MacDon D1X Series User manual

D1X and D1XL Series
Draper Header
Unloading and Assembly Instructions (North America)
215489 Revision A
Original Instruction
The Harvesting Specialists.

D1XL Series Draper Header for M1 Series Windrowers

Published: January 2021
© 2021 MacDon Industries, Ltd.
The information in this publication is based on the information available and in effect at the time of printing. MacDon
Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the
information in this publication. MacDon Industries, Ltd. reserves the right to make changes at any time without notice.

Introduction
This instruction manual describes the unloading, setup, and predelivery requirements for MacDon D1X and D1XL Series
Draper Headers for M1 Series Windrowers.

$
%
Figure 1: M1240 Header Hydraulics Configurations
NOTE:
Confirm the windrower is equipped with a draper-ready header
drive BEFORE connecting to the header:
•All M1170 header drives are draper-ready.
•If the M1240 header drive is configured to only operate a
rotary disc (B), convert the header drive to draper-ready (A)
using kit MD #B5999.
For instructions on connecting the windrower hydraulics to a D1X
or D1XL Series Header, refer to the windrower operator’s
manual.
To ensure the best performance of this product and the safety of your customers, 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.
Conventions
The following conventions are used in this document:
•Right and left are determined from the operator’s position. The front of the header faces the crop.
•Unless otherwise noted, use the standard torque values provided in this manual.
NOTE:
Keep your MacDon publications up-to-date. The latest version can be downloaded from our website (www.macdon.com)or
from our Dealer portal (https://portal.macdon.com) (login required).
This document is currently available in English only.
215489 iRevision A

Summary of Changes
At MacDon, we’re continuously making improvements, and occasionally these improvements affect product
documentation. The following list provides an account of major changes from the previous version of this document.
Section Summary of Change Internal Use
Only
2.1 Unloading Header from
Trailer, page 7
Revised topic. Some contents moved to 9.2 Header Specifications
for Unloading and Assembly, page 109
Engineering
2.1 Unloading Header from
Trailer, page 7
Added step. Technical
Publications
2.1 Unloading Header from
Trailer, page 7
Added step and illustration for D1XL. ECN 59347
2.2 Lowering Header to Field
Position, page 9
Changed title from Lowering Header. Technical
Publications
2.2.1 Lowering Single-Reel
Header, page 9
Added Important note about lifting requirements. Technical
Publications
2.2.2 Lowering Double-Reel
Header, page 12
Added Important note about lifting requirements. Technical
Publications
4.1 Installing the Hydraulic Hose
Management System, page 21
Revised steps and illustration. Technical
Publications
3 Adding Ballast, page 19 Removed cross-reference. Technical
Publications,
Product Support
6.5.2 Centering Single Reel, page
65
Changed title from Checking and Adjusting Draper Tension. Technical
Publications
•6.6 Reel Clearance to
Cutterbar, page 67
•6.6.1 Measuring Reel
Clearance, page 67
•6.6.2 Adjusting Reel
Clearance, page 69
Moved topics after Centering the Reel. Product Support
6.7 Checking and Adjusting
Draper Tension, page 71
Changed title from Adjusting Draper Tension. Technical
Publications
6.14 Header System Calibration,
page 86 •Changed title from Calibrating the Header Systems.
•Revised topic.
Technical
Publications
6.14.1 Calibrating the Knife Drive
on the Harvest Performance
Tracker Display, page 86
Revised topic. Technical
Publications
6.14.2 Calibrating Header
Position Sensors on the Harvest
Performance Tracker Display,
page 89
Added topic. Technical
Publications
9.2 Header Specifications for
Unloading and Assembly, page
109
Replaced Lifting Requirements topic. New topic include the
necessary specifications for unloading and assembly.
Engineering
215489 ii Revision A

215489 iii Revision A
Introduction ................................................................................................................................................i
Summary of Changes....................................................................................................................................ii
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Signal Words .........................................................................................................................................1
1.2 General Safety .......................................................................................................................................2
1.3 Welding Precaution ................................................................................................................................4
1.4 Safety Signs ...........................................................................................................................................5
Chapter 2: Unloading the Header .............................................................................................................. 7
2.1 Unloading Header from Trailer..................................................................................................................7
2.2 Lowering Header to Field Position .............................................................................................................9
2.2.1 Lowering Single-Reel Header............................................................................................................9
2.2.2 Lowering Double-Reel Header ........................................................................................................ 12
2.3 Removing Shipping Supports .................................................................................................................. 16
Chapter 3: Adding Ballast......................................................................................................................... 19
Chapter 4: Attaching Header to Windrower ........................................................................................... 21
4.1 Installing the Hydraulic Hose Management System..................................................................................... 21
4.2 Attaching Draper Header Supports .......................................................................................................... 27
4.3 Connecting Center-Link.......................................................................................................................... 28
4.4 Connecting Hydraulics ........................................................................................................................... 33
Chapter 5: Assembling the Header .......................................................................................................... 37
5.1 Positioning Transport Lights ................................................................................................................... 37
5.2 Attaching Reel Lift Cylinders ................................................................................................................... 40
5.3 Installing Disc Segments of Outboard Reel Endshields ................................................................................. 49
5.4 Attaching Cam Arms ............................................................................................................................. 50
5.5 Installing Crop Dividers .......................................................................................................................... 52
5.6 Attaching Reel Height Sensor –D1XL Headers ........................................................................................... 54
5.7 Installing Options ................................................................................................................................. 56
Chapter 6: Performing Predelivery Checks.............................................................................................. 57
6.1 Checking Tire Pressure –Transport and Stabilizer Wheels, Option for D1XL Headers ........................................ 57
6.2 Checking Wheel Bolt Torque –Transport and Stabilizer Wheels, Option for D1XL Headers ................................ 58
6.3 Checking Knife Drive Box ....................................................................................................................... 59
6.4 Checking and Adjusting Knife Drive Belt Tension ........................................................................................ 60
6.4.1 Checking and Tensioning Untimed Double-Knife Drive Belts ................................................................ 60
6.4.2 Tensioning Timed Double-Knife Drive Belts....................................................................................... 61
6.4.3 Tensioning Timed Knife Drive V-Belts............................................................................................... 63
6.5 Centering the Reel ................................................................................................................................ 64
6.5.1 Centering Double Reel .................................................................................................................. 64
TABLE OF CONTENTS

215489 iv Revision A
6.5.2 Centering Single Reel.................................................................................................................... 65
6.6 Reel Clearance to Cutterbar................................................................................................................... 67
6.6.1 Measuring Reel Clearance ............................................................................................................. 67
6.6.2 Adjusting Reel Clearance ............................................................................................................... 69
6.7 Checking and Adjusting Draper Tension.................................................................................................... 71
6.8 Checking and Adjusting Draper Seal ......................................................................................................... 73
6.9 Checking and Adjusting Skid Shoe Settings ................................................................................................ 76
6.10 Leveling the Header ............................................................................................................................ 77
6.11 Checking and Adjusting Endshields......................................................................................................... 78
6.12 Lubricating Header.............................................................................................................................. 82
6.12.1 Greasing Procedure .................................................................................................................... 82
6.12.2 Lubrication Points ...................................................................................................................... 83
6.13 Checking Manuals............................................................................................................................... 85
6.14 Header System Calibration ................................................................................................................... 86
6.14.1 Calibrating the Knife Drive on the Harvest Performance Tracker Display .............................................. 86
6.14.2 Calibrating Header Position Sensors on the Harvest Performance Tracker Display.................................. 89
Chapter 7: Running up the Header .......................................................................................................... 93
Chapter 8: Performing Post Run-Up Adjustments .................................................................................. 95
8.1 Adjusting Knife..................................................................................................................................... 95
Chapter 9: Reference ................................................................................................................................ 97
9.1 Torque Specifications ............................................................................................................................ 97
9.1.1 SAE Bolt Torque Specifications ....................................................................................................... 97
9.1.2 Metric Bolt Specifications .............................................................................................................. 99
9.1.3 Metric Bolt Specifications Bolting into Cast Aluminum ...................................................................... 101
9.1.4 Flare-Type Hydraulic Fittings ........................................................................................................ 102
9.1.5 O-Ring Boss Hydraulic Fittings –Adjustable .................................................................................... 103
9.1.6 O-Ring Boss Hydraulic Fittings –Non-Adjustable.............................................................................. 105
9.1.7 O-Ring Face Seal Hydraulic Fittings................................................................................................ 106
9.1.8 Tapered Pipe Thread Fittings........................................................................................................ 107
9.2 Header Specifications for Unloading and Assembly................................................................................... 109
9.3 Conversion Chart................................................................................................................................ 111
9.4 Definitions ........................................................................................................................................ 112
Predelivery Checklist .............................................................................................................................. 115
TABLE OF CONTENTS

215489 1Revision A
Chapter 1: Safety
Understanding and following safety procedures consistently will help to ensure the safety of machine operators and
bystanders.
1.1 Signal Words
Three signal words, DANGER,WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words,
IMPORTANT and NOTE, identify non-safety related information.
Signal words are 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.
IMPORTANT:
Indicates a situation that, if not avoided, could result in a malfunction or damage to the machine.
NOTE:
Provides additional information or advice.

215489 2Revision A
1.2 General Safety
Protect yourself when assembling, operating, and servicing machinery.

Figure 1.1: Safety Equipment
CAUTION
The following general farm safety precautions should be part of
your operating procedure for all types of machinery.
Wear all protective clothing and personal safety devices that
could be necessary for the job at hand. Do NOT take chances.
You may need the following:
•Hard hat
•Protective footwear with slip-resistant soles
•Protective glasses or goggles
•Heavy gloves
•Wet weather gear
•Respirator or filter mask

Figure 1.2: Safety Equipment
In addition, take the following precautions:
•Be aware that exposure to loud noises can cause hearing
impairment or loss. Wear suitable hearing protection devices
such as earmuffs or earplugs to help protect against loud
noises.

Figure 1.3: Safety Equipment
•Provide a first aid kit in case of emergencies.
•Keep a properly maintained fire extinguisher on the machine.
Be familiar with its proper use.
•Keep young children away from machinery at all times.
•Be aware that accidents often happen when the Operator is
tired or in a hurry. Take time to consider the safest way.
NEVER ignore warning signs of fatigue.
SAFETY

215489 3Revision A

Figure 1.4: Safety around Equipment
•Wear close-fitting clothing and cover long hair. NEVER wear
dangling items such as scarves or bracelets.
•Keep all shields in place. NEVER alter or remove safety
equipment. Make sure driveline guards can rotate
independently of shaft and can telescope freely.
•Use only service and repair parts made or approved by
equipment manufacturer. Substituted parts may not meet
strength, design, or safety requirements.

Figure 1.5: Safety around Equipment
•Keep hands, feet, clothing, and hair away from moving parts.
NEVER attempt to clear obstructions or objects from a
machine while the engine is running.
•Do NOT modify the machine. Unauthorized modifications
may impair machine function and/or safety. It may also
shorten the machine’s life.
•To avoid 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.

Figure 1.6: Safety around Equipment
•Keep service area clean and dry. Wet and/or oily floors are
slippery. Wet spots can be dangerous when working with
electrical equipment. Be sure all electrical outlets and tools
are properly grounded.
•Keep work area well lit.
•Keep machinery clean. Straw and chaff on a hot engine are
fire hazards. Do NOT allow oil or grease to accumulate on
service platforms, ladders, or controls. Clean machines before
storage.
•NEVER use gasoline, naphtha, or any volatile material for
cleaning purposes. These materials may be toxic and/or
flammable.
•When storing machinery, cover sharp or extending
components to prevent injury from accidental contact.
SAFETY

215489 4Revision A
1.3 Welding Precaution
To prevent damage to sensitive electronics, welding should never be attempted on the header while it is connected to a
windrower.
WARNING
Severe damage to sensitive, expensive electronics can result from welding on the header while it is connected to the
windrower. It can be impossible to know what effect high current could have with regard to future malfunctions or
shorter lifespan. It is very important that welding on the header is not attempted while the header is connected to the
windrower.
If it is unfeasible to disconnect the header from the windrower before welding, refer to the windrower’s technical manual
for welding precautions detailing all electrical components that must be disconnected first for safe welding.
SAFETY

215489 5Revision A
1.4 Safety Signs
Safety signs are usually yellow decals placed on the machine where there is a risk of personal injury, or where the operator
has to take extra precautions before operating controls. Operator manuals and technical manuals identify the location and
meaning of all safety signs placed on the machine.

Figure 1.7: Operator’s Manual Decal
•Keep safety signs clean and legible at all times.
•Replace safety signs that are missing or illegible.
•If the original part on which a safety sign was installed is
replaced, be sure the repair part displays the current
safety sign.
SAFETY

215489 7Revision A
Chapter 2: Unloading the Header
Perform all procedures in this chapter in the order they are listed.
2.1 Unloading Header from Trailer
In North America, headers are shipped on flat bed trailers. Following instructions carefully will help ensure headers make it
from the trailer to the assembly area safely..
DANGER
To avoid injury to bystanders from being struck by machinery, do NOT allow people to stand in unloading area.
DANGER
Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment
may result in chain breakage, vehicle tipping, machine damage or bodily harm to operators or bystanders.
IMPORTANT:
For lifting equipment requirements, refer to 9.2 Header Specifications for Unloading and Assembly, page 109.
To unload the headers from a trailer, follow these steps:
1. Move the trailer into position and block the trailer wheels.
2. Lower the trailer storage stands.

$
%
&
Figure 2.1: D1X Header Shipping Supports
3. For D1X: Approach one of the headers and slide forks (A)
underneath shipping support (B) as far as possible without
contacting the shipping support of second header (C).
IMPORTANT:
Avoid lifting the second header and ensure the forks do
NOT interfere with the shipping frame. If the forks contact
the second header, the header could be damaged.

215489 8Revision A

$
%
&
Figure 2.2: D1XL Header Shipping Supports
4. For D1XL: Approach one of the headers and slide forks (A)
through four forklift brackets (B) underneath the shipping
support, as far as possible without contacting the shipping
support of second header (C).
IMPORTANT:
Avoid lifting the second header and ensure the forks do
NOT interfere with the shipping frame. If the forks contact
the second header, the header could be damaged.
5. Remove the hauler’s tie-down straps, chains, and wooden blocks.
6. Slowly raise the header off the trailer deck.
WARNING
Be sure forks are secure before moving away from load. Stand clear when lifting.
7. Back up until the header clears the trailer and slowly lower it to 150 mm (6 in.) from the ground.
8. Take the header to the storage or setup area. Ensure the ground is flat and free of rocks or debris that could damage
the header.
9. Lower header to the ground.
10. Repeat the previous steps for unloading the second header.
11. Check for shipping damage and missing parts.
UNLOADING THE HEADER

215489 9Revision A
2.2 Lowering Header to Field Position
The procedure for lowering the header varies depending on whether the header has a single or double reel.
To lower the header, refer to the procedure according to the type of header:
•Single-reel headers: refer to 2.2.1 Lowering Single-Reel Header, page 9
•Double-reel headers: refer to2.2.2 Lowering Double-Reel Header, page 12
2.2.1 Lowering Single-Reel Header
Lower the header to field position to prepare it for assembly and setup.
IMPORTANT:
For lifting equipment requirements, refer to 9.2 Header Specifications for Unloading and Assembly, page 109.

$
%
Figure 2.3: Shipping Frame
1. Approach the header from its underside and place the forks
under the top of shipping frame (A).
2. Attach chain (B) at each end of the shipping frame and
secure the other end to the lifting vehicle.
UNLOADING THE HEADER

215489 10 Revision A





Figure 2.4: Lowering the Header
CAUTION
Stand clear when lowering, as machine may swing.
3. Back up SLOWLY while lowering the forks until the header
is just above the ground. Refer to the four positions in the
illustration.
UNLOADING THE HEADER

215489 11 Revision A

$
Figure 2.5: Block under Cutterbar
4. Place 150 mm (6 in.) blocks (A) under each end and at the
center of the cutterbar, then lower the header onto the
blocks.
5. Remove the chain and move the lifting vehicle to the rear
of the header.

$
Figure 2.6: Center-link Anchor –Single-Reel
6. Attach the chain to center-link anchor (A) on the frame
tube and raise the rear of the header so that the stand can
be lowered.
UNLOADING THE HEADER

215489 12 Revision A

$
%
Figure 2.7: Header Stand
7. Lower the header stand by pulling pin (A), lowering
stand (B), and releasing pin (A) to secure the stand in place.
8. If the ground is soft, place a block under the stand.
9. Lower the header onto the stand.
2.2.2 Lowering Double-Reel Header
Lower the header to field position to prepare it for assembly and setup.
IMPORTANT:
For lifting equipment requirements, refer to 9.2 Header Specifications for Unloading and Assembly, page 109.

Figure 2.8: Underside of Header
1. Drive the lifting vehicle to approach the header from its
underside.

$
Figure 2.9: Shipping Support –Double-Reel,
D1XL Shown
2. Attach a chain to shipping support (A) at the center
reel arm.
IMPORTANT:
Do NOT lift the header at this location. This procedure is
only for laying the machine over into working position.
NOTE:
Right reel removed for clarity.
UNLOADING THE HEADER

215489 13 Revision A





Figure 2.10: Lowering the Header
CAUTION
Stand clear when lowering, as machine may swing.
3. Back up SLOWLY while lowering the forks until the header
is just above the ground. Refer to the four positions in the
illustration.
UNLOADING THE HEADER

215489 14 Revision A

$
Figure 2.11: Block under Cutterbar
4. Place 150 mm (6 in.) blocks (A) under each end and at the
center of the cutterbar, and then lower the header onto the
blocks.
5. Remove the chain and move the lifting vehicle to the rear
of the header.

$
Figure 2.12: Center-Link Anchor –Double-Reel
6. Attach the chain to center-link anchor (A) on the frame
tube and raise the rear of the header so that the stand can
be lowered.
UNLOADING THE HEADER