MacDon D1X Series User manual

D1X and D1XL Series
Draper Header
Unloading and Assembly Instructions (North America)
215653 Revision A
Original Instruction
The Harvesting Specialists.

D1XL Series Draper Header for M1 Series Windrowers

Published: October 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 manual contains unloading, assembly, and predelivery information for MacDon D1X and D1XL Series Draper Headers
for M1 Series Windrowers.
To ensure the best performance of this product and the safety of your customers, carefully follow this unloading and
assembly procedure.
Some sections or steps apply to multiple header configurations and sizes. Follow the procedures relevant for the header
you are assembling.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
Retain this instruction for future reference.

$
%
Figure 1: M1240 Header Hydraulics Configurations
NOTE:
Confirm that the windrower is equipped with a draper-ready
header drive BEFORE attempting to attach the header to the
windrower. Remember:
•All M1170 header drives are draper-ready.
•If the M1240 header drive is configured to operate solely
with a rotary disc header (hydraulic configuration [B]),
convert the header drive to draper-ready (hydraulic
configuration [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.
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).
If the shipment is damaged or is missing parts, contact [email protected].
This document is currently available in English.
215653 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 Unloading Header, page 7 Added steps for lowering the header onto its jack stand to both
subtopics. Changed order of subtopics.
Technical
Publications
2.2.2 Lowering Single-Reel
Header, page 12
Added “Proceed to”step. Technical
Publications
4 Assembling Header, page 21 Changed order of chapters: Assembling Header now comes
before Attaching Header to Windrower.
Technical
Publications
5.1 Installing Hydraulic Hose
Management System, page 41
Added step to check cinch straps. ECR 22987
6.1 Checking Tire
Pressure –Transport and
Stabilizer Wheels, Option for
D1XL Series Headers, page 57
Revised pressure recommendations, added safety note, revised
hazard statement.
Design
Engineering
6.4 Checking and Adjusting Knife
Drive Belt Tension, page 60
In all sub-topics: changed order of steps so that the belt tension is
checked first, and added “proceed to”steps where appropriate.
Technical
Publications
6.6.2 Adjusting Reel Clearance,
page 69
Added steps for engaging and disengaging the reel safety props. Technical
Publications
6.8 Checking and Adjusting
Draper Seal, page 75
Procedure now instructs the reader to repeat the height
adjustment steps for each deck support. Added reel safety prop
engage and disengage steps.
Technical
Publications
6.12 Checking Grease Points,
page 86
Replaced greasing procedure. Technical
Publications
6.13 Checking Manuals, page 87 Added instructions for checking for the presence of manuals. Technical
Publications
8.1 Adjusting Knife, page 97 Added specification for the gap between the knifehead and the
pitman arm.
Technical
Publications
Predelivery Checklist, page 115 Added instruction to check for quick cards. Clarified procedure. Technical
Publications
215653 ii Revision A

215653 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 Header..................................................................................................................... 7
2.1 Unloading Header from Trailer..................................................................................................................7
2.2 Lowering Header to Field Position .............................................................................................................9
2.2.1 Lowering Double-Reel Header ..........................................................................................................9
2.2.2 Lowering Single-Reel Header.......................................................................................................... 12
2.3 Removing Shipping Supports .................................................................................................................. 16
Chapter 3: Adding Ballast......................................................................................................................... 19
Chapter 4: Assembling Header................................................................................................................. 21
4.1 Positioning Transport Lights ................................................................................................................... 21
4.2 Attaching Reel-Lift Cylinders ................................................................................................................... 24
4.3 Installing Disc Segments of Outboard Reel Endshields ................................................................................. 33
4.4 Attaching Cam Arms ............................................................................................................................. 34
4.5 Installing Crop Dividers .......................................................................................................................... 36
4.6 Attaching Reel Height Sensor –D1XL Series Headers................................................................................... 38
4.7 Installing Options ................................................................................................................................. 40
Chapter 5: Attaching Header to Windrower ........................................................................................... 41
5.1 Installing Hydraulic Hose Management System .......................................................................................... 41
5.2 Attaching Draper Header Supports .......................................................................................................... 47
5.3 Connecting Center-Link.......................................................................................................................... 48
5.4 Connecting Hydraulics ........................................................................................................................... 54
Chapter 6: Performing Predelivery Checks.............................................................................................. 57
6.1 Checking Tire Pressure –Transport and Stabilizer Wheels, Option for D1XL Series Headers ............................... 57
6.2 Checking Wheel Bolt Torque –Option for D1XL Series 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 Reel ..................................................................................................................................... 64
6.5.1 Centering Double Reel .................................................................................................................. 64
TABLE OF CONTENTS

215653 iv Revision A
6.5.2 Centering Single Reel.................................................................................................................... 65
6.6 Reel-to-Cutterbar Clearance ................................................................................................................... 67
6.6.1 Measuring Reel Clearance ............................................................................................................. 67
6.6.2 Adjusting Reel Clearance ............................................................................................................... 69
6.7 Checking and Adjusting Draper Tension.................................................................................................... 73
6.8 Checking and Adjusting Draper Seal ......................................................................................................... 75
6.9 Checking and Adjusting Skid Shoe Settings ................................................................................................ 80
6.10 Leveling Header.................................................................................................................................. 81
6.11 Checking and Adjusting Endshields......................................................................................................... 82
6.12 Checking Grease Points........................................................................................................................ 86
6.13 Checking Manuals............................................................................................................................... 87
6.14 Header System Calibration ................................................................................................................... 88
6.14.1 Calibrating Knife Drive on Harvest Performance Tracker Display ......................................................... 88
6.14.2 Calibrating Header Position Sensors on Harvest Performance Tracker Display ....................................... 91
Chapter 7: Running up Header................................................................................................................. 95
Chapter 8: Performing Post Run-Up Adjustments .................................................................................. 97
8.1 Adjusting Knife..................................................................................................................................... 97
Chapter 9: Reference ................................................................................................................................ 99
9.1 Torque Specifications ............................................................................................................................ 99
9.1.1 SAE Bolt Torque Specifications ....................................................................................................... 99
9.1.2 Metric Bolt Specifications ............................................................................................................ 101
9.1.3 Metric Bolt Specifications Bolting into Cast Aluminum ...................................................................... 103
9.1.4 Flare-Type Hydraulic Fittings ........................................................................................................ 103
9.1.5 O-Ring Boss Hydraulic Fittings –Adjustable .................................................................................... 104
9.1.6 O-Ring Boss Hydraulic Fittings –Non-Adjustable.............................................................................. 106
9.1.7 O-Ring Face Seal Hydraulic Fittings................................................................................................ 107
9.1.8 Tapered Pipe Thread Fittings........................................................................................................ 108
9.2 Lifting Vehicle Specifications................................................................................................................. 110
9.3 Conversion Chart................................................................................................................................ 112
9.4 Definitions ........................................................................................................................................ 113
Predelivery Checklist .............................................................................................................................. 115
TABLE OF CONTENTS

215653 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.

215653 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. 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. Familiarize yourself with its use.
•Keep young children away from machinery at all times.
•Be aware that accidents often happen when Operators are
fatigued or in a hurry. Take time to consider the safest way
to accomplish a task. NEVER ignore the signs of fatigue.
SAFETY

215653 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. Ensure that the driveline guards can rotate
independently of their shaft, and that they can telescope
freely.
•Use only service and repair parts made or approved by the
equipment manufacturer. Parts from other manufacturers
may not meet the correct 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 the functionality and/or safety of the machine. It
may also shorten the machine’s service life.
•To avoid injury or death from the 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 the machine service area clean and dry. Wet and/or
oily floors are slippery. Wet spots can be dangerous when
working with electrical equipment. Ensure that all electrical
outlets and tools are properly grounded.
•Keep the 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 they are stored.
•NEVER use gasoline, naphtha, or any volatile material for
cleaning purposes. These materials may be toxic and/or
flammable.
•When storing machinery, cover any sharp or extending
components to prevent injury from accidental contact.
SAFETY

215653 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

215653 5Revision A
1.4 Safety Signs
Safety signs are decals placed on the machine where there is a risk of personal injury, or where the Operator should take
extra precautions before operating the controls. They are usually yellow.

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, ensure that the repair part displays the current
safety sign.
SAFETY

215653 7Revision A
Chapter 2: Unloading Header
Unload all header parts before beginning assembly. Carefully follow these procedures in the order in which they are
presented.
2.1 Unloading Header from Trailer
A trailer will typically have two headers on it. Ensure that you use a forklift which meets the minimum length and capacity
requirements when unloading a header.
DANGER
To prevent injury to bystanders caused by being struck by machinery, do NOT allow people to stand in the
unloading area.
DANGER
The equipment used for loading or unloading a header must meet or exceed the requirements specified in this
document. 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 Lifting Vehicle Specifications, page 110.
1. Move the trailer into position and block the trailer wheels.
2. Lower the trailer storage stands.

$
%
&
Figure 2.1: D1X Series Header Shipping Supports
3. D1X Series headers: Approach one of the headers and slide
forks (A) underneath shipping support (B). Insert the forks
as far as possible without contacting the shipping support
of second header (C).
IMPORTANT:
Ensure that the forklift’s forks are lifting only ONE header.
Inspect the positioning of the forks before lifting the
header.

215653 8Revision A

$
%
&
Figure 2.2: D1XL Series Header Shipping Supports
4. D1XL Series headers: Approach one of the headers and
slide forks (A) through four forklift brackets (B) underneath
the shipping support. Insert the forks as far as possible
without contacting the shipping support of second
header (C).
IMPORTANT:
Ensure that the forklift’s forks are lifting only ONE header.
Inspect the positioning of the forks before lifting the
header.
5. Remove the straps and chains securing the header to the trailer deck.
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 the forklift up until the header clears the trailer. Slowly lower the header until it sits 150 mm (6 in.) off of the
ground.
8. Take the header to the storage or setup area.
NOTE:
Ensure that the ground where the header is to be placed is flat and free of rocks or debris that could damage the
header.
9. Lower the header to the ground.
10. Unload the second header. Refer to Steps 2, page 7 to 9, page 8 for instructions.
11. Check the unloaded headers for damage and missing parts.
UNLOADING HEADER

215653 9Revision A
2.2 Lowering Header to Field Position
Headers are shipped resting on their backs, and must be lowered before assembly can continue. The procedure for
lowering the header differs depending on whether the header has a single or double reel.
To lower the header, follow the relevant procedure:
•Single-reel headers: refer to 2.2.2 Lowering Single-Reel Header, page 12.
•Double-reel headers: refer to 2.2.1 Lowering Double-Reel Header, page 9.
2.2.1 Lowering Double-Reel Header
The header will need to be lowered to the field position to prepare it for further assembly.
IMPORTANT:
For information on lifting equipment requirements, refer to 9.2 Lifting Vehicle Specifications, page 110.

Figure 2.3: Underside of Header
1. Orient the forklift so that you are approaching the header
from its underside.

$
Figure 2.4: Shipping Support –Double-Reel,
D1XL Series Header
2. Attach a chain to shipping support (A) at the center
reel arm.
IMPORTANT:
Do NOT lift the header at this location. The purpose of this
procedure is to lay the header into its working position.
NOTE:
The right reel has been removed from the illustration for
the sake of clarity.
UNLOADING HEADER

215653 10 Revision A





Figure 2.5: Lowering the Header
CAUTION
Stand clear when lowering the header; the machine may sway
from side to side.
3. Back the forklift up SLOWLY while lowering the forks until
the header is just above the ground, as shown in the
numbered steps in the illustration.
UNLOADING HEADER

215653 11 Revision A

$
Figure 2.6: Block under Cutterbar
4. Place 150 mm (6 in.) blocks (A) under each end of the
header, and one block at the center of the cutterbar. Lower
the header onto the blocks.
5. Remove the chain and move the forklift to the rear of the
header.

$
Figure 2.7: Center-Link Anchor –Double-Reel Header
6. Attach the chain to center-link anchor (A) on the frame
tube. Raise the rear of the header so that the stand can be
lowered.
UNLOADING HEADER

215653 12 Revision A

$
%
Figure 2.8: Header Stand
7. To lower the header stand: pull pin (A), gently lower
stand (B) to the desired height, and then release pin (A)
again to lock the stand at that height.
NOTE:
If the ground is soft, place a block under the stand.
8. Lower the header onto the stand.
9. Remove the chain.
10. Proceed to 2.3 Removing Shipping Supports, page 16.
2.2.2 Lowering Single-Reel Header
The header will need to be lowered to the field position to prepare it for further assembly.
IMPORTANT:
For information on lifting equipment requirements, refer to 9.2 Lifting Vehicle Specifications, page 110.

$
%
Figure 2.9: Shipping Frame
1. Approach the header from its underside and place the
forklift forks under the top bar of shipping frame (A).
2. Attach chain (B) at each end of the shipping frame and
secure the other end of the chain to the lifting vehicle.
UNLOADING HEADER

215653 13 Revision A





Figure 2.10: Lowering the Header
CAUTION
Stand clear when lowering the header; the machine may sway
from side to side.
3. Back the forklift up SLOWLY while lowering the forks until
the header is just above the ground, as shown in the
numbered steps in the illustration.
UNLOADING HEADER

215653 14 Revision A

$
Figure 2.11: Block under Cutterbar
4. Place 150 mm (6 in.) blocks (A) under each end of the
header and at the center of the cutterbar. 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 –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 HEADER