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MacDon D1X Series Unloading And Assembly Instructions Download Page 101

214778

95

Revision A

8.4

Definitions

The following terms and acronyms may be used in this instruction:

Term

Definition

API

American Petroleum Institute

ASTM

American Society of Testing and Materials

Bolt

A headed and externally threaded fastener that is designed to be paired with a nut

Cab-forward

Windrower operation with Operator and cab facing in direction of travel

CDM

Cab display module on a windrower

Center-link

A hydraulic cylinder link between header and machine used to change header angle

CGVW

Combined gross vehicle weight

D1X Series header

MacDon D115X, D120X, and D125X rigid draper headers for M1 Series Windrowers

D1XL Series header

MacDon D130XL, D135XL, D140XL, and D145XL rigid draper headers for M1 Series
Windrowers

DDD

Double-draper drive

DK

Double knife

DKD

Double-knife drive

DR

Double reel

DWA

Double Windrow Attachment

Engine-forward

Windrower operation with Operator and engine facing in direction of travel

Export header

Header configuration typical outside North America

FFFT

Flats from finger tight

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

GSL

Ground speed lever

GVW

Gross vehicle weight

Hard joint

A joint made with use of a fastener where joining materials are highly incompressible

Header

A machine that cuts and lays crop into a windrow and is attached to a windrower

Hex key

A tool of hexagonal cross-section used to drive bolts and screws that have a hexagonal
socket in head (internal-wrenching hexagon drive); also known as an Allen key and various
other synonyms

HDS

Hydraulic deck shift

hp

Horsepower

HPT display

Harvest Performance Tracker display module on a windrower

ISC

Intermediate Speed Control

JIC

Joint Industrial Council: A standards body that developed standard sizing and shape for
original 37° flared fitting

Knife

A cutting device which uses a reciprocating cutter (also called a sickle)

REFERENCE

Summary of Contents for D1X Series

Page 1: ...D1X and D1XL Series Draper Header Unloading and Assembly Instructions North America 214778 Revision A Original Instruction The harvesting specialists...

Page 2: ...D1XL Draper Header for Self Propelled Windrowers 1016762 Published September 2018...

Page 3: ...h 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 u...

Page 4: ...ers 3 1 Installing the Hydraulic Hose Management Arm page 17 Added note about quick disconnect couplers hard plumb connections for M1 Series 3 4 Connecting Hydraulics page 28 Increased detail illustra...

Page 5: ...he Header 31 4 1 Positioning Transport Lights 31 4 2 Attaching Reel Lift Cylinders 33 4 3 Installing Disc Segments of Outboard Reel Endshields 41 4 4 Attaching Cam Arms 42 4 5 Installing Crop Dividers...

Page 6: ...up the Header 77 Chapter 7 Performing Post Run Up Adjustments 79 7 1 Adjusting Knife 79 Chapter 8 Reference 81 8 1 Torque Specifications 81 8 1 1 SAE Bolt Torque Specifications 81 8 1 2 Metric Bolt Sp...

Page 7: ...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 uns...

Page 8: ...oggles Heavy gloves Wet weather gear Respirator or filter mask 1000005 Figure 1 2 Safety Equipment Be aware that exposure to loud noises can cause hearing impairment or loss Wear suitable hearing prot...

Page 9: ...achine function and or safety It may also shorten machine 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 l...

Page 10: ...Keep safety signs clean and legible at all times Replace safety signs that are missing or illegible If original part on which a safety sign was installed is replaced be sure the repair part displays t...

Page 11: ...icle tipping 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 ch...

Page 12: ...orks contact the second header the header could be damaged 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 mov...

Page 13: ...e 7 2 2 2 Lowering Double Reel Header page 10 2 2 1 Lowering Single Reel Header Reposition header in preparation for assembly and setup as follows 1008905 A B Figure 2 3 Shipping Frame 1 Choose an are...

Page 14: ...1 2 3 4 Figure 2 4 Lowering the Header CAUTION Stand clear when lowering as machine may swing 4 Back up SLOWLY while lowering forks until header is just above the ground Refer to the four positions in...

Page 15: ...hain and move lifting vehicle to rear of header 7 Attach chain to center link anchor on frame tube and raise rear of header so that stand can be lowered 1008297 A B Figure 2 6 Header Stand 8 Lower hea...

Page 16: ...Underside of Header 1 Choose an area with level ground 2 Drive lifting vehicle to approach header from its underside 1016590 A Figure 2 8 Shipping Support 3 Attach a chain to shipping support A at cen...

Page 17: ...1 2 3 4 Figure 2 9 Lowering the Header CAUTION Stand clear when lowering as machine may swing 4 Back up SLOWLY while lowering forks until header is just above the ground Refer to the four positions i...

Page 18: ...and move lifting vehicle to rear of header 7 Attach chain to center link anchor on frame tube and raise rear of header so that stand can be lowered 1008297 A B Figure 2 11 Header Stand 8 Lower the he...

Page 19: ...Shipping Supports 1 Cut straps and remove draper header supports A from shipping support Set draper header supports aside for installation 1008913 A Figure 2 13 Single Reel 2 Single reel only Cut ban...

Page 20: ...pport B to header legs and remove support 1016583 A Figure 2 16 Outer Leg Shipping Support 9 1 12 2 m 30 40 ft 1026957 A Figure 2 17 Outer Leg Shipping Support 4 6 7 6 m 15 25 ft 5 Remove the four bol...

Page 21: ...ire A securing the endshield to the panel Repeat at the opposite side 8 Loosen the three nuts B securing the shipping support to the endsheet 9 Slide shipping support C backward to remove 10 Tighten n...

Page 22: ......

Page 23: ...nt is required to complete this task the hydraulic hose management arm weighs approximately 54 kg 120 lb 1024555 A B Figure 3 1 Hoses and Connector Attached to the Header 1 Disconnect harness connecto...

Page 24: ...15 ft and 6 1 m 20 ft Headers With the sling attached to the lifting device and supporting the hose management arm A lift the hydraulic hose management arm A out of the inboard shipping stand B and re...

Page 25: ...rm to outboard shipping support C Retain hardware NOTE Sling not shown in illustration 9 Remove bolts and nuts D securing shipping support C to the frame channel E Discard shipping support C 1020181 A...

Page 26: ...ting device and supporting the hose management arm cut and remove the wire A that secures the hose management arm to channel latch on top of header frame tube 1016797 A Figure 3 9 Hose Management Arm...

Page 27: ...wo bolts A and shipping support B from the coupler holder C Discard shipping support B and reinstall the two bolts at the same location on the coupler holder to secure the hose cover 1024557 A B C Fig...

Page 28: ...hipping supports in Step 1 page 13 1015587 A B Figure 3 13 Draper Header Support 2 Remove hairpin and clevis pin B from the draper header support A 1015593 A B C D Figure 3 14 Draper Header Support 3...

Page 29: ...TANT If the center link is too low it may contact the header as the windrower approaches the header for hookup 1000754 A B Figure 3 16 Header Leg 3 Remove hairpin A from pin B and remove pin B from he...

Page 30: ...1018911 A B C D E F Figure 3 20 GSL Switches A Reel Down B Reel Up C Header Tilt Down D Header Tilt Up E Header Down F Header Up 8 Self Aligning Hydraulic Center Link a Press HEADER DOWN switch on the...

Page 31: ...k 11 Self Aligning Hydraulic Center Link a Adjust position of the center link cylinder A with the switches on the GSL until hook B is above the header attachment pin IMPORTANT Hook release C must be d...

Page 32: ...ter hook engages pin d Check that center link A is locked onto header by pulling upward on rod end B of cylinder CAUTION Check to be sure all bystanders have cleared the area e Start engine 1014786 A...

Page 33: ...elease spring pin 1014791 A Figure 3 27 Cylinder Safety Prop 18 Disengage safety prop by turning lever A downward to raise safety prop until lever locks into vertical position NOTE If safety prop will...

Page 34: ...indrower 2 Remove all remaining ties and shipping wire from hose management arm 1015479 A B Figure 3 30 Platform 3 Ensure cab door is closed on the left cab forward side of the windrower 4 Push latch...

Page 35: ...ck disconnect F from storage location and connect to receptacle on frame NOTE Hose quick disconnect F is only present on M1240 machines configured for draper headers and on M1170 machines configured f...

Page 36: ...78 30 Revision A 1015750 Figure 3 35 Hydraulic Multicouplers and Hose Routing 16 Ensure hydraulic hose routing is as straight as possible and avoids potential rub wear points ATTACHING HEADER TO WINDR...

Page 37: ...position on the inboard sides of the reel arms 1023878 B A Figure 4 1 Right Light Assembly in Shipping Position 1 Remove lock nut B holding right light assembly A to reel arm and remove light assembl...

Page 38: ...ht assembly B to reel arm and remove light assembly Retain lock nut 1023919 A B Figure 4 4 Left Transport Light 4 Position the left light assembly B perpendicular to left reel arm and attach using ret...

Page 39: ...660 1 2 A A A Figure 4 5 Right Reel Arm 1 Single Reel 2 Double Reel 1014042 A Figure 4 6 Left Reel Arm CAUTION Bolts A with tags on reel arms keep the reel from sliding forward Ensure fore aft cylinde...

Page 40: ...uivalent lifting device 2 Remove shipping wire banding from the reel lift cylinder 1006382 A Figure 4 8 Outboard Reel Arm Support 3 Lift reel and remove two top bolts A on outboard reel arm supports R...

Page 41: ...der mounting holes until they 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 Inser...

Page 42: ...ket head bolt and 5 8 in nut from cylinder rod end Retain hardware b Attach rod end of cylinder B to reel arm with socket head bolt and nut A Access hardware through holes in reel arm braces c Torque...

Page 43: ...cylinder mounting holes until they line up with the lug on endsheet and the hole in the reel arm 15 Secure cylinder to endsheet and reel arm with pins as shown Insert cotter pin A OUTBOARD at reel ar...

Page 44: ...reel only Remove the remaining bolt A disengage center reel arm shipping support B from cutterbar and remove shipping support 1006378 A Figure 4 18 Outboard Reel Arm Supports 18 Remove bolts A from re...

Page 45: ...l 2 Double Reel 1014042 A Figure 4 20 Left Reel Arm 19 Remove brace bolts and tags A locking the reel fore aft position at outer reel arms NOTE Do NOT use hydraulic pressure to move fore aft cylinder...

Page 46: ...B A Figure 4 21 Center Reel Arm Shipping Channel Double Reel Only 20 Double reel only Remove the remaining three bolts A locking the reel fore aft position at the center reel arm and remove shipping c...

Page 47: ...trieve the bag of hardware removed from the center draper support 2 Remove the two bolts A securing the disc segments to support tabs Retain for reinstallation later 3 Engage slots on disc segment B o...

Page 48: ...Remove shipping wire A and foam and remove cam arm assembly B from the tine tube 1026960 A B C Figure 4 26 Cam Arm Assembly 2 Nine bat reel headers Install cam arm assembly A onto arm B and secure wi...

Page 49: ...otate tine bar crank A and position link B so attachment holes in bar crank are aligned with hole in link 7 Install bolt C in link and position shim D on bolt so that shim is between link and tine bar...

Page 50: ...torage bracket C 2 Remove divider rods B from the storage bracket C and pull away from the lower divider rod support D Set aside for installation later 3 Return lock tab to its original position and t...

Page 51: ...d on Crop Divider 8 Position divider rod B on tip of crop divider as shown and tighten bolt A 1007921 A Figure 4 35 Adjustment Hardware 9 Check that divider does NOT move laterally Adjust bolts A as r...

Page 52: ...214778 46 Revision A 4 6 Installing Options Retrieve the kits supplied as options with the header and install them according to the instructions supplied with each kit ASSEMBLING THE HEADER...

Page 53: ...m 20 ft single reel double knife timed Base D125X 7 6 m 25 ft single reel double knife timed Base D130XL 9 1 m 30 ft single reel double knife timed Transport D130XL 9 1 m 30 ft single reel double kni...

Page 54: ...tion Initial Rear Ballast Kit Additional Rear Ballast Kits D145XL 13 7 m 45 ft double reel double knife untimed Transport 1 1 D145XL 13 7 m 45 ft double reel double knife untimed Transport Upper cross...

Page 55: ...machine 1 Perform the final checks as listed on the Predelivery Checklist yellow sheet attached to this instruction Predelivery Checklist page 99 to ensure the machine is field ready Refer to the fol...

Page 56: ...ensure that transport and stabilizer wheel bolts are correctly torqued 1001277 2 3 4 5 6 1 Figure 5 1 Sequence for Tightening Bolts 1 Check wheel bolt torque is 110 120 Nm 80 90 lbf ft and adjust as...

Page 57: ...tup of machine always stop engine and remove key before making adjustments to machine 1024277 A B Figure 5 2 Endshield Latch Access 1 Press down on the latch in the opening A on the inboard side of th...

Page 58: ...peration 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 Remove breather B and check oil level The...

Page 59: ...rtighten the belt 1 Open the left endshield 1022180 A B C Figure 5 5 Knife Drive NOTE Belt guide removed for illustration purposes 2 Loosen the two bolts A securing the motor assembly to the header en...

Page 60: ...hten belt IMPORTANT Do NOT use the adjuster bolt at the drive pulley to adjust timing belt tension 1 Open the endshield 1019546 A B Figure 5 7 Left Knife Drive 2 Loosen two nuts A enough to allow the...

Page 61: ...re 5 11 Left Knife Drive 6 Ensure there is a clearance 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 Tigh...

Page 62: ...belts 1 Loosen the two bolts A 2 Turn drawbolt B clockwise to tighten or counterclockwise to loosen belts C tension NOTE Tension is checked at midspan of the belts The belts should deflect 4 mm 5 32...

Page 63: ...Double Reel Measurement Locations 1 Measure clearances at locations A between reels and both endsheets The clearances should be the same if the reels are centered If the reels are not centered proceed...

Page 64: ...el and endsheets The clearances should be the same if the reel is centered If the reel is not centered proceed to Step 2 page 58 If the reel is centered proceed to 5 6 Adjusting Draper Tension page 59...

Page 65: ...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 fully raise the header 3 Shut down the windrower and remove the key fr...

Page 66: ...the halfway point in the window 8 To tighten draper tension turn adjuster bolt A clockwise The white indicator bar B will move inboard in the direction of arrow E to indicate that the draper is tight...

Page 67: ...aper A should run 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 Che...

Page 68: ...ort B NOTE Deck shown with draper removed 5 Tap deck C to lower deck relative to supports and achieve the recommended setting Tap support B using a punch to raise deck relative to supports 6 Tighten d...

Page 69: ...header or reel 1007626 A C B Figure 5 25 Inner Skid Shoe 1 Check 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 Rem...

Page 70: ...he 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 windrowe...

Page 71: ...Reel Ends Single Reel Double Reel 4 6 m 15 ft 20 mm 3 4 in 6 1 m 20 ft 20 mm 3 4 in 7 6 m 25 ft 25 mm 1 in 9 1 m 30 ft 55 mm 2 11 64 in 25 mm 1 in 10 7 m 35 ft 70 mm 2 3 4 in 25 mm 1 in 12 2 m 40 ft...

Page 72: ...ate for reel flexing NOTE When measuring 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 ree...

Page 73: ...t A d Repeat at opposite side 1009601 A B C Figure 5 33 Underside of Center Arm 3 For double reel Adjust center arm lift cylinder stop A to change clearance at inboard ends of reels as follows a Loose...

Page 74: ...s and the header frame and compare to the values in Table 5 3 page 68 Table 5 3 Endshield Gap at Various Temperatures Temperature in C F Gap X mm in 7 45 13 18 1 2 23 32 18 65 10 15 3 8 19 32 29 85 7...

Page 75: ...ld free of hinge tab A if additional clearance is required and swing shield towards the rear of the header 5 Engage safety catch B on hinge arm to secure the shield in fully open position Adjusting th...

Page 76: ...d gap at various temperatures 4 Tighten the three bolts A on the latch assembly 1025332 A B A A A Figure 5 40 Left Endshield Support Tube on D1X Header 5 Tighten the four bolts A on support tube brack...

Page 77: ...4778 71 Revision A 1024276 A Figure 5 42 Left Endshield 3 Swing endshield in direction A into closed position Engage lock with a firm push 4 Verify that endshield is locked PERFORMING PREDELIVERY CHEC...

Page 78: ...er WARNING To avoid bodily injury or death from unexpected start up of machine always stop engine and remove key from ignition before leaving operator s seat for any reason 1001335 Figure 5 43 Single...

Page 79: ...knife pressing on guards do NOT overgrease the knifehead A Apply 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 g...

Page 80: ...e 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 46 Reel Shaft Bearing...

Page 81: ...e left endshield 1024802 A Figure 5 47 Manual Case 1 Open the left endshield Remove the cable tie on manual case A 2 Confirm that the case contains the following manuals Operator s Manual Quick Card P...

Page 82: ......

Page 83: ...rking brake and remove key 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 u...

Page 84: ......

Page 85: ...odily injury or death from unexpected startup of machine always stop engine and remove key before adjusting machine 1007894 A B Figure 7 1 Knifehead and Pitman Arm 1 Stop engine and remove the key 2 C...

Page 86: ...214778 80 Revision A 1001261 Figure 7 3 Straightening Tool Downward Adjustment 5 Adjust guard tips downward by positioning tool as shown and pushing down PERFORMING POST RUN UP ADJUSTMENTS...

Page 87: ...regular nuts by 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 followi...

Page 88: ...2 105 116 77 86 5 8 11 144 160 107 118 3 4 10 259 286 192 212 7 8 9 413 456 306 338 1 8 619 684 459 507 A 1004958 B C D Figure 8 3 Bolt Grades A Nominal Size B SAE 8 C SAE 5 D SAE 2 Table 8 3 SAE Grad...

Page 89: ...11 299 330 221 345 3 4 10 531 587 393 435 7 8 9 855 945 633 700 1 8 1165 1288 863 954 8 1 2 Metric Bolt Specifications 1001370 1001370 A Figure 8 5 Bolt Grades Table 8 5 Metric Class 8 8 Bolts and Cl...

Page 90: ...65 72 48 53 14 2 0 104 115 77 85 16 2 0 161 178 119 132 20 2 5 314 347 233 257 24 3 0 543 600 402 444 1001370 1001370 A Figure 8 7 Bolt Grades Table 8 7 Metric Class 10 9 Bolts and Class 10 Free Spinn...

Page 91: ...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 8 1 3 Metric Bolt Specifications Bolting into...

Page 92: ...ten nut E with other wrench to torque shown 5 Assess final condition of connection Table 8 10 Flare Type Hydraulic Tube Fittings SAE Dash Size Thread Size in Torque Value1 Flats from Finger Tight FFFT...

Page 93: ...far as possible 3 Check that O ring A is NOT on threads and adjust if necessary 4 Apply hydraulic system oil to O ring A 1003432 D A E B C Figure 8 12 Hydraulic Fitting 5 Install fitting B into port...

Page 94: ...3 106 115 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 12 176 193 130 14...

Page 95: ...n Table 8 12 page 89 6 Check final condition of fitting Table 8 12 O Ring Boss ORB Hydraulic Fittings Non Adjustable SAE Dash Size Thread Size in Torque Value3 Nm lbf ft lbf in 2 5 16 24 6 7 53 62 3 3...

Page 96: ...to O ring B 3 Align tube or hose assembly so that flat face of sleeve A 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 bo...

Page 97: ...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 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 2...

Page 98: ...ways 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 clea...

Page 99: ...B C 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 IMPORTANT Forklifts are normally rated for a load c...

Page 100: ...essure 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 m...

Page 101: ...ne facing in direction of travel Export header Header configuration typical outside North America FFFT Flats from finger tight Finger tight Finger tight is a reference position where sealing surfaces...

Page 102: ...wer Self propelled machine consisting of a power unit with a header Soft joint A joint made with use of a fastener where joining materials are compressible or experience relaxation over a period of ti...

Page 103: ...214778 97 Revision A Term Definition Windrower Power unit of a self propelled header WOT Wide open throttle REFERENCE...

Page 104: ......

Page 105: ...ox page 51 Check knife drive box lube level 5 3 Checking Knife Drive Box page 51 Check knife drive belt s tension 5 4 Checking and Adjusting Knife Drive Belt Tension page 53 Check if reel is centered...

Page 106: ...king and Adjusting Knife Drive Belt Tension page 53 Check knife sections for discoloration caused by misaligned components 7 1 Adjusting Knife page 79 Check for hot spots on the cutterbar above the dr...

Page 107: ......

Page 108: ...16 891 7313 f 816 891 7323 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Centre t 7 495 775 6971 f 7 495 967 7600 MacDon Australia Pty Ltd...

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