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ASSEMBLING THE HEADER

4.7 Adding Ballast

M1-Series windrowers use counterweight kits to add ballast. The counterweights are used to improve a windrower’s
balance while operating with a header. Each kit comes with eight counterweights totaling 163 kg (360 lb.) and
required hardware. The M1-Series windrowers will hold a maximum of 24 counterweights totaling 490 kg (1080 lb.).

Table

4.1 Available Ballast Kits for Different Header Types and Con

gurations, page 45

lists the number of

counterweight kits required for each D1XL Series and D125X header con

fi

guration. Install them according to the

instructions supplied with each kit.

Table 4.1 Available Ballast Kits for Different Header Types and Con

fi

gurations

Header Type

Description

Header Con

fi

guration

Initial Rear

Ballast Kit

Additional Rear

Ballast Kits

D125X

25-ft. single reel,

double knife, timed

Base

-

-

D130XL

30-ft. single reel,

double knife, timed

Transport

-

-

D130XL

30-ft single reel,

double knife, timed

Transport

Upper cross auger

Vertical knives

-

-

D135XL

35-ft. single reel,

double knife,

untimed

Base

-

-

D135XL

35-ft single reel,

double knife,

untimed

Transport

-

-

D135XL

35-ft. single reel,

double knife,

untimed

Transport

Upper cross auger

Vertical knives

-

-

D135XL

35-ft. double reel,

double knife,

untimed

Base

-

-

D135XL

35-ft. double reel,

double knife,

untimed

Transport

-

-

D135XL

35-ft. double reel,

double knife,

untimed

Transport

Upper cross auger

Vertical knives

-

-

D140XL

40-ft. double reel,

double knife,

untimed

Base

-

-

D140XL

40-ft. double reel,

double knife,

untimed

Transport

-

-

D140XL

40-ft. double reel,

double knife,

untimed

Transport

Upper cross auger

Vertical knives

1

-

214047

45

Revision A

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Summary of Contents for D125X

Page 1: ...The harvesting specialists D1X Series Draper Header for Windrowers Unloading and Assembly Instructions North America 214047 Revision A 2017 Model Year Original Instruction ...

Page 2: ...D1X Series Draper Header for Self Propelled Windrowers Published December 2016 ...

Page 3: ... to completion Some sections steps apply to multiple header configurations and sizes Refer to the instructions for your specific header Carefully read all the material provided before attempting to unload assemble or use the machine Retain this instruction for future reference NOTE Keep your MacDon publications up to date The latest version can be downloaded from our website www macdon com or from...

Page 4: ......

Page 5: ... Checks 47 5 1 Checking Tire Pressure Transport and Stabilizer Wheels 47 5 2 Checking Wheel Bolt Torque 48 5 3 Checking Knife Drive Box 49 5 4 Checking and Adjusting Knife Drive Belt Tension 51 5 4 1 Tensioning Non Timed Knife Drive Belts 51 5 4 2 Tensioning Timed Knife Drive Belts 52 5 4 3 Tensioning Timed Knife Drive V Belts 54 5 5 Centering the Reel 55 5 5 1 Centering Double Reels 55 5 5 2 Cent...

Page 6: ...uminum 84 8 1 4 Flare Type Hydraulic Fittings 84 8 1 5 O Ring Boss ORB Hydraulic Fittings Adjustable 86 8 1 6 O Ring Boss ORB Hydraulic Fittings Non Adjustable 88 8 1 7 O Ring Face Seal ORFS Hydraulic Fittings 89 8 1 8 Tapered Pipe Thread Fittings 91 8 2 Lifting Equipment Requirements 92 8 3 Conversion Chart 93 8 4 Definitions 94 Predelivery Checklist 97 214047 iv Revision A ...

Page 7: ...d endshield 2 3 Removing Shipping Supports page 13 Updated illustration to show sling position when unloading hose management arm 3 1 Installing the Hydraulic Hose Management Arm page 17 New hose management arm shipping bracket illustrated throughout the Installing the Hydraulic Hose Management Arm procedure 3 1 Installing the Hydraulic Hose Management Arm page 17 Updated Checking and Adjusting Dr...

Page 8: ......

Page 9: ...imminently hazardous situation that if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation that if not avoided could result in death or serious injury It may also be used to alert against unsafe practices CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It may be used to alert against u...

Page 10: ...or or filter mask Figure 1 1 Safety Equipment Be aware that exposure to loud noises can cause hearing impairment or loss Wear suitable hearing protection devices such as ear muffs or ear plugs to help protect against objectionable or loud noises Figure 1 2 Safety Equipment Provide a first aid kit for use in case of emergencies Keep a fire extinguisher on the machine Be sure fire extinguisher is pr...

Page 11: ...achine s life To avoid bodily injury or death from unexpected startup of machine ALWAYS stop the engine and remove the key from the ignition before leaving the operator s seat for any reason Figure 1 5 Safety around Equipment Keep service area clean and dry Wet or oily floors are slippery Wet spots can be dangerous when working with electrical equipment Be sure all electrical outlets and tools are...

Page 12: ...ace safety signs that are missing or become illegible If original parts on which a safety sign was installed are replaced be sure repair part also bears current safety sign Safety signs are available from your MacDon Dealer Figure 1 7 Operator s Manual Decal 214047 4 Revision A ...

Page 13: ...ping or machine damage IMPORTANT Forklifts are normally rated with the load centered 610 mm 24 in from the back end of forks To obtain forklift capacity for a load centered at 1220 mm 48 in check with your forklift distributor Table 2 1 Lifting Vehicle Minimum Lifting Capacity 3178 kg 7000 lb load center A at 1220 mm 48 in B from back of forks Minimum Fork Length C 1981 mm 78 in Figure 2 1 Minimum...

Page 14: ...s may occur 4 Remove hauler s tie down straps chains and wooden blocks 5 Slowly raise header off trailer deck WARNING Be sure forks are secure before moving away from load Stand clear when lifting 6 Back up until header clears trailer and slowly lower to 150 mm 6 in from ground Figure 2 2 Header Shipping Supports 7 Take header to the storage or setup area Ensure ground is flat and free of rocks or...

Page 15: ...ge 7 2 2 2 Lowering Double Reel Header page 9 2 2 1 Lowering Single Reel Header Reposition header in preparation for assembly and setup as follows 1 Choose an area with level ground 2 Approach header from its underside and place forks under top of shipping frame A 3 Attach a chain B at each end of the shipping frame and secure other end to lifting vehicle Figure 2 3 Shipping Frame 214047 7 Revisio...

Page 16: ...ON Stand clear when lowering as machine may swing 4 Back up SLOWLY while lowering forks until header is just above the ground Refer to the four positions in the illustration Figure 2 4 Lowering the Header 214047 8 Revision A ...

Page 17: ...Figure 2 5 Block at One End of Cutterbar 8 Lower header stand by pulling pin A lowering stand B and releasing pin A to secure stand in place 9 If ground is soft place a block under the stand 10 Lower header onto stand Figure 2 6 Header Stand 2 2 2 Lowering Double Reel Header Reposition header in preparation for assembly and setup as follows 1 Choose an area with level ground 2 Drive lifting vehicl...

Page 18: ...ttach a chain to shipping support A at center reel arm IMPORTANT Do NOT lift header at this location This procedure is only for laying the machine over into working position Figure 2 8 Shipping Support 214047 10 Revision A ...

Page 19: ...N Stand clear when lowering as machine may swing 4 Back up SLOWLY while lowering forks until header is just above the ground Refer to the four positions in the illustration Figure 2 9 Lowering the Header 214047 11 Revision A ...

Page 20: ...7 Attach chain to center link anchor on frame tube and raise rear of header so that stand can be lowered Figure 2 10 Block at One End of Cutterbar 8 Lower the header stand pull pin A lower stand B and release pin A to secure stand in place 9 If ground is soft place a block under the stand 10 Lower header onto stand 11 Remove chain Figure 2 11 Header Stand 214047 12 Revision A ...

Page 21: ...rts A from shipping support Set draper header supports aside for reinstallation Figure 2 12 Straps Draper Header Supports and Shipping Supports 2 Single reel only Cut banding A securing reel to cutterbar and backtube Figure 2 13 Single Reel 3 Remove four bolts A securing upper support B to header legs and remove support Figure 2 14 Upper Support 214047 13 Revision A ...

Page 22: ... Figure 2 15 Lower Support 5 Remove the four bolts A from the shipping stands at both outboard header legs and remove the shipping stands Figure 2 16 Outer Leg Shipping Supports 6 Remove reel anti rotation brace A from between reel and endsheet Figure 2 17 Anti Rotation Brace 214047 14 Revision A ...

Page 23: ...ring the shipping support to the endsheet 9 Slide shipping support C backward to remove 10 Tighten nuts B Figure 2 18 Endsheet Shipping Support 11 At the right hand side of the header loosen the two nuts A securing the shipping support B to the endsheet 12 Slide shipping support B backward to remove 13 Tighten nuts A Figure 2 19 Endsheet Shipping Support 214047 15 Revision A ...

Page 24: ......

Page 25: ...is task the hydraulic hose management arm weighs approximately 54 kg 120 lb NOTE Hydraulic hoses were removed from the illustrations in this procedure for clarity 1 Cut and remove the wire A securing the hydraulic hose management arm B to the diagonal brace C Figure 3 1 Hydraulic Hose Management Arm 2 Position a sling A between the gas spring cylinder B and around the support arm C 3 Attach sling ...

Page 26: ...g plate E Retain bolts and nuts for use later Discard shipping plate E Figure 3 3 Hydraulic Hose Management Arm Base Frame 6 25 35 Foot Headers With the sling attached to the lifting device and supporting the hose management arm A remove the two bolts and nuts B that secures the hose management arm to the shipping support C Figure 3 4 Hydraulic Hose Management Arm in Shipping Position 30 35 Foot H...

Page 27: ...agement arm cut and remove the wire A that secures the hose management arm to channel latch on top of header frame tube Figure 3 5 Hose Management Arm Shipping Wire 8 With the help of the sling and lifting device position the hose management arm A as shown Figure 3 6 Hose Management Arm in Field Position 214047 19 Revision A ...

Page 28: ...d shipping support B and reinstall the two bolts at the same location on the coupler holder to secure the hose cover Figure 3 8 Hose Management Arm Shipping Support Bracket 25 35 Foot Headers 12 Cut the cable tie securing the hoses in position A and secure the hoses with the strap B bolted on the frame IMPORTANT Note the routing of the hoses in the hose management arm field position in Figure 3 9 ...

Page 29: ...supports removed from shipping supports in Step 1 page 13 2 Remove hairpin and clevis pin B from the draper header support A Figure 3 10 Draper Header Support 3 Position the draper header support B on lift linkage A and reinstall clevis pin C NOTE To avoid pin snagging the windrow install the clevis pin on the outboard side of the draper header support 4 Secure clevis pin C with hairpin D 5 Repeat...

Page 30: ...bove the attachment pin on the header IMPORTANT If the center link is too low it may contact the header as the windrower approaches the header for hookup Figure 3 12 Center Link without Self Alignment 3 Remove hairpin A from pin B and remove pin B from header leg Repeat on the other header leg CAUTION Check to be sure all bystanders have cleared the area 4 Start engine Figure 3 13 Header Leg CAUTI...

Page 31: ...draulic center link with optional self alignment a Press HEADER DOWN switch on the ground speed lever GSL to fully retract header lift cylinders b Press REEL UP switch on the GSL to raise the center link until the hook is above the attachment pin on the header IMPORTANT If the center link is too low it may contact the header as the windrower approaches the header for hookup Figure 3 17 Ground Spee...

Page 32: ...k with optional self alignment a Adjust position of the center link cylinder A with the switches on the GSL until the hook B is above the header attachment pin IMPORTANT Hook release C must be down to enable self locking mechanism b If the hook release C is open up stop the engine and remove ignition key Manually push the hook release C down after hook engages the header pin c Lower center link A ...

Page 33: ...k that center link A is locked onto header by pulling upward on rod end B of cylinder e Start engine Figure 3 20 Hydraulic Center Link CAUTION Check to be sure all bystanders have cleared the area 13 Press the HEADER UP switch A to raise header to maximum height 14 Stop the engine and remove key from ignition Figure 3 21 Ground Speed Lever 15 Engage safety prop on the windrower s lift cylinder as ...

Page 34: ...23 Header Leg 18 Disengage safety prop by turning lever A downward to raise safety prop until lever locks into vertical position NOTE If safety prop will not disengage raise header to release the prop 19 Repeat for opposite side Figure 3 24 Cylinder Safety Prop CAUTION Check to be sure all bystanders have cleared the area 20 Start engine and press HEADER DOWN switch A on GSL to fully lower header ...

Page 35: ...s and shipping wire from hose management arm Figure 3 26 Hydraulic Hose Management Arm 3 Ensure cab door is closed on the left cab forward side of the windrower 4 Push latch B and pull platform A toward walking beam until it stops and latch engages Figure 3 27 Platform 5 Unhook hoses from arm assembly 6 Connect hydraulic hose management arm A to windrower by securing the ball joint B on arm into t...

Page 36: ...electrical connector clockwise 11 Remove hose quick disconnect F from storage location and connect to receptacle on frame Figure 3 29 Draper Reel Multicoupler 12 Retrieve knife and reel drive multicoupler A from hose management arm 13 Push knob B on hydraulic receptacle and pull handle C fully away from windrower 14 Open cover D and position coupler onto receptacle Align pins in coupler with slots...

Page 37: ...ATTACHING HEADER TO WINDROWER 17 Ensure hydraulic hose routing is as straight as possible and avoids potential rub wear points Figure 3 32 Hydraulic Multicouplers and Hose Routing 214047 29 Revision A ...

Page 38: ......

Page 39: ... Attaching Reel Lift Cylinders CAUTION Bolts A with tags on reel arms keep the reel from sliding forward Ensure fore aft cylinders are attached before removing bolts Figure 4 1 Right Reel Arm Parts Removed for Clarity Top Image Single Reel Bottom Image Double Reel Figure 4 2 Left Reel Arm 214047 31 Revision A ...

Page 40: ...g from the reel lift cylinder Figure 4 3 Reel Tube 3 Lift reel and remove two top bolts A on outboard reel arm supports Repeat for opposite side Figure 4 4 Outboard Reel Arm Support 4 Double reel headers only Lift reel and remove two top bolts A on center reel arm to allow the center reel arm to move Figure 4 5 Center Reel Arm Double Reel Header Only 214047 32 Revision A ...

Page 41: ...line up with the lug on endsheet and the hole in the reel arm 7 Secure cylinder to endsheet and reel arm with pins as shown Insert cotter pin A OUTBOARD at reel arm Insert cotter pin B INBOARD at endsheet Figure 4 6 Right Hand Shown 8 Move reel safety props A to engaged position B at outer arm Figure 4 7 Reel Safety Props 214047 33 Revision A ...

Page 42: ...d bolt and 5 8 in nut from cylinder rod end Retain hardware for Step 13 page 34 13 Double reel only Attach rod end of cylinder B to reel arm with socket head bolt and nut A Access hardware through holes in reel arm braces 14 Double reel only Torque bolt and nut A to 54 61 N m 40 45 lbf ft 15 Double reel only Remove pin at barrel end of cylinder 16 Double reel only Adjust reel height so pin can be ...

Page 43: ...ey line up with the lug on endsheet and the hole in the reel arm 21 Secure cylinder to endsheet and reel arm with pins as shown Insert cotter pin A OUTBOARD at reel arm Insert cotter pin B INBOARD at endsheet Figure 4 11 Cylinder and Endsheet 22 Move the reel safety props A to engaged position B Figure 4 12 Reel Safety Prop 214047 35 Revision A ...

Page 44: ...age center reel arm shipping support B from cutterbar and remove shipping support Figure 4 13 Center Reel Arm Shipping Support 24 Remove bolts A from reel arm support at endsheet and remove support Repeat at other side Figure 4 14 Outboard Reel Arm Supports 214047 36 Revision A ...

Page 45: ...ore aft position at outer reel arms NOTE Do NOT use hydraulic pressure to move fore aft cylinder to aid in removing brace bolts Cylinder damage may occur Figure 4 15 Right Reel Arm Top Image Single Reel Bottom Image Double Reel Figure 4 16 Left Reel Arm 214047 37 Revision A ...

Page 46: ...ouble reel only Remove the remaining three bolts A locking the reel fore aft position at the center reel arm and remove shipping channel B Figure 4 17 Center Reel Arm Shipping Channel Double Reel Header Only 214047 38 Revision A ...

Page 47: ...l Endshield Cam End Shown Tail End Similar 2 Remove the two bolts A securing the disc segments to support tabs Retain for reinstallation later 3 Engage slots on disc segment B on endshield support tabs C Figure 4 19 Reel Endshield 4 Secure the other end of the disc segment to support using the bolt A that was removed earlier 5 Position last disc segment B in front of disc segment C and behind disc...

Page 48: ...ks and endshields Figure 4 22 Hardware Bag Right Hand Reel 4 Rotate tine bar crank A and position link B so attachment holes in bar crank are aligned with hole in link 5 Install bolt C in link and position shim D on bolt so that shim is between link and tine bar crank NOTE Bolts are pre coated with Loctite so no further locking method is required 6 Realign link B and tine bar crank A and thread in...

Page 49: ...C to the bracket storage 2 Remove divider rods C from the bracket storage D and set aside for installation later 3 Return lock tab to its original position and tighten bolt B Figure 4 24 Crop Divider on Endsheet 4 Support the crop divider remove shipping wire A at front end and remove bolt B 5 Remove bolt and washer C Figure 4 25 Crop Divider on Endsheet 6 Position crop divider as shown and insert...

Page 50: ...on tip of crop divider as shown and tighten bolt A Figure 4 28 Divider Rod on Crop Divider 9 Check that divider does NOT move laterally Adjust bolts A as required to tighten divider and remove lateral play when pulling at divider tip 10 Repeat Step 4 page 41 to Step 9 page 42 on the left side of the header Figure 4 29 Adjustment Hardware 214047 42 Revision A ...

Page 51: ...EADER 4 5 Positioning Transport Lights Transport lights are located on each of the outboard reel arms 1 Position lights A perpendicular to header Figure 4 30 Transport Light Perpendicular to Header 214047 43 Revision A ...

Page 52: ...ASSEMBLING THE HEADER 4 6 Installing Options Retrieve the kits supplied as options with the header and install them according to the instructions supplied with each kit 214047 44 Revision A ...

Page 53: ...eader Type Description Header Configuration Initial Rear Ballast Kit Additional Rear Ballast Kits D125X 25 ft single reel double knife timed Base D130XL 30 ft single reel double knife timed Transport D130XL 30 ft single reel double knife timed Transport Upper cross auger Vertical knives D135XL 35 ft single reel double knife untimed Base D135XL 35 ft single reel double knife untimed Transport D135X...

Page 54: ...5XL 45 ft double reel double knife untimed Base 1 D145XL 45 ft double reel double knife untimed Transport 1 1 D145XL 45 ft double reel double knife untimed Transport Upper cross auger Vertical knives 1 1 When the recommended fluid ballast has been added proceed to 5 Performing Predelivery Checks page 47 214047 46 Revision A ...

Page 55: ... the final checks as listed on the Predelivery Checklist yellow sheet attached to this instruction Predelivery Checklist page 97 to ensure the machine is field ready Refer to the following pages for detailed instructions as indicated on the Checklist The completed Checklist should be retained either by the Operator or the Dealer 5 1 Checking Tire Pressure Transport and Stabilizer Wheels Check tire...

Page 56: ...wing procedure to ensure that transport and stabilizer wheel bolts are correctly torqued 1 Check wheel bolt torque is 110 120 N m 80 90 lbf ft and adjust as necessary Refer to bolt tightening sequence illustration at right Figure 5 1 Bolt Tightening Sequence 214047 48 Revision A ...

Page 57: ...rom unexpected startup of machine always stop engine and remove key before making adjustments to machine 1 Press down on the latch in the opening A on the inboard side of the endsheet 2 Pull endshield open using handle depression B Figure 5 2 Endshield Latch Access 3 Swivel the endshield toward the back of the header and use the safety latch B to secure the endshield support tube A to the endsheet...

Page 58: ...ing normal operation Failure to do so can result in damage to the knife drive box 4 Check position of plug A and breather B at knife drive box Position MUST be as shown 5 Check oil level It should be between the lower hole C on the dipstick and the bottom end of the dipstick NOTE Check oil level with top of knife drive box horizontal and with the dipstick screwed in Figure 5 4 Knife Drive Box 2140...

Page 59: ...ey before making adjustments to machine IMPORTANT To prolong the belt and drive life do NOT overtighten the belt 1 Open the left endshield 2 Loosen the two bolts A securing the motor assembly to the header endsheet 3 Turn the adjuster bolt B clockwise to move the drive motor until a force of 133 N 30 lbf deflects the belt C 24 28 mm 15 16 1 1 8 in at the midspan Figure 5 5 Left Side Shown Right Si...

Page 60: ... life do NOT over tighten belt IMPORTANT Do NOT use the adjuster bolt at the drive pulley to adjust timing belt tension 1 Open the endshield 2 Loosen two nuts A enough to allow the idler pulleys B to pivot Figure 5 7 LH Knife Drive 3 Thread flange nut C down adjuster bolt B to push the bracket A up NOTE Tension is checked at midspan of the belts The belts should deflect 20 mm 3 4 in with 89 N 20 l...

Page 61: ...of 2 5 3 5 mm 1 8 in between the lower belt A and lower guide B 7 If necessary loosen the three bolts C and adjust lower guide B as required Tighten bolts 8 Check that upper belt D and upper guide E also has a clearance of 1 5 2 5 mm 1 16 1 8 in If necessary loosen the two bolts F and adjust as required Tighten the bolts 9 Close the endshield 10 Repeat procedure for other side of header Figure 5 1...

Page 62: ...A 2 Turn drawbolt B clockwise to tighten or counterclockwise to loosen belts C tension NOTE Tension is checked at mid span of the belts The belts should deflect 4 mm 5 32 in with 52 77 N 12 17 lbf of force applied to each belt 3 Tighten bolts A Figure 5 12 Knife Drive V belts 214047 54 Revision A ...

Page 63: ...rances should be the same if the reels are centered If the reels are not centered proceed to Step 2 page 55 Figure 5 13 Double Reel Measurement Locations 2 Loosen bolts A on each brace B located on both sides of the reel support arm C 3 Move the forward end of the reel center support arm C laterally as required to center both reels 4 Tighten bolts A and torque to 359 N m 265 lbf ft Figure 5 14 Ree...

Page 64: ... is centered If not centered continue on the next step Figure 5 15 Single Reel Measurement Locations 2 Loosen bolt A on the brace B at both ends of the reel 3 Move the forward end of the reel support arm C laterally as required to center the reel 4 Tighten bolts A and torque to 359 N m 265 lbf ft Figure 5 16 Reel Support Arm 214047 56 Revision A ...

Page 65: ...gine and fully raise the header 3 Shut down the self propelled windrower and remove the key from the ignition 4 Engage the header safety props Figure 5 17 Left Tension Adjuster Shown Right Opposite 5 Ensure the draper guide the rubber track on the underside of the draper is properly engaged in the groove A on the drive roller Figure 5 18 Drive Roller 6 Ensure the idler roller A is between the drap...

Page 66: ... turn it clockwise The white indicator bar B will move inboard in the direction of arrow E to indicate that the draper is tightening Tighten until the white indicator bar is at the halfway point in the window IMPORTANT To avoid premature failure of the draper draper rollers and or tightener components do not operate with the tension set so the white bar is not visible To prevent scooping dirt ensu...

Page 67: ...just below cutterbar B with a gap of 1 3 mm 1 32 1 8 in between the top of deck front track and cutterbar If deck height is acceptable skip the remaining steps and proceed to 5 8 Checking and Adjusting Skid Shoe Settings page 61 If deck height is NOT acceptable adjust seal as described in the following steps Figure 5 21 Draper Cutterbar Gap NOTE Take measurement at deck supports A with the header ...

Page 68: ... C to lower deck relative to supports and achieve the recommended setting Tap support B using a punch to raise deck relative to supports 6 Tighten deck support hardware A 7 Tension drapers Refer to 5 6 Adjusting Draper Tension page 57 Figure 5 24 Draper Deck Supports Draper Removed 214047 60 Revision A ...

Page 69: ...before working under header or reel 1 Note the adjustment hole positions on the lugs A on each skid shoe They should be the same 2 If necessary adjust skid shoe as follows a Remove lynch pin B b Hold shoe and remove pin C by disengaging frame and then pulling away from shoe c Raise or lower skid shoe to desired position using holes in support as a guide d Reinsert pin C engage in frame and secure ...

Page 70: ...ent 1 If the header is not level check the pressure of the windrower s tires to ensure they are properly inflated refer to your windrower operator s manual 2 If the header is still not level adjust the windrower linkages as required refer to the appropriate section in the windrower operator s manual NOTE The float springs are NOT used to level the header 214047 62 Revision A ...

Page 71: ...o Guard Cutterbar Clearance X 3 mm 1 8 in at Reel Ends Header Width Single Reel Double Reel 25 ft 25 mm 1 in 30 ft 45 mm 1 3 4 in 35 ft 60 mm 2 3 8 in 40 ft 45 ft 20 mm 3 4 in Figure 5 27 Finger Clearance 5 10 1 Measuring Reel Clearance DANGER To avoid bodily injury or death from unexpected start up or fall of raised machine always stop engine remove key and engage safety props before going under ...

Page 72: ...ng reel clearance at the center of a double reel header measure the lowest reel 6 Check all possible points of contact between points B and C Depending on the reel fore aft position minimum clearance can result at the guard tine hold down or cutterbar 7 Adjust the reel if necessary Refer to 5 10 2 Adjusting Reel Clearance page 65 Figure 5 29 Reel Clearance Figure 5 30 Single Reel Measurement Locat...

Page 73: ...peat procedure if necessary 1 Shut down the self propelled windrower and remove the key from the ignition 2 Adjust outboard reel arm lift cylinders to set clearance at outboard ends of reel as follows a Loosen bolt A b Turn cylinder rod B out of clevis to raise reel and increase clearance to cutterbar or turn cylinder rod into clevis to lower reel and decrease clearance c Tighten bolt A d Repeat a...

Page 74: ...at Various Temperatures page 66 Table 5 3 Endshield Gap at Various Temperatures Temperature in Degrees C F Gap X in mm in 7 45 13 18 1 2 23 32 18 65 10 15 3 8 19 32 29 85 7 12 9 32 15 32 41 105 4 9 5 32 11 32 NOTE If the endshield gap is correct skip to the next procedure If adjustment is required follow these steps Figure 5 34 Gap between Endshield and Header Frame Opening the endshield 2 Push re...

Page 75: ...ll the endshield free of hinge tab A if additional clearance is required and swing shield towards the rear of the header 6 Engage safety catch B on hinge arm to secure the shield in fully open position Figure 5 37 Left Endshield Adjusting the endshield gap 7 Loosen the four bolts A on the support tube bracket B Figure 5 38 LH Endshield Support Tube 214047 67 Revision A ...

Page 76: ... bolts A on the latch assembly 11 Tighten the four bolts on the support tube bracket 12 Close endshield Figure 5 39 LH Endshield Latch Assembly Closing the endshield 13 Disengage lock B to allow endshield to move 14 Insert front of endshield behind hinge tab A and into divider cone Figure 5 40 Left Endshield 15 Swing endshield in direction A into closed position Engage lock with a firm push 16 Ver...

Page 77: ...treme pressure EP performance with 10 max molybdenum disulphide NLGI Grade 2 lithium base Driveline slip joints 5 12 1 Greasing Procedure Greasing points are marked on the machine by decals showing a grease gun and grease interval in hours of operation Master grease point location decals are provided on the header DANGER To avoid bodily injury or death from unexpected start up of machine always st...

Page 78: ...ows fitting except where noted 3 Leave excess grease on fitting to keep out dirt 4 Replace any loose or broken fittings immediately 5 Remove and thoroughly clean any fitting that will not take grease Also clean lubricant passageway Replace fitting if necessary 6 Use clean high temperature extreme pressure grease only Figure 5 42 Single Knife Header Master Grease Point Decal Figure 5 43 Double Knif...

Page 79: ... only 1 2 pumps of grease with a grease gun or just until the knifehead starts to move away from the arm Do NOT use an electric grease gun If more than 6 8 pumps of the grease gun are required to fill the cavity replace the seal in the knifehead Check for signs of excessive heating on first few guards after greasing If required relieve pressure by pressing check ball in grease fitting Figure 5 44 ...

Page 80: ... taking grease OVERGREASING WILL DAMAGE U JOINT Six to eight pumps is sufficient at first grease factory As U joint wears and requires more than six pumps grease the joint more often Figure 5 45 Reel Shaft Bearings A Reel Shaft Right Hand Bearing One Place B Reel Center Bearing One Place C Reel U joint One Place D Reel Shaft Left Hand Bearing One Place 214047 72 Revision A ...

Page 81: ...inside the left hand endshield 1 Open the left hand endshield and remove the cable tie on the manual case Figure 5 46 Manual Case 2 Confirm that the case contains the following manuals Operator s Manual Quick Card Parts Catalog 3 Close case and endshield Figure 5 47 D1XL Series Manuals 214047 73 Revision A ...

Page 82: ......

Page 83: ...ey 1 Start the windrower and run header for 5 minutes watching and listening FROM THE OPERATOR S SEAT for binding or interfering parts NOTE Reels and drapers will not operate until oil flow fills the lines 2 Run header for an additional 10 minutes at operating speed watching and listening FROM THE OPERATOR S SEAT for binding or interfering parts 3 Shut down the windrower and remove key 4 Perform t...

Page 84: ......

Page 85: ...ath from unexpected startup of machine always stop engine and remove key before making adjustments to machine 1 Stop engine and remove the key 2 Check guards for signs of heating during run up due to insufficient clearance between guard and knife 3 If heating is evident check gap between knifehead A and pitman arm B A business card should slide easily through the gap If not adjust gap by loosening...

Page 86: ...PERFORMING POST RUN UP ADJUSTMENTS 5 Adjust guard tips downward by positioning tool as shown and pushing down Figure 7 3 Guard Tips Downward Adjustment 214047 78 Revision A ...

Page 87: ...f 0 65 Self Tapping Screws Standard torque is to be used not to be used on critical or structurally important joints 8 1 1 SAE Bolt Torque Specifications Torque values shown in following tables are valid for non greased or non oiled threads and heads therefore do NOT grease or oil bolts or cap screws unless otherwise specified in this manual Table 8 1 SAE Grade 5 Bolt and Grade 5 Free Spinning Nut...

Page 88: ...456 306 338 1 8 619 684 459 507 Figure 8 2 Bolt Grades A Nominal Size B SAE 8 C SAE 5 D SAE 2 Table 8 3 SAE Grade 8 Bolt and Grade G Distorted Thread Nut Torque Nm Torque lbf ft lbf in Nominal Size A 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...

Page 89: ...65 1288 863 954 Figure 8 4 Bolt Grades A Nominal Size B SAE 8 C SAE 5 D SAE 2 8 1 2 Metric Bolt Specifications Table 8 5 Metric Class 8 8 Bolts and Class 9 Free Spinning Nut Torque Nm Torque lbf ft lbf in Nominal Size A Min Max Min Max 3 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...

Page 90: ...16 2 0 161 178 119 132 20 2 5 314 347 233 257 24 3 0 543 600 402 444 Figure 8 6 Bolt Grades Table 8 7 Metric Class 10 9 Bolts and Class 10 Free Spinning Nut Torque Nm Torque lbf ft lbf in Nominal Size A Min Max Min Max 3 0 5 1 8 2 18 19 3 5 0 6 2 8 3 1 27 30 4 0 7 4 2 4 6 41 45 5 0 8 8 4 9 3 82 91 6 1 0 14 3 15 8 140 154 8 1 25 38 42 28 31 10 1 5 75 83 56 62 12 1 75 132 145 97 108 14 2 0 210 232 1...

Page 91: ...Size A 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 42 12 1 75 90 99 66 73 14 2 0 143 158 106 117 16 2 0 222 246 165 182 20 2 5 434 480 322 356 24 3 0 750 829 556 614 Figure 8 8 Bolt Grades 214047 83 Revision A ...

Page 92: ...d 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 8 10 Flare Type Hydraulic Tube Fittings page 85 4 Use two wrenches to prevent fitting D from rotating Pla...

Page 93: ... 20 19 21 14 15 2 2 6 9 16 18 30 33 22 24 2 1 1 2 8 3 4 16 57 63 42 46 2 1 1 2 10 7 8 14 81 89 60 66 1 1 2 1 1 2 12 1 1 16 12 113 124 83 91 1 1 2 1 1 4 14 1 3 16 12 136 149 100 110 1 1 2 1 1 4 16 1 5 16 12 160 176 118 130 1 1 2 1 20 1 5 8 12 228 250 168 184 1 1 24 1 7 8 12 264 291 195 215 1 1 32 2 1 2 12 359 395 265 291 1 1 40 3 12 1 1 1 Torque values shown are based on lubricated connections as i...

Page 94: ...s NOT on threads and adjust if necessary 4 Apply hydraulic system oil to O ring A Figure 8 11 Hydraulic Fitting 5 Install fitting B into port until back up washer D and O ring A contact part face E 6 Position angle fittings by unscrewing no more than one turn 7 Turn lock nut C down to washer D and tighten to torque shown Use two wrenches one on fitting B and other on lock nut C 8 Check final condi...

Page 95: ...4 7 16 20 19 21 14 15 5 1 2 20 21 33 15 24 6 9 16 18 26 29 19 21 8 3 4 16 46 50 34 37 10 7 8 14 75 82 55 60 12 1 1 16 12 120 132 88 97 14 1 3 8 12 153 168 113 124 16 1 5 16 12 176 193 130 142 20 1 5 8 12 221 243 163 179 24 1 7 8 12 270 298 199 220 32 2 1 2 12 332 365 245 269 2 Torque values shown are based on lubricated connections as in reassembly 214047 87 Revision A ...

Page 96: ... Check final condition of fitting Figure 8 13 Hydraulic Fitting Table 8 12 O Ring Boss ORB Hydraulic Fittings Non Adjustable Torque Value3 SAE Dash Size Thread Size in Nm lbf ft lbf in 2 5 16 24 6 7 53 62 3 3 8 24 12 13 106 115 4 7 16 20 19 21 14 15 5 1 2 20 21 33 15 24 6 9 16 18 26 29 19 21 8 3 4 16 46 50 34 37 10 7 8 14 75 82 55 60 12 1 1 16 12 120 132 88 97 14 1 3 8 12 153 168 113 124 16 1 5 16...

Page 97: ...or C comes in full contact with O ring B 4 Thread tube or hose nut D until hand tight The nut should turn freely until it is bottomed out 5 Torque fittings according to values in Table 8 13 O Ring Face Seal ORFS Hydraulic Fittings page 90 NOTE If applicable hold hex on fitting body E to prevent rotation of fitting body and hose when tightening fitting nut D 6 Use three wrenches when assembling uni...

Page 98: ... 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 Note5 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 4 Torque values and angles shown are based on lubricated connection as in reassembly 5 O ring face seal type end not defined for this tube size 214047 90 Revision A ...

Page 99: ...s finish alignment of fitting in tightening direction Never back off loosen pipe threaded connectors to achieve alignment 5 Clean all residue and any excess thread conditioner with appropriate cleaner 6 Assess final condition of fitting Pay special attention to possibility of cracks to port opening 7 Mark final position of fitting If a fitting leaks disassemble fitting and check for damage NOTE Ov...

Page 100: ...klifts are normally rated for a load center 610 mm 24 in ahead of back end of the forks To obtain the forklift capacity for a load center A at 1220 mm 48 in B check with your forklift distributor The minimum fork length C is 1981 mm 78 in Figure 8 16 Minimum Lifting Capacity A Load Center of Gravity B Load Center 1220 mm 48 in from Back of Forks C Minimum Fork Length 1981 mm 78 in Table 8 15 Lifti...

Page 101: ... megapascals MPa x 145 038 Pressure bar Non SI bar x 14 5038 pounds per square inch psi Newton meters Nm x 0 7376 pound feet or foot pounds lbf ft Torque Newton meters Nm x 8 8507 pound inches or inch pounds lbf in Temperature Celsius C C x 1 8 32 degrees Fahrenheit F meters per minute m min x 3 2808 feet per minute ft min meters per second m s x 3 2808 feet per second ft s Velocity kilometers per...

Page 102: ...uration typical outside North America Finger tight Finger tight is a reference position where sealing surfaces or components are making contact with each other and fitting has been tightened to a point where fitting is no longer loose FFFT Flats from finger tight GSL Ground speed lever GVW Gross vehicle weight Hard joint A joint made with use of a fastener where joining materials are highly incomp...

Page 103: ...ith a header Soft joint A joint made with use of a fastener where joining materials are compressible or experience relaxation over a period of time spm Strokes per minute SR Single reel Truck A four wheel highway road vehicle weighing no less than 3400 kg 7500 lb Timed knife drive Synchronized motion applied at cutterbar to two separately driven knives from a single hydraulic motor Tension Axial l...

Page 104: ......

Page 105: ...ng Knife Drive Box page 49 Check knife drive box lube level 5 3 Checking Knife Drive Box page 49 Check knife drive belt s tension 5 4 Checking and Adjusting Knife Drive Belt Tension page 51 Check if reel is centered between header endsheets 5 5 Centering the Reel page 55 Grease all bearings and U joints 5 12 Lubricating the Header page 69 Check draper tension 5 6 Adjusting Draper Tension page 57 C...

Page 106: ...usting Knife Drive Belt Tension page 51 Check knife sections for discoloration caused by misaligned components 7 1 Adjusting Knife page 77 Check for hot spots on the cutterbar above the draper seal Adjust deck height as required 5 7 Checking and Adjusting Draper Seal page 59 Check for hydraulic leaks Check that manual storage case contains operator s manual and parts catalog 5 13 Checking Manuals ...

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Page 108: ...ates 64153 1924 t 816 891 7313 f 816 891 7323 MacDon Australia Pty Ltd A C N 079 393 721 P O Box 103 Somerton Victoria Australia 3062 54 National Boulevard Campbellfield Victoria Australia 3061 t 61 3 8301 1911 f 61 3 8301 1912 MacDon Brasil Agribusiness Ltda Rua Grã Nicco 113 sala 202 B 02 Mossunguê Curitiba Paraná CEP 81200 200 Brasil t 55 41 2101 1713 f 55 41 2101 1699 LLC MacDon Russia Ltd 123...

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