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MacDon D130XL, Assembly Instructions Manual

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1

Safety

1.1

Signal Words

Three signal words,

DANGER

,

WARNING

, and

CAUTION

, are used to alert you to hazardous situations. The

appropriate signal word for each situation has been selected using the following guidelines:

DANGER

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

WARNING

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. 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.

214017

1

Revision A

Summary of Contents for D130XL

Page 1: ...The harvesting specialists D1 XL Series Draper Header for Windrowers Unloading and Assembly Instructions North America 214017 Revision A 2016 Model Year Original Instruction ...

Page 2: ...D1 XL Series Draper Header for Self Propelled Windrowers Published April 2016 ...

Page 3: ...stomers carefully follow the unload and assembly procedure from the beginning through 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 This instruction is available in the ...

Page 4: ......

Page 5: ...50 4 7 Adding Tire Ballast 51 5 Performing Predelivery Checks 53 5 1 Checking Tire Pressure Transport and Stabilizer Wheels 53 5 2 Checking Wheel Bolt Torque 54 5 3 Checking Knife Drive Box 55 5 4 Checking and Adjusting Knife Drive Belt Tension 57 5 4 1 Tensioning Non Timed Knife Drive Belts 57 5 4 2 Tensioning Timed Knife Drive Belts 58 5 4 3 Tensioning Timed Knife Drive V Belts 60 5 5 Centering ...

Page 6: ... 3 Flare Type Hydraulic Fittings 88 8 1 4 O Ring Boss ORB Hydraulic Fittings Adjustable 90 8 1 5 O Ring Boss ORB Hydraulic Fittings Non Adjustable 92 8 1 6 O Ring Face Seal ORFS Hydraulic Fittings 93 8 1 7 Tapered Pipe Thread Fittings 95 8 2 Lifting Equipment Requirements 96 8 3 Conversion Chart 97 8 4 Definitions 98 Predelivery Checklist 101 214017 iv Revision A ...

Page 7: ...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 8: ...ter 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 the fire extinguisher is properl...

Page 9: ...rten the machine s life To avoid bodily injury or death from unexpected startup of machine always shut down the engine and remove the key from ignition before leaving operator s seat for any reason Figure 1 5 Safety around Equipment Keep the 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 an...

Page 10: ...ce safety signs that are missing or become illegible If original parts on which a safety sign was installed are replaced be sure the repair part also bears the current safety sign Safety signs are available from MacDon Parts Figure 1 7 Operator s Manual Decal 214017 4 Revision A ...

Page 11: ... or machine damage IMPORTANT Forklifts are normally rated with the load centered 24 in 610 mm from the back end of forks To obtain forklift capacity for a load centered at 48 in 1220 mm check with your forklift distributor Table 2 1 Lifting Vehicle Minimum Lifting Capacity 7000 lb 3178 kg load center A at 48 in 1220 mm B from back of forks Minimum Fork Length C 78 in 1981 mm Figure 2 1 Minimum Lif...

Page 12: ...ers 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 unit clears trailer and slowly lower to 6 in 150 mm 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 13: ... Reel Header page 7 2 2 2 Lowering Double Reel Header page 9 2 2 1 Lowering Single Reel Header Reposition header in preparation for assembly and setup as follows 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 frame and secure other end to lifting vehicle Figure 2 3 Shipping Frame 214017 7 Revis...

Page 14: ...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 214017 8 Revision A ...

Page 15: ...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 16: ...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 214017 10 Revision A ...

Page 17: ...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 214017 11 Revision A ...

Page 18: ...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 214017 12 Revision A ...

Page 19: ...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 214017 13 Revision A ...

Page 20: ... 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 214017 14 Revision A ...

Page 21: ...oosen the two nuts B securing the shipping support to the endsheet 9 Slide shipping support C backward to remove 10 Tighten nuts B Figure 2 18 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 214017 15 Revision A ...

Page 22: ......

Page 23: ...rm weighs approximately 120 lb 54 kg NOTE Hydraulic hoses were removed from the illustrations in this procedure to show 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 on top of the gas spring cylinder B and around the support arm C 3 Cut cable tie D and remove the latch support ass...

Page 24: ...nuts D from the plate support E 6 Retain bolts and nuts for use later Figure 3 3 Hydraulic Hose Management Arm Base Frame 7 30 35 Foot Headers With the sling supporting the hose management arm A remove the two bolts and nuts B that secure it to the shipping support C Figure 3 4 Hydraulic Hose Management Arm in Shipping Position 30 35 Foot Headers 214017 18 Revision A ...

Page 25: ...porting the hose management arm cut and remove the wire A that secure it to channel latch on top of header frame tube Figure 3 5 9 With the help of the sling position the hose management arm A as shown Figure 3 6 Hose Management Arm in Field Position 214017 19 Revision A ...

Page 26: ...d shipping support B and reinstall the two bolts on the same location on the coupler holder to secure the hose cover Figure 3 8 Hose Management Arm Shipping Support Bracket 30 35 Foot Headers 13 Cut the cable tie securing the hoses in position A and secure the hoses with the strap A bolted on the frame IMPORTANT Note the routing of the hoses in the hose management arm field position in Figure 3 9 ...

Page 27: ...y A Figure 3 10 Latch Support Assembly 16 Align the bolts A on the latch support assembly B to the holes on the support channel C of the windrower s outer leg and secure with the three nuts removed earlier NOTE Ensure the hook D is still free to move after tightening bolt and nut E Figure 3 11 Latch Support Assembly on Windrower Leg 214017 21 Revision A ...

Page 28: ... hairpin and clevis pin B from the draper header support A Figure 3 12 Draper Header Support 2 Position the draper header support B on lift linkage A and reinstall clevis pin C NOTE To avoid catching the pin on passing crop install the clevis pin on the outboard side of the draper header support 3 Secure clevis pin C with hairpin D 4 Repeat for opposite lift linkage Figure 3 13 Draper Header Suppo...

Page 29: ...ly injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Stop windrower engine and remove key from ignition 2 Relocate pin A in frame linkage as required to raise the center link B until the hook is above the attachment pin on the header IMPORTANT If the center link is too low it may co...

Page 30: ... springs tension is fully released Figure 3 16 Float Springs 5 In the windrower cab press scroll knob A on Harvest Performance Tracker HPT to highlight QUICK MENU options 6 Rotate scroll knob A to highlight the HEADER FLOAT symbol B and press scroll knob to select The screen changes Figure 3 17 HPT Display 7 Press soft key 3 A to remove float Figure 3 18 HPT Display 214017 24 Revision A ...

Page 31: ...TILT UP A and HEADER TILT DOWN B cylinder switches on the ground speed lever GSL to extend or retract center link cylinder until the hook is aligned with the header attachment pin 11 Stop engine and remove key from ignition Figure 3 20 GSL 12 Push down on rod end of link cylinder B until hook engages and locks onto header pin IMPORTANT Hook release must be down to enable self locking mechanism If ...

Page 32: ...o release and lower safety prop onto cylinder b Repeat for opposite lift cylinder IMPORTANT Ensure the safety props engage over cylinder piston rods If safety prop does not engage properly raise header until prop fits over the rod Figure 3 23 Cylinder Safety Prop 17 Install the pin B through header leg engaging U bracket in draper header support on both sides and secure with hairpin A 18 Raise hea...

Page 33: ...nd press HEADER DOWN switch A on GSL to fully lower header 22 Stop engine and remove key Figure 3 26 GSL 3 3 2 Hydraulic Link with Optional Self Alignment Kit The following connection procedure applies to M1240 windrowers hydraulic center link with the optional self alignment kit installed DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remo...

Page 34: ... linkages when lowering header lift legs without a header or weight box attached to the windrower ensure the float springs tension is fully released Figure 3 28 Header Float Springs 4 In the windrower cab press scroll knob A on Harvest Performance Tracker HPT to highlight QUICK MENU options 5 Rotate scroll knob A to highlight the HEADER FLOAT symbol B and press scroll knob to select Screen changes...

Page 35: ...nt 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 31 GSL 9 Drive the windrower slowly forward until the draper header supports A enter the header legs B Continue driving slowly forward until lift linkages contact the support plates in the header legs and the header nudges forward 10 Ensure that lift lin...

Page 36: ... C must be down to enable self locking mechanism If the release is open up manually push it down after hook engages header pin 12 Lower center link A onto the header with REEL DOWN switch on the GSL until it locks into position hook release C is down 13 Check that center link is locked onto header by pressing the REEL UP switch on the GSL Figure 3 34 Center Link CAUTION Check to be sure all bystan...

Page 37: ...e 3 36 Cylinder Safety Prop 17 Install pin B through the header leg engaging U bracket in draper header support on both sides and secure with a hairpin A 18 Raise header stand D to storage position by pulling spring pin C and lifting stand into uppermost position Release spring pin Figure 3 37 Header Leg 19 Disengage safety prop by turning lever A downward to raise safety prop until lever locks in...

Page 38: ... TO WINDROWER CAUTION Check to be sure all bystanders have cleared the area 21 Start engine and press HEADER DOWN switch A on GSL to fully lower header 22 Stop engine and remove key Figure 3 39 GSL 214017 32 Revision A ...

Page 39: ...b forward side of windrower Figure 3 40 Hydraulic Hose Management Arm 2 Connect hydraulic hose management arm A to windrower by securing the ball joint B on arm into the latch support C on windrower Figure 3 41 Windrower Left Leg 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...

Page 40: ...o receptacles and secure by turning collar on electrical connector clockwise Figure 3 43 Draper Reel Multicoupler 9 Retrieve knife and reel drive multicoupler A from hose management arm 10 Push knob B on hydraulic receptacle and pull handle C fully away from windrower 11 Open cover D and position coupler onto receptacle Align pins in coupler with slots in handle C and push handle toward windrower ...

Page 41: ...ATTACHING HEADER TO WINDROWER 14 Ensure hydraulic hose routing is as straight as possible and avoids potential rub wear points Figure 3 46 Hydraulic Multicouplers and Hose Routing 214017 35 Revision A ...

Page 42: ......

Page 43: ... 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 214017 37 Revision A ...

Page 44: ...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 214017 38 Revision A ...

Page 45: ...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 214017 39 Revision A ...

Page 46: ...y Remove socket head bolt and nut from cylinder rod end 13 Double reel only Attach rod end of cylinder 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 40 45 ft lbf 54 61 N m 15 Double reel only Remove pin at barrel end of cylinder 16 Double reel only Adjust reel height so pin can be installed at barrel end of...

Page 47: ... 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 214017 41 Revision A ...

Page 48: ...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 214017 42 Revision A ...

Page 49: ... HEADER 25 Remove brace bolts and tags A locking the reel fore aft position at outer reel arms Figure 4 15 Right Reel Arm Top Image Single Reel Bottom Image Double Reel Figure 4 16 Left Reel Arm 214017 43 Revision A ...

Page 50: ...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 214017 44 Revision A ...

Page 51: ...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 52: ...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 53: ...s 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 inse...

Page 54: ...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 47 to Step 9 page 48 on the left side of the header Figure 4 29 Adjustment Hardware 214017 48 Revision A ...

Page 55: ...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 214017 49 Revision A ...

Page 56: ...ASSEMBLING THE HEADER 4 6 Installing Options Retrieve the kits supplied as options with the header and install them according to the instructions supplied with each kit 214017 50 Revision A ...

Page 57: ... 377 Table 4 2 Recommended Ballast Recommended Ballast Level Ground Hills Header Size Rec Tire Size Per Tire U S Gal liters Both Tires lb kg 2 Per Tire U S Gal liters Both Tires lb kg 30 ft Single Reel or Double Reel without conditioner 35 ft Single Reel 7 5 x 16 10 x 16 16 5 x 16 1 0 0 10 38 200 91 30 ft Double Reel with steel fingers and conditioner 35 ft Double Reel 5 or 6 bat Level ground 10 x...

Page 58: ......

Page 59: ...the final checks as listed on the Predelivery Checklist yellow sheet attached to this instruction Predelivery Checklist page 101 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 60: ...rm the following procedure to ensure that transport and stabilizer wheel bolts are correctly torqued 1 Check wheel bolt torque is 80 90 ft lbf 110 120 N m Refer to bolt tightening sequence illustration at right Figure 5 1 Bolt Tightening Sequence 214017 54 Revision A ...

Page 61: ...ngine and remove key before making adjustments to machine 1 Press down 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 Figure 5 3 Left Hand Endshield Support Tube 21401...

Page 62: ...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 63: ...chine IMPORTANT To prolong the belt and drive life do NOT overtighten the belt 1 Open the 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 30 lbf 133 N deflects the belt C 15 16 1 1 8 in 24 28 mm at the mid span Figure 5 5 Left Side Shown Right Side Opposite for Double Knife Headers 4...

Page 64: ...PORTANT Do NOT use the adjuster bolt at the drive pulley to adjust timing belt tension 1 Open the endshield 2 Loosen hex nuts A enough to allow the idler pulleys B to pivot Figure 5 7 LH Knife Drive 3 Pull the idler pulley A as high as possible by hand 4 Thread flange nut B down adjuster bolt C to achieve final tension NOTE Tension is checked at mid span of the belts The belts should deflect 11 16...

Page 65: ...to the belt Figure 5 10 LH Knife Drive 7 Ensure there is a clearance of 0 10 0 14 in 2 5 3 5 mm between the lower belt A and lower guide B 8 If necessary loosen the three bolts C and adjust lower guide B as required Tighten bolts 9 Check that upper belt D and upper guide E also has a clearance of 1 16 1 8 in 1 5 2 5 mm If necessary loosen the two bolts F and adjust as required Tighten bolts 10 Clo...

Page 66: ...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 5 32 in 4 mm with 12 17 lbf 52 77 N of force applied to each belt 3 Tighten bolts A Figure 5 12 Knife Drive V belts 214017 60 Revision A ...

Page 67: ... Reels page 62 5 5 1 Centering Double Reels 1 Measure clearances at locations A between reels and both endsheets The clearances should be the same if the reels are centered If not centered continue on the next step 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 la...

Page 68: ...me if the reel 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 265 ft lbf 359 N m Figure 5 16 Reel Support Arm 214017 62 Revision A ...

Page 69: ...eep the draper from sagging below the cutterbar 1 Ensure the white indicator bar A is at the halfway point in the window WARNING Check to be sure all bystanders have cleared the area 2 Start the engine and raise the header 3 Stop the engine remove the key from the ignition and engage the header safety props Figure 5 17 Left Tension Adjuster Shown Right Opposite 4 Ensure the draper guide the rubber...

Page 70: ...he window 7 Turn the adjuster bolt A clockwise to tighten 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 no...

Page 71: ...a gap of 1 8 in 3 mm 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 67 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 in working position and decks slid ...

Page 72: ... 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 63 Figure 5 24 Draper Deck Supports Draper Removed 214017 66 Revision A ...

Page 73: ...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 74: ...t 1 If the header is not level check the pressure of the windrower s tires to ensure they are properly inflated refer to your windrower s operator s manual 2 If the header is still not level adjust the windrower linkages as required refer to the appropriate section in the windrower s operator s manual NOTE The float springs are NOT used to level the header 214017 68 Revision A ...

Page 75: ... 2 Finger to Guard Cutterbar Clearance X 1 8 in 3 mm at Reel Ends Header Width Single Reel Double Reel 30 ft 1 3 4 in 45 mm 35 ft 2 3 8 in 60 mm 40 ft 45 ft 3 4 in 20 mm 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 header...

Page 76: ... reel flexing 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 71 Figure 5 29 Reel Clearance Figure 5 30 Single Reel Measurement Locations Two Places Figure 5 31 Double Reel Measurement Locations Four...

Page 77: ...rance to cutterbar or turn cylinder rod into clevis to lower reel and decrease clearance c Tighten bolt A d Repeat at opposite side Figure 5 32 Outside Reel Arm 3 For Double Reel Only Adjust center arm lift cylinder stop A to change clearance at inboard ends of reels as follows NOTE Instructions apply to double reel headers only and are performed from the underside of the arm a Loosen nut B b Turn...

Page 78: ... Temperatures page 72 Table 5 3 Endshield Gap at Various Temperatures Temperature in Degrees F C Gap X in Inches mm 25 4 1 1 10 28 45 7 1 24 65 18 13 16 20 85 29 5 8 16 105 41 1 2 12 125 52 5 16 8 145 63 3 16 4 165 89 0 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 endshiel...

Page 79: ...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 214017 73 Revision A ...

Page 80: ...e bolts A on 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 Verify...

Page 81: ...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 82: ...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 Knife Header Master Grease Point Deca...

Page 83: ... 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 84: ...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 Universal One Place D Reel Shaft Left Hand Bearing One Place 214017 78 Revision A ...

Page 85: ...e the cable tie on the manual case Figure 5 46 Manual Case 2 Confirm that the case contains the following manuals D1 XL Series Draper Header for Self Propelled Windrowers Operator s Manual D1 XL Series Draper Header for Self Propelled Windrowers Quick Card D1 XL Series Draper Header Parts Catalog 3 Close case and endshield Figure 5 47 D1 XL Series Manuals 214017 79 Revision A ...

Page 86: ......

Page 87: ...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 88: ......

Page 89: ...eath 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 loosenin...

Page 90: ...PERFORMING POST RUN UP ADJUSTMENTS 5 Adjust guard tips downward by positioning tool as shown and pushing down Figure 7 3 Guard Tips Downward Adjustment 214017 84 Revision A ...

Page 91: ... tightness of bolts Understand torque categories for bolts and cap screws by using their identifying head markings 8 1 1 Metric Bolt Specifications Table 8 1 Metric Class 8 8 Bolts and Class 9 Free Spinning Nut Torque ft lbf in lbf Torque N m Nominal Size A Min Max Min Max 3 0 5 13 14 1 4 1 6 3 5 0 6 20 22 2 2 2 5 4 0 7 29 32 3 3 3 7 5 0 8 59 66 6 7 7 4 6 1 0 101 112 11 4 12 6 8 1 25 20 23 28 30 1...

Page 92: ...16 2 0 119 132 161 178 20 2 5 233 257 314 347 24 3 0 402 444 543 600 Figure 8 2 Bolt Grades Table 8 3 Metric Class 10 9 Bolts and Class 10 Free Spinning Nut Torque ft lbf in lbf Torque N m Nominal Size A Min Max Min Max 3 0 5 18 19 1 8 2 3 5 0 6 27 30 2 8 3 1 4 0 7 41 45 4 2 4 6 5 0 8 82 91 8 4 9 3 6 1 0 140 154 14 3 15 8 8 1 25 28 31 38 42 10 1 5 56 62 75 83 12 1 75 97 108 132 145 14 2 0 156 172 ...

Page 93: ...Size A Min Max Min Max 3 0 5 12 13 1 3 1 5 3 5 0 6 19 21 2 1 2 3 4 0 7 28 31 3 1 3 4 5 0 8 56 62 6 3 7 6 1 0 95 105 10 7 11 8 8 1 25 19 21 26 29 10 1 5 38 42 51 57 12 1 75 66 73 90 99 14 2 0 106 117 143 158 16 2 0 165 182 222 246 20 2 5 322 356 434 480 24 3 0 556 614 750 829 Figure 8 4 Bolt Grades 214017 87 Revision A ...

Page 94: ... 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 the flared surfaces 3 Torque the fitting nut E to the specified number of flats from finger tight FFFT or to a given torque value in Table 8 6 Flare Type Hydraulic Tube Fittings page 89 4 Use two wrenches to prevent fitting D from rotating Place ...

Page 95: ... 20 14 15 19 21 2 2 6 9 16 18 22 24 30 33 2 1 1 2 8 3 4 16 42 46 57 63 2 1 1 2 10 7 8 14 60 66 81 89 1 1 2 1 1 2 12 1 1 16 12 83 91 113 124 1 1 2 1 1 4 14 1 3 16 12 100 110 136 149 1 1 2 1 1 4 16 1 5 16 12 118 130 160 176 1 1 2 1 20 1 5 8 12 168 184 228 250 1 1 24 1 7 8 12 195 215 264 291 1 1 32 2 1 2 12 265 291 359 395 1 1 40 3 12 1 1 3 Torque values shown are based on lubricated connections as i...

Page 96: ...n the threads and adjust if necessary 4 Apply hydraulic system oil to the O ring A Figure 8 7 Hydraulic Fitting 5 Install fitting B into port until back up washer D and O ring A contact the 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 the other on lock nut C 8 Check the...

Page 97: ...4 7 16 20 14 15 19 21 5 1 2 20 15 24 21 33 6 9 16 18 19 21 26 29 8 3 4 16 34 37 46 50 10 7 8 14 55 60 75 82 12 1 1 16 12 88 97 120 132 14 1 3 8 12 113 124 153 168 16 1 5 16 12 130 142 176 193 20 1 5 8 12 163 179 221 243 24 1 7 8 12 199 220 270 298 32 2 1 2 12 245 269 332 365 4 Torque values shown are based on lubricated connections as in reassembly 214017 91 Revision A ...

Page 98: ... 6 Check the final condition of the fitting Figure 8 9 Hydraulic Fitting Table 8 8 O Ring Boss ORB Hydraulic Fittings Non Adjustable Torque Value5 SAE Dash Size Thread Size in ft lbf in lbf N m 2 5 16 24 53 62 6 7 3 3 8 24 106 115 12 13 4 7 16 20 14 15 19 21 5 1 2 20 15 24 21 33 6 9 16 18 19 21 26 29 8 3 4 16 34 37 46 50 10 7 8 14 55 60 75 82 12 1 1 16 12 88 97 120 132 14 1 3 8 12 113 124 153 168 ...

Page 99: ... 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 the values in Table 8 9 O Ring Face Seal ORFS Hydraulic Fittings page 94 NOTE If applicable hold the hex on the fitting body E to prevent rotation of fitting body and hose when tightening the fitting nut D 6 Use three wrenches when a...

Page 100: ... 3 8 29 32 40 44 8 13 16 1 2 41 45 55 61 10 1 5 8 59 65 80 88 12 1 3 16 3 4 85 94 115 127 14 Note7 7 8 16 1 7 16 1 111 122 150 165 20 1 11 16 1 1 4 151 167 205 226 24 1 2 1 1 2 232 256 315 347 32 2 1 2 2 376 414 510 561 6 Torque values and angles shown are based on lubricated connection as in reassembly 7 O ring face seal type end not defined for this tube size 214017 94 Revision A ...

Page 101: ...Always finish alignment of fitting in the tightening direction Never back off loosen pipe threaded connectors to achieve alignment 5 Clean all residue and any excess thread conditioner with the appropriate cleaner 6 Assess the final condition of the fitting Pay special attention to the possibility of cracks to the port opening 7 Mark the final position of the fitting If a fitting leaks disassemble...

Page 102: ...ts are normally rated for a load center 24 in 610 mm ahead of back end of the forks To obtain the forklift capacity for a load center A at 48 in 1220 mm B check with your forklift distributor The minimum fork length C is 78 in 1981 mm Figure 8 12 Minimum Lifting Capacity A Center of Gravity of the Load B Load Center 48 in 1220 mm from Back of Forks C Minimum Fork Length 78 in 1981 mm Table 8 11 Li...

Page 103: ...x 00689 megapascals MPa Pressure pounds per square inch psi 14 5038 bar Non SI bar pound feet or foot pounds ft lbf x 1 3558 Newton meters N m Torque pound inches or inch pounds in lbf x 0 1129 Newton meters N m Temperature degrees Fahrenheit F F 32 x 0 56 Celsius C feet per minute ft min x 0 3048 meters per minute m min feet per second ft s x 0 3048 meters per second m s Velocity miles per hour m...

Page 104: ...tion typical outside North America Finger tight Finger tight is a reference position where sealing surfaces or components are making contact with each other and the fitting has been tightened to a point where the fitting is no longer loose FFFT Flats from finger tight GSL Ground speed lever GVW Gross vehicle weight Hard joint A joint made with the use of a fastener where the joining materials are ...

Page 105: ...in one of the mating parts SDD Single draper drive Self Propelled SP Windrower Self propelled machine consisting of a power unit with a header SK Single knife SKD Single knife drive Soft joint A joint made with the use of a fastener where the 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 vehic...

Page 106: ... driven knives from a single hydraulic motor or two hydraulic motors Washer A thin cylinder with a hole or slot located in the center that is to be used as a spacer load distribution element or a locking mechanism Windrower Power unit of a self propelled header WCM Windrower control module 214017 100 Revision A ...

Page 107: ...ing Knife Drive Box page 55 Check knife drive box lube level 5 3 Checking Knife Drive Box page 55 Check knife drive belt s tension 5 4 Checking and Adjusting Knife Drive Belt Tension page 57 Check if reel is centered between header endsheets 5 5 Centering the Reel page 61 Grease all bearings and U joints 5 12 Lubricating the Header page 75 Check draper tension 5 6 Adjusting Draper Tension page 63 ...

Page 108: ... Tension page 57 Check knife sections for discoloration caused by misaligned components 7 1 Adjusting Knife page 83 Check for hot spots on the cutterbar above the draper seal Adjust deck height as required 5 7 Checking and Adjusting Draper Seal page 65 Check for hydraulic leaks Check that manual storage case contains operator s manual and parts catalog 5 13 Checking Manuals page 79 Date checked Ch...

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Page 110: ...204 885 5590 f 204 832 7749 MacDon Inc 10708 N Pomona Avenue Kansas City Missouri United States 64153 1924 t 816 891 7313 f 816 891 7323 MacDon Australia Pty Ltd A C N 079 393 721 P O Box 243 Suite 3 143 Main Street Greensborough Victoria Australia 3088 t 03 9432 9982 f 03 9432 9972 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Centre t...

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