loss at cutterbar 259 c...

Page 306: ...double windrowing 79 driving on windrows 83 types of windrows 80 windrow characteristics 82 wobble boxes See knife drive system knife drive box wot definition 25 INDEX ...

Page 307: ...an area protected from dust moisture and other contaminants Table 16 Recommended Fluids and Lubricants Lubricant Specification Description Use Capacities Grease SAE multi purpose High temperature extreme pressure EP performance with 1 max molybdenum disulphide NLGI Grade 2 lithium base As required unless otherwise specified Gear lubricant SAE 85W 140 API service class GL 5 Knife drive box 2 2 lite...

Page 308: ...CUSTOMERS MacDon com DEALERS Portal MacDon com Trademarks of products are the marks of their respective manufacturers and or distributors Printed in Canada ...

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