MacDon D1X Series, Assembly Instructions Manual

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 unl...

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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 T...

Page 6: ...minum 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...

Page 7: ...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 manag...

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Page 9: ...mminently hazardous situation that if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation that if not avoided could result in death or serious injury...

Page 10: ...r 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...

Page 11: ...chine 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...

Page 12: ...ce 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 f...

Page 13: ...ing 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...

Page 14: ...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 Ba...

Page 15: ...e 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 f...

Page 16: ...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 4 Lowering the Hea...

Page 17: ...igure 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 h...

Page 18: ...tach 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...

Page 19: ...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 Head...

Page 20: ...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...

Page 21: ...ts 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 cutterb...

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 rota...

Page 23: ...ing 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 nu...

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Page 25: ...s 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 t...

Page 26: ...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 support...

Page 27: ...gement 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 lif...

Page 28: ...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 th...

Page 29: ...upports 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...

Page 30: ...ove 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...

Page 31: ...raulic 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 li...

Page 32: ...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...

Page 33: ...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 P...

Page 34: ...3 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...

Page 35: ...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 towar...

Page 36: ...lectrical 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 multicoup...

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...

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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 Rem...

Page 40: ...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 heade...

Page 41: ...ine 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 endsh...

Page 42: ...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 hole...

Page 43: ...y 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 e...

Page 44: ...ge 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 Rep...

Page 45: ...re 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 Ree...

Page 46: ...uble 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 Heade...

Page 47: ...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...

Page 48: ...s 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 posi...

Page 49: ...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 o...

Page 50: ...n 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...

Page 51: ...ADER 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 214...

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: ...ader 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 D...

Page 54: ...XL 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...

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 de...

Page 56: ...ing 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...

Page 57: ...om 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...

Page 58: ...ng 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 b...

Page 59: ...y 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 he...

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 p...

Page 61: ...f 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 al...

Page 62: ...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 f...

Page 63: ...ances 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 bot...

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 a...

Page 65: ...ine 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 E...

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...

Page 67: ...ust 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...

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...

Page 69: ...efore 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 s...

Page 70: ...nt 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...

Page 71: ...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 Cleara...

Page 72: ...g 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 c...

Page 73: ...eat 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...

Page 74: ...t 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 3...

Page 75: ...l 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...

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 endshi...

Page 77: ...reme 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 g...

Page 78: ...ws 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 A...

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...

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 S...

Page 81: ...nside 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 Manua...

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Page 83: ...y 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 l...

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Page 85: ...th 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 i...

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: ...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 val...

Page 88: ...56 306 338 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 M...

Page 89: ...5 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...

Page 90: ...6 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...

Page 91: ...ize 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 10...

Page 92: ...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...

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 1...

Page 94: ...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 P...

Page 95: ...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...

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...

Page 97: ...r 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...

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...

Page 99: ...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...

Page 100: ...lifts 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 m...

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...

Page 102: ...ration 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...

Page 103: ...th 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 wh...

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Page 105: ...g 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 re...

Page 106: ...sting 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 Adj...

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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...