MacDon D1X Series Operator's Manual

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Brand: MacDon
Category: Farm Equipment
Model: D1X Series (Operator's Manual)
File Type: PDF
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Pages: 308

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Text of the manual

D1X and D1XL Series

Draper Headers for M1 Series Windrowers Operator’s Manual 215651 Revision B 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.

Declaration of Conformity

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��������� ���������� ����������������������� �� ���� ���� ����������� ��� � ��������� ���� �� �������� ���� ���� � ������� ���� ��������� �� ������ ���� ������ ����� �� ����������� ���������� �� ��������� ����������� ������ ������������ ���������� �������� �������� �� ����� ����� �� ��� ����-������ �� ��� ����-������ ����� � ���� �� ����������� ���� ��������� � ���������� �� ������ ���������� �� �������� � ����������� ���� ���� � �������� �� ������ ���������� ���������� � ������� ��������� �������� ��� �������� ������� ������ ������ ������ ����� ��������� ������ �� ����� ��������� ���������� ����������������������� �� ��� ��� ������������ �� ��������� ��� ������� ���� ����� � ������ ���� �������� ���������� ���� ��������� ��� ���������� ������� ��������� ����������� ��������� �� ��������� ��������� ��� ��� �� �������� � ����������� �� ��� ����-������ �� ��� ����-������ ����� � ����� ��������� ������������ ���� �������� � ������ ���� ���������� ��������������� ������������ ���� ��� � ������ ����� ��������� ��������������� ���- ����� ���������� �������� ��� �������� ��������� ��������� ������ ������ ���� ��������� ������ �� ����� ��������� ��������� ����������������������� 215651 ii Revision B

This instructional manual contains information on D1X and D1XL Series Draper Headers. Teamed with a MacDon M1 Series

Windrower, D1X and D1XL Series Draper Headers will cut and lay crop into fluffy, uniform windrows. The D1X and D1XL Series Draper Headers are designed as straight-cut headers, and are equipped to work well in all straight-cut conditions whether cutting on or above the ground. Use this manual as your first source of information about the machine. If you follow the instructions provided, your header will work well for many years. If you require more detailed service information, contact your MacDon Dealer. When setting up the machine or making adjustments, review and follow the recommended machine settings in all relevant MacDon publications. Failure to do so may compromise machine function and machine life and may result in a hazardous situation. MacDon provides warranty for Customers who operate and maintain their equipment as described in this manual. A copy of the MacDon Industries Limited Warranty Policy, which explains this warranty, should have been provided to you by your Dealer. Damage resulting from any of the following conditions will void the warranty: • Accident • Misuse • Abuse • Improper maintenance or neglect • Abnormal or extraordinary use of the machine • Failure to use the machine, equipment, component, or part in accordance with the manufacturer’s instructions This manual is currently available in English, French, German, Latvian, and Lithuanian. 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. Carefully read the information provided in this manual before attempting to maintain, service, or use the machine. The Table of Contents and Index will guide you to specific areas within this manual. Examine the Table of Contents and familiarize yourself with the organization of the information. NOTE: Keep your MacDon publications up-to-date. The most current version can be downloaded from our website (www.macdon.com) or from our Dealer-only site (https://portal.macdon.com) (login required). 215651 iii Revision B

Figure 1: Left Endshield Manual Storage Location

Keep this manual handy for frequent reference or to pass on to new Operators or Owners. A manual storage case (A) is located inside the left endshield. Call your MacDon Dealer if you need assistance, information, or additional copies of this manual. 215651 iv Revision B

Summary of Changes

This list covers changes made since the last revision (215651 Rev. A). Section Summary of Change Internal Use Only Introduction, page iii Added German and Lithuanian to the list of available translations. Publications 2.3 Specifications, page 28 Corrected header model numbers. Publications 3.7.7 Knife Speed Information, page 66 Corrected header model numbers. Publications Adjusting Reel Cam, page 70 Revised topic to show D1X and D1XL content; erroneously included content for the wrong header model. Product Support Replacing Reel Endshield Supports, page 223 Revised procedure for clarity. Publications 215651 v Revision B

Model and Serial Number

Record the model number, serial number, and model year of the header and Slow Speed Transport / Stabilizer Wheel option (if installed) on the lines below. ������� � Figure 2: Header Serial Number Plate Location Header Model: Serial Number: Model Year: Header serial number plate (A) is located on the upper corner on the left endsheet. ������� � Figure 3: Transport / Stabilizer Wheel Location Transport / Stabilizer Wheel Option Serial Number: Model Year: Transport serial number plate (A) is located on the right axle assembly. 215651 vi Revision B

Declaration of Conformity..............................................................................................................................i

Introduction .............................................................................................................................................. iii Summary of Changes ................................................................................................................................... v Model and Serial Number ............................................................................................................................ vi Chapter 1: Safety ........................................................................................................................................ 1 1.1 Safety Alert Symbols ...............................................................................................................................1 1.2 Signal Words .........................................................................................................................................2 1.3 General Safety .......................................................................................................................................3 1.4 Maintenance Safety ................................................................................................................................5 1.5 Hydraulic Safety .....................................................................................................................................6 1.6 Welding Precaution ................................................................................................................................7 1.7 Safety Signs...........................................................................................................................................8 1.7.1 Installing Safety Decals....................................................................................................................8 1.8 Safety Decal Locations.............................................................................................................................9 1.9 Understanding Safety Signs .................................................................................................................... 17 Chapter 2: Product Overview................................................................................................................... 25 2.1 Definitions .......................................................................................................................................... 25 2.2 Component Identification ...................................................................................................................... 27 2.3 Specifications....................................................................................................................................... 28 2.4 Dimensions ......................................................................................................................................... 31 Chapter 3: Operation................................................................................................................................ 33 3.1 Owner/Operator Responsibilities ............................................................................................................ 33 3.2 Operational Safety................................................................................................................................ 34 3.2.1 Header Safety Props ..................................................................................................................... 34 3.2.2 Reel Safety Props ......................................................................................................................... 35 Engaging Reel Safety Props........................................................................................................... 35 Disengaging Reel Safety Props ...................................................................................................... 36 3.2.3 Header Endshields ....................................................................................................................... 37 Opening Endshields..................................................................................................................... 37 Closing Endshields ...................................................................................................................... 38 Removing Endshields................................................................................................................... 39 Installing Endshields.................................................................................................................... 39 Checking and Adjusting Endshields ................................................................................................ 40 3.2.4 Daily Start-Up Check..................................................................................................................... 42 3.3 Break-in Period .................................................................................................................................... 43 3.4 Shutting down the Windrower................................................................................................................ 44 3.5 Cab Controls........................................................................................................................................ 45 3.6 Header Setup....................................................................................................................................... 46 3.6.1 Header Attachments..................................................................................................................... 46 3.6.2 Header Settings ........................................................................................................................... 46 TABLE OF CONTENTS

3.6.3 Reel Settings ............................................................................................................................... 56

3.7 Header Operating Variables.................................................................................................................... 58 3.7.1 Cutting Height ............................................................................................................................. 58 Cutting off the Ground ................................................................................................................ 58 Cutting on the Ground................................................................................................................. 61 3.7.2 Header Float ............................................................................................................................... 63 3.7.3 Header Angle .............................................................................................................................. 63 Adjusting Header Angle ............................................................................................................... 64 3.7.4 Reel Speed.................................................................................................................................. 64 Optional Reel Drive Sprockets....................................................................................................... 65 3.7.5 Ground Speed ............................................................................................................................. 65 3.7.6 Draper Speed .............................................................................................................................. 66 3.7.7 Knife Speed Information................................................................................................................ 66 3.7.8 Reel Height ................................................................................................................................. 66 3.7.9 Reel Fore-Aft Position................................................................................................................... 67 Adjusting Reel Fore-Aft Position .................................................................................................... 67 3.7.10 Reel Tine Pitch........................................................................................................................... 68 Reel Cam Settings....................................................................................................................... 68 Adjusting Reel Cam ..................................................................................................................... 70 3.7.11 Crop Dividers............................................................................................................................. 70 Removing Crop Dividers with Latch Option from Header.................................................................... 70 Removing Crop Dividers without Latch Option from Header............................................................... 71 Installing Crop Dividers with Latch Option onto Header ..................................................................... 72 Installing Crop Dividers without Latch Option onto Header ................................................................ 73 3.7.12 Crop Divider Rods....................................................................................................................... 75 Removing Crop Divider Rods......................................................................................................... 75 Installing Crop Divider Rods.......................................................................................................... 76 3.8 Delivery Opening.................................................................................................................................. 77 3.8.1 Manually Adjusting Delivery Opening on Header ............................................................................... 77 3.8.2 Adjusting Delivery Opening on Header using Hydraulic Deck Shift......................................................... 78 3.9 Double Windrowing .............................................................................................................................. 79 3.9.1 Shifting Decks Hydraulically ........................................................................................................... 79 3.10 Windrow Types .................................................................................................................................. 80 3.11 Haying Tips........................................................................................................................................ 82 3.11.1 Curing ...................................................................................................................................... 82 3.11.2 Topsoil Moisture ........................................................................................................................ 82 3.11.3 Weather and Topography ............................................................................................................ 82 3.11.4 Windrow Characteristics.............................................................................................................. 82 3.11.5 Driving on Windrow.................................................................................................................... 83 3.11.6 Raking and Tedding .................................................................................................................... 83 3.11.7 Using Chemical Drying Agents ...................................................................................................... 83 3.12 Levelling the Header............................................................................................................................ 84 3.13 Unplugging the Cutterbar..................................................................................................................... 85 3.14 Upper Cross Auger .............................................................................................................................. 86 3.15 Transporting Header ........................................................................................................................... 87 TABLE OF CONTENTS

3.15.1 Transporting Header on Windrower .............................................................................................. 87

3.15.2 Towing ..................................................................................................................................... 87 Attaching Header to Towing Vehicle .............................................................................................. 88 Towing the Header ..................................................................................................................... 88 3.15.3 Converting from Transport to Field Position.................................................................................... 89 Removing Tow-Bar...................................................................................................................... 89 Storing Tow-Bar.......................................................................................................................... 90 Moving Front (Left) Wheels into Field Position................................................................................. 92 Moving Rear (Right) Wheels into Field Position................................................................................ 94 3.15.4 Converting from Field to Transport Position.................................................................................... 96 Moving Front (Left) Wheels into Transport Position.......................................................................... 96 Moving Rear (Right) Wheels into Transport Position ......................................................................... 98 Attaching Tow-Bar .................................................................................................................... 101 Chapter 4: Header Attachment/Detachment........................................................................................ 105 4.1 Attaching Header to M1 Series Windrowers ............................................................................................ 105 4.2 Detaching Header from M1 Series Windrowers........................................................................................ 109 Chapter 5: Maintenance and Servicing.................................................................................................. 113 5.1 Preparing Machine for Servicing............................................................................................................ 113 5.2 Maintenance Specifications.................................................................................................................. 114 5.2.1 Installing a Roller Chain............................................................................................................... 114 5.2.2 Installing Sealed Bearing.............................................................................................................. 114 5.3 Maintenance Requirements ................................................................................................................. 116 5.3.1 Maintenance Schedule/Record..................................................................................................... 116 5.3.2 Break-In Inspection .................................................................................................................... 117 5.3.3 Preseason Servicing.................................................................................................................... 118 5.3.4 End-of-Season Service................................................................................................................. 118 5.3.5 Checking Hydraulic Hoses and Lines .............................................................................................. 119 5.3.6 Lubrication ............................................................................................................................... 120 Lubricating Header.................................................................................................................... 120 Lubrication Service Intervals ....................................................................................................... 121 5.4 Electrical System ................................................................................................................................ 127 5.4.1 How It Works ............................................................................................................................ 127 5.4.2 Replacing Light Bulbs.................................................................................................................. 128 5.4.3 Checking and Adjusting Reel Height Sensor..................................................................................... 129 5.5 Cutterbar .......................................................................................................................................... 132 5.5.1 Replacing Knife Section ............................................................................................................... 132 5.5.2 Spare Knife ............................................................................................................................... 133 5.5.3 Removing Knife ......................................................................................................................... 134 5.5.4 Removing Knifehead Bearing........................................................................................................ 134 5.5.5 Installing Knifehead Bearing......................................................................................................... 135 5.5.6 Installing Knife........................................................................................................................... 136 5.5.7 Knife Guards ............................................................................................................................. 137 Adjusting Pointed Knife Guards ................................................................................................... 137 Replacing Pointed Guards .......................................................................................................... 138 Replacing Stub Knife Guards ....................................................................................................... 139 TABLE OF CONTENTS

5.5.8 Knife Hold-Downs ...................................................................................................................... 141

Checking and Adjusting Hold-Downs with Pointed Guards................................................................ 141 Checking and Adjusting Hold-Down at Double-Knife Center Pointed Guard ......................................... 142 Checking and Adjusting Hold-Down with Stub Guards ..................................................................... 143 5.5.9 Knifehead Shield........................................................................................................................ 144 Installing Knifehead Shield.......................................................................................................... 144 5.6 Knife Drive System.............................................................................................................................. 146 5.6.1 Knife Drive Box.......................................................................................................................... 146 Checking Knife Drive Box Mounting Bolts...................................................................................... 146 Removing Knife Drive Box .......................................................................................................... 147 Removing Knife Drive Box Pulley ................................................................................................. 149 Installing Knife Drive Box Pulley................................................................................................... 150 Installing Knife Drive Box............................................................................................................ 151 Changing Oil in Knife Drive Box ................................................................................................... 157 5.6.2 Knife Drive Belts ........................................................................................................................ 157 Untimed Double-Knife Drive Belts – D1XL Only .............................................................................. 157 Timed Double-Knife Drive Belts................................................................................................... 161 5.7 Drapers............................................................................................................................................. 175 5.7.1 Removing Drapers...................................................................................................................... 175 5.7.2 Installing Drapers....................................................................................................................... 175 5.7.3 Checking and Adjusting Draper Tension ......................................................................................... 177 5.7.4 Adjusting Draper Tracking............................................................................................................ 179 5.7.5 Adjusting Deck Height................................................................................................................. 181 5.7.6 Replacing Draper Clips (Option).................................................................................................... 186 5.7.7 Draper Roller Maintenance.......................................................................................................... 187 Inspecting Draper Roller Bearing ................................................................................................. 187 Draper Deck Idler Roller............................................................................................................. 187 Draper Deck Drive Roller............................................................................................................ 191 5.7.8 Draper Deflectors....................................................................................................................... 195 Removing Narrow Draper Deflectors............................................................................................ 195 Installing Narrow Draper Deflectors ............................................................................................. 196 5.8 Reel ................................................................................................................................................. 198 5.8.1 Reel-to-Cutterbar Clearance......................................................................................................... 198 Measuring Reel Clearance .......................................................................................................... 198 Adjusting Reel Clearance............................................................................................................ 200 5.8.2 Reel Frown ............................................................................................................................... 202 Adjusting Reel Frown................................................................................................................. 202 5.8.3 Centering the Reel ..................................................................................................................... 203 Centering Double Reel............................................................................................................... 203 Centering Single Reel................................................................................................................. 204 5.8.4 Reel Fingers .............................................................................................................................. 205 Removing Steel Fingers.............................................................................................................. 205 Installing Steel Fingers ............................................................................................................... 206 Removing Plastic Fingers............................................................................................................ 206 Installing Plastic Fingers ............................................................................................................. 207 5.8.5 Tine Tube Bushings .................................................................................................................... 208 Removing Bushings from Reels.................................................................................................... 208 Installing Bushings onto Reels ..................................................................................................... 214 5.8.6 Reel Endshields.......................................................................................................................... 220 TABLE OF CONTENTS

Replacing Reel Endshields .......................................................................................................... 220

Replacing Reel Endshields – Right Reel on Double-Reel Header......................................................... 222 Replacing Reel Endshield Supports............................................................................................... 223 5.9 Reel Drive ......................................................................................................................................... 225 5.9.1 Reel Drive Cover ........................................................................................................................ 225 Removing Reel Drive Cover ........................................................................................................ 225 Installing Reel Drive Cover.......................................................................................................... 226 5.9.2 Reel Drive Chain ........................................................................................................................ 227 Loosening Reel Drive Chain ........................................................................................................ 227 Tightening Reel Drive Chain........................................................................................................ 228 5.9.3 Reel Drive Sprocket .................................................................................................................... 229 Removing Reel Drive Sprocket .................................................................................................... 230 Installing Reel Drive Sprocket...................................................................................................... 230 5.9.4 Double-Reel Drive U-Joint............................................................................................................ 231 Removing Double-Reel Drive U-Joint............................................................................................ 231 Installing Double-Reel U-Joint ..................................................................................................... 233 5.9.5 Reel Drive Motor ....................................................................................................................... 234 Removing Reel Drive Motor........................................................................................................ 234 Installing Reel Drive Motor......................................................................................................... 234 5.9.6 Replacing Double-Reel Header Drive Chain..................................................................................... 235 Replacing Chain Using the Reel Drive Method................................................................................ 235 Replacing Chain Using the Breaking the Chain Method.................................................................... 237 5.9.7 Replacing Single-Reel Header Drive Chain....................................................................................... 238 5.10 Transport System (Option) ................................................................................................................. 239 5.10.1 Checking Wheel Bolt Torque ...................................................................................................... 239 5.10.2 Checking Axle Bolt Torque ......................................................................................................... 239 5.10.3 Checking Tire Pressure .............................................................................................................. 240 Chapter 6: Options and Attachments.................................................................................................... 243 6.1 Reel ................................................................................................................................................. 243 6.1.1 Multi-Crop Rapid Reel Conversion Kit ............................................................................................ 243 6.1.2 Reel Arm Extension Kit – North American-Configured Headers Only.................................................... 243 6.1.3 Lodged Crop Reel Finger Kit ......................................................................................................... 244 6.1.4 Reel Tine Tube Conversion Kit ...................................................................................................... 244 6.1.5 Reel Endshield Kit ...................................................................................................................... 244 6.1.6 Tine Tube Reinforcing Kit............................................................................................................. 245 6.1.7 Reel Drop Rate Adjuster Kit.......................................................................................................... 245 6.2 Cutterbar Kits .................................................................................................................................... 246 6.2.1 Cutterbar Wearplate................................................................................................................... 246 6.2.2 Knife Cutout Cover..................................................................................................................... 246 6.2.3 Rock Retarder ........................................................................................................................... 247 6.2.4 Stub Guard Conversion Kit........................................................................................................... 247 6.2.5 Vertical Knife Mounts ................................................................................................................. 247 6.3 Header Kits........................................................................................................................................ 249 6.3.1 Divider Quick Latch Kit................................................................................................................ 249 6.3.2 Stabilizer Wheels ....................................................................................................................... 249 TABLE OF CONTENTS

6.3.3 Secondary Stabilizer Wheel.......................................................................................................... 250

6.3.4 Stabilizer Wheels and Transport Package ....................................................................................... 250 6.3.5 Skid Shoe Kits............................................................................................................................ 251 6.3.6 Steel Skid Shoes......................................................................................................................... 251 6.4 Crop Delivery Kits ............................................................................................................................... 252 6.4.1 Draper Deflector – Wide ............................................................................................................. 252 6.4.2 Draper Clips .............................................................................................................................. 252 6.4.3 Upper Cross Auger ..................................................................................................................... 253 6.4.4 Rice Divider Rods ....................................................................................................................... 253 6.4.5 Double Draper Drive Kit .............................................................................................................. 253 6.4.6 Draper Extension Kit................................................................................................................... 254 6.4.7 Swath Forming Rods – Center Delivery .......................................................................................... 254 6.4.8 Swath Rods............................................................................................................................... 254 6.4.9 HC10 Hay Conditioner................................................................................................................. 255 6.4.10 Hydraulic Deck Shift Package...................................................................................................... 255 6.4.11 Upper Cross Auger Hydraulic Kit for Double Draper Drive................................................................ 255 Chapter 7: Unloading and Assembly...................................................................................................... 257 Chapter 8: Troubleshooting.................................................................................................................... 259 8.1 Crop Loss .......................................................................................................................................... 259 8.2 Cutting Action and Knife Components.................................................................................................... 261 8.3 Reel Delivery ..................................................................................................................................... 264 8.4 Header and Drapers............................................................................................................................ 266 8.5 Cutting Edible Beans ........................................................................................................................... 268 8.6 Windrow Formation............................................................................................................................ 271 Chapter 9: Reference.............................................................................................................................. 273 9.1 Torque Specifications .......................................................................................................................... 273 9.1.1 SAE Bolt Torque Specifications ..................................................................................................... 273 9.1.2 Metric Bolt Specifications............................................................................................................ 275 9.1.3 Metric Bolt Specifications Bolting into Cast Aluminum...................................................................... 277 9.1.4 Flare-Type Hydraulic Fittings ........................................................................................................ 277 9.1.5 O-Ring Boss Hydraulic Fittings – Adjustable .................................................................................... 278 9.1.6 O-Ring Boss Hydraulic Fittings – Non-Adjustable.............................................................................. 280 9.1.7 O-Ring Face Seal Hydraulic Fittings................................................................................................ 281 9.1.8 Tapered Pipe Thread Fittings........................................................................................................ 282 9.2 Conversion Chart................................................................................................................................ 284 Index........................................................................................................................................................ 285 Recommended Fluids and Lubricants.................................................................................................... 293 TABLE OF CONTENTS

Understanding and consistently following these safety procedures will help to ensure the safety of those operating the

machine and of bystanders. 1.1 Safety Alert Symbols The safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. ������� Figure 1.1: Safety Symbol This symbol means: • ATTENTION! • BECOME ALERT! • YOUR SAFETY IS INVOLVED! Carefully read and follow the safety message accompanying this symbol. Why is safety important to you? • Accidents disable and kill • Accidents cost • Accidents can be avoided

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. SAFETY

Protect yourself when assembling, operating, and servicing machinery.

������� Figure 1.2: 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 1.3: 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 1.4: 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

Figure 1.5: 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 1.6: 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 1.7: 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

Protect yourself when maintaining machinery.

������� Figure 1.8: Safety around Equipment To ensure your safety while maintaining the machine: • Review the operator’s manual and all safety items before the operation and/or maintenance of the machine. • Place all controls in Neutral, stop the engine, set the parking brake, remove the ignition key, and wait for all moving parts to stop before servicing, adjusting, and/or repairing the machine. • Follow good shop practices: – Keep service areas clean and dry – Ensure that electrical outlets and tools are properly grounded – Keep the work area well lit ������� Figure 1.9: Equipment is NOT Safe for Children • Relieve pressure from hydraulic circuits before servicing and/or disconnecting the machine. • Ensure that all components are tight and that steel lines, hoses, and couplings are in good condition before applying pressure to hydraulic systems. • Keep hands, feet, clothing, and hair away from all moving and/or rotating parts. • Clear the area of bystanders, especially children, when carrying out any maintenance, repairs, or adjustments. • Install the transport lock or place safety stands under the frame before working under the machine. • If more than one person is servicing the machine at the same time, be aware that rotating a driveline or other mechanically-driven component by hand (for example, accessing a lubricant fitting) will cause drive components in other areas (belts, pulleys, and knives) to move. Stay clear of driven components at all times. ������� Figure 1.10: Safety Equipment • Wear protective gear when working on the machine. • Wear heavy gloves when working on knife components. SAFETY

Protect yourself when assembling, operating, and servicing hydraulic components.

������� Figure 1.11: Testing for Hydraulic Leaks • Always place all hydraulic controls in Neutral before leaving the operator’s seat. • Make sure that all components in the hydraulic system are kept clean and in good condition. • Replace any worn, cut, abraded, flattened, or crimped hoses and steel lines. • Do NOT attempt any makeshift repairs to hydraulic lines, fittings, or hoses by using tapes, clamps, cements, or welding. The hydraulic system operates under extremely high pressure. Makeshift repairs can fail suddenly and create hazardous conditions. ������� Figure 1.12: Hydraulic Pressure Hazard • Wear proper hand and eye protection when searching for high-pressure hydraulic fluid leaks. Use a piece of cardboard as a backstop instead of your hands to isolate and identify a leak. • If injured by a concentrated, high-pressure stream of hydraulic fluid, seek medical attention immediately. Serious infection or toxic reaction can develop from hydraulic fluid piercing the skin. ������� Figure 1.13: Safety around Equipment • Ensure that all components are tight and that steel lines, hoses, and couplings are in good condition before applying pressure to a hydraulic system. SAFETY

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, contact your MacDon Dealer for welding precautions detailing all electrical components that must be disconnected first for safe welding. SAFETY

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 1.14: 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. • Replacement safety signs are available from your MacDon Dealer Parts Department. 1.7.1 Installing Safety Decals If a safety decal is damaged it should be replaced. 1. Decide exactly where you are going to place the decal. 2. Clean and dry the installation area. 3. Remove the smaller portion of the split backing paper. 4. Place the decal in position and slowly peel back the remaining paper, smoothing the decal as it is applied. 5. Prick small air pockets with a pin and smooth them out. SAFETY

Safety Decal Locations

Safety decals are installed in several locations on the header. Replace any missing or damaged decals on the machine with identical parts. ������� � � � Figure 1.15: Upper Cross Auger (Optional) A - MD #279085 ������� � � Figure 1.16: Slow Speed Transport (Optional) A - MD #220799 SAFETY

Figure 1.17: Slow Speed Transport Tow-Bar (Optional)

A - MD #220797 B - MD #220798 ������� � � Figure 1.18: Vertical Knife (Optional) A - MD #174684 SAFETY

Figure 1.19: Endsheets, Reel Arms, and Backsheet

A - MD #184422 (Four Places) B - MD #131393 (Three Places on Single Reel) C - MD #174632 D - MD #166466 (Two Places) E - MD #131392 (Double Reel) F - MD #131391 (Two Places) SAFETY

Figure 1.20: Backtube – D115X Draper Header

A - MD #184422 B - MD #184372 C - MD #131391 SAFETY

Figure 1.21: Backtube – D120X Draper Header

A - MD #184372 B - MD #166466 C - MD #131391 SAFETY

Figure 1.22: Backtube – D125X Draper Header

A - MD #184372 B - MD #166466 C - MD #131391 SAFETY

Figure 1.23: Backtube – D135XL Draper Header (D130XL Draper Header Similar)

A - MD #184372 B - MD #166466 C - MD #131391 D - MD #131392 (D135XL Double Reel Only) SAFETY

Figure 1.24: Backtube – D140XL Draper Header (D145XL Draper Header Similar)

A - MD #184372 B - MD #166466 C - MD #131391 D - MD #131392 SAFETY

Understanding Safety Signs

Consult this section to learn the dangers that each type of safety sign denotes. ������� Figure 1.25: MD #113482 MD #113482 General hazard pertaining to machine operation and servicing DANGER To prevent injury or death from improper or unsafe machine operation: • Read the operator’s manual and follow all safety instructions. If you do not have a manual, obtain one from your Dealer. • Do NOT allow untrained persons to operate the machine. • Review the safety instructions with all Operators every year. • Ensure that all the safety signs are installed and legible. • Make certain everyone is clear of the machine before starting engine and during operation. • Keep riders off of the machine. • Keep all the shields in place and stay clear of the moving parts. • Disengage the header drive, put the transmission in Neutral, and wait for all movement to stop before leaving the operator’s position. • Stop the engine and remove the key from the ignition before servicing, adjusting, lubricating, cleaning, or unplugging the machine. • Engage the safety locks to prevent lowering of a raised unit before servicing it in the raised position. • Use the slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited by law. ������� Figure 1.26: MD #131391 MD #131391 Header crushing hazard DANGER To prevent injury or death from fall of a raised header: • Fully raise the header, stop the engine, remove the key, and engage the safety props on the windrower before going under header. • Alternatively, rest header on ground, stop the engine, and remove the key before servicing. SAFETY

Figure 1.27: MD #131392

MD #131392 Reel crushing hazard WARNING • To prevent injury from the fall of a raised reel; fully raise the reel, stop the engine, remove the key, and engage the safety prop on each reel support arm before working on or under the reel. ������� Figure 1.28: MD #131393 MD #131393 Reel crushing hazard WARNING • To prevent injury from the fall of a raised reel; fully raise the reel, stop the engine, remove the key, and engage the mechanical safety lock on each reel support arm before working on or under the reel. ������� Figure 1.29: MD #166466 MD #166466 High-pressure oil hazard WARNING High-pressure hydraulic fluid can penetrate human skin, which can cause serious injury such as gangrene, which can be fatal. To prevent this: • Do NOT go near hydraulic fluid leaks. • Do NOT use a finger or skin to check for hydraulic fluid leaks. • Lower the load or relieve the pressure in the hydraulic system before loosening any hydraulic fittings. • If you are injured, seek emergency medical help. IMMEDIATE surgery is required to remove hydraulic fluid which has penetrated the skin. SAFETY

Figure 1.30: MD #174436

MD #174436 High-pressure oil hazard WARNING To prevent serious injury, gangrene, or death: • Do NOT go near leaks. • Do NOT use a finger or skin to check for leaks. • Lower the load or relieve hydraulic pressure before loosening fittings. • High-pressure oil can easily puncture skin, and can cause serious injury, gangrene, or death. • If injured, seek emergency medical help. Immediate surgery is required to remove oil. ������� Figure 1.31: MD #174632 MD #174632 Reel entanglement hazard DANGER To prevent injury from entanglement with the rotating reel: • Stand clear of the header while the machine is running. ������� Figure 1.32: MD #174682 MD #174682 Auger entanglement hazard DANGER To prevent injury: • Stop the engine and remove the key before servicing the auger. • Do NOT reach into moving parts while the machine is running. SAFETY

Figure 1.33: MD #174684

MD #174684 Knife cutting hazard WARNING To prevent injury from a sharp cutting knife: • Wear heavy canvas or leather gloves when working with the knife. • Be sure no one is near the vertical knife when removing or rotating the knife. ������� Figure 1.34: MD #184372 MD #184372 General hazard pertaining to machine operation and servicing DANGER To prevent injury or death from the improper or unsafe operation of the machine: • Read the operator’s manual and follow all safety instructions. If you do not have a manual, obtain one from your Dealer. • Do NOT allow untrained persons to operate the machine. • Review these safety instructions with all machine Operators every year. • Ensure that all safety signs are installed and are legible. • Make certain that bystanders are clear of the header before starting the engine and during operation of the header. • Keep riders off of the machine. • Keep all shields in place. Stay clear of moving parts. • Disengage the header drive, put the transmission into Neutral, and wait for all movement to stop before leaving the operator’s position. • Stop the engine and remove the key from the ignition before servicing, adjusting, lubricating, cleaning, or unplugging the machine. • Before servicing a header in the raised position, engage the windrower’s cylinder safety props. • Display a slow-moving vehicle emblem and activate the header’s warning lights when operating the header on roadways (unless these actions are prohibited by law). SAFETY

Figure 1.35: MD #184422

MD #184422 Hand and arm entanglement hazard WARNING To prevent injury: • Stop the engine and remove the key before opening any shielding. • Do NOT operate the header without the shields in place. ������� Figure 1.36: MD #193147 MD #193147 Loss of control hazard DANGER To prevent injury or death from loss of control: • Ensure the tow-bar lock mechanism is locked. ������� Figure 1.37: MD #220797 MD #220797 Transport tipping hazard DANGER To prevent serious injury or death from the transport tipping: • Read the operator’s manual for more information on potential tipping or rollover of the header while transporting. SAFETY

Figure 1.38: MD #220798

MD #220798 Loss of control hazard. DANGER To prevent serious injury or death from loss of control: • Do NOT tow the header with a dented or otherwise damaged tow pole. • Consult the operator’s manual for more information. ������� Figure 1.39: MD #220799 MD #220799 Loss of control hazard WARNING To prevent serious injury or death from loss of control: • Ensure the tow-bar lock mechanism is locked. ������� Figure 1.40: MD #279085 MD #279085 Auger entanglement hazard DANGER To prevent injury from the rotating auger: • Stand clear of the auger while the machine is running. • Stop the engine and remove the key before servicing the auger. • Do NOT reach into moving parts while the machine is running. SAFETY

Figure 1.41: MD #304865

MD #304865 Header crushing hazard WARNING To prevent injury or death from the fall of a raised header: • Do NOT lift the header at the marked locations. • Only use locations marked for this purpose to lower the header from the vertical to the horizontal position. SAFETY

The product overview provides the dimensions, details, and performance criteria for the various sizes and configurations.

2.1 Definitions The following terms, abbreviations, and acronyms may be used in this manual. Term Definition API American Petroleum Institute ASTM American Society of Testing and Materials Bolt A headed and externally threaded fastener designed to be paired with a nut Cab-forward Windrower operation mode, in which the Operator’s seat faces the header Center-link A hydraulic cylinder connection between the header and the vehicle, which is used to change the angle of the header relative to the vehicle 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 The header configuration typical outside North America FFFT Flats from finger tight Finger tight Finger tight is a reference position in which the given sealing surfaces or components are making contact with each other and the fitting has been tightened by hand to a point where the fitting is no longer loose and cannot be tightened further by hand 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 when attached to a windrower Hex key A tool of hexagonal cross-section used to drive bolts and screws that have a hexagonal socket in the head (internal-wrenching hexagon drive); also known as an Allen key HDS Hydraulic deck shift hp Horsepower HPT display Harvest Performance Tracker display module on an M1 Series 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 found on a header’s cutterbar which uses a reciprocating cutter (also called a sickle) to cut crop so that it can be fed into the header M1 Series Windrowers MacDon M1170 and M1240 Windrowers n/a Not applicable

North American header

The header configuration typical in North America NPT National Pipe Thread: A style of fitting used for low-pressure port openings. Threads on NPT fittings are uniquely tapered for an interference fit Nut An internally threaded fastener designed to be paired with a bolt ORB O-ring boss: A style of fitting commonly used in port openings on manifolds, pumps, and motors ORFS O-ring face seal: A style of fitting commonly used for connecting hoses and tubes. This style of fitting is also commonly called ORS, which stands for O-Ring Seal PARK The slot opposite the NEUTRAL position on operator’s console of M1 Series windrowers RoHS (Reduction of Hazardous Substances) A directive by the European Union to restrict use of certain hazardous substances (such as hexavalent chromium used in some yellow zinc platings) rpm Revolutions per minute SAE Society of Automotive Engineers Screw A headed and externally threaded fastener that threads into preformed threads or forms its own thread when inserted into a mating part SDD Single-draper drive Soft joint A flexible joint made by use of a fastener in which the joining materials compress or relax over a period of time spm Strokes per minute SR Single reel Tension An axial load placed on a bolt or screw, usually measured in Newtons (N) or pounds (lb.). This term can also be used to describe the force a belt exerts on a pulley or sprocket TFFT Turns from finger tight Timed knife drive Synchronized motion applied at cutterbar to two separately driven knives from a single hydraulic motor Torque The product of a force * the length of a lever arm, usually measured in Newton-meters (Nm) or foot-pounds (lbf∙ft) Torque angle A tightening procedure in which a fitting is assembled to a specified tightness (usually finger tight) and then the nut is turned farther by a specified number of degrees until it achieves its final position Torque-tension The relationship between the assembly torque applied to a piece of hardware and the axial load it induces in a bolt or screw Truck A four-wheel highway/road vehicle weighing no less than 3400 kg (7500 lb.) UCA Upper Cross Auger Untimed knife drive Unsynchronized motion applied at the cutterbar to two separately driven knives from a single hydraulic motor or from two hydraulic motors Washer A thin cylinder with a hole or a slot located in the center, used as a spacer, a load distribution element, or a locking mechanism Windrower The power unit for a header WOT Wide-open throttle PRODUCT OVERVIEW

Operating and maintaining the header requires understanding the names of its parts and their locations.

������� � � � � � � � � � � � � � � � � Figure 2.1: Windrower Header Components A - Reel Cam B - Reel Tines C - Draper D - Center Reel Arm Prop Handle E - Hydraulic Connections F - Transport Light G - Reel Safety Prop H - Endshield J - Reel Lift Cylinder K - Skid Shoe L - Reel Fore-Aft Cylinder M - Knife Drive Box N - Crop Divider P - Crop Divider Rod Q - Reel Endshield R - Hydraulic Hose Management System PRODUCT OVERVIEW

Here is a list of all the specifications for D1X and D1XL windrower-configured headers.

The following symbol and letters are used in the table below: S: standard / OF: optional (factory installed) / OD: optional (dealer installed) / –: not available Table 2.1 Header Specifications Cutterbar Effective cutting width (distance between crop divider points) D115X – 4.6 m (15 ft.) header 4572 mm (180 in.) S D120X – 6.1 m (20 ft.) header 6096 mm (240 in.) S D125X – 7.6 m (25 ft.) header 7620 mm (300 in.) S D130XL – 9.1 m (30 ft.) header 9144 mm (360 in.) S D135XL – 10.7 m (35 ft.) header 10,668 mm (420 in.) S D140XL – 12.2 m (40 ft.) header 12,192 mm (480 in.) S D145XL – 13.7 m (45 ft.) header 13,716 mm (540 in.) S Cutterbar lift range at guard tip (center-link fully retracted) 1265 mm (49 13/16 in.) — Knife Double-knife drive 4.6–10.7 m (15–35 ft.) (timed): One hydraulic motor with two banded-belts to two heavy duty knife drive boxes S Double-knife drive 12.2–13.7 m (40–45 ft.) (untimed): Two untimed hydraulic motors with cogged-belts to two heavy duty knife drive boxes S Knife stroke 76 mm (3 in.) S Double-knife speed (strokes per minute)1 D115X 1500–1900 spm S Double-knife speed (strokes per minute)1 D120X 1500–1900 spm S Double-knife speed (strokes per minute)1 D125X 1400–1700 spm S Double-knife speed (strokes per minute)1 D130XL 1200–1600 spm S Double-knife speed (strokes per minute)1 D135XL 1200–1400 spm S Double-knife speed (strokes per minute)1 D140XL 1100–1400 spm S Double-knife speed (strokes per minute)1 D145XL 1100–1400 spm S Knife Sections Over-serrated, solid, bolted, 9 serrations per inch S Over-serrated, solid, bolted, 14 serrations per inch OD Knife overlap at center (double-knife headers) 3 mm (1/8 in.) S Guards and Hold-Down Clips Guard: pointed, forged, double heat treated (DHT) Hold-down clip: sheet metal, adjustment bolt OF Guard: stub, forged bottom, forged top, adjustment plate OD Guard: stub, forged bottom, sheet metal top, adjustment bolt OD PRODUCT OVERVIEW 1. Under normal cutting conditions, set knife speed at the knife drive pulley between 600 and 640 rpm (1200 and 1280 spm). If set to low side of range, you could experience knife stalling.

Header Specifications (continued)

Guard Angle – Cutterbar on Ground Center-link retracted D115X, D120X, D125X 7.5° S Center-link retracted D130XL, D135XL, D140XL, D145XL 2.5° S Center-link extended D115X, D120X, D125X 17.0° S Center-link extended D130XL, D135XL, D140XL, D145XL 12.0° S Conveyor (Draper) and Decks Draper width (D1X Series) 1057 mm (41.6 in.) S Draper width (D1XL Series) 1270 mm (50 in.) S Draper drive Hydraulic S Draper speed 225 m/min. (0–742 fpm) S Delivery opening width (center delivery), variable by shifting decks 4.6 m (15 ft.) 1540–1770 mm (60 5/8 – 69 11/16 in.) S Delivery opening width (center delivery), variable by shifting decks 6.1–13.7 m (20–45 ft.) 1720–1950 mm (67 1/8 – 76 11/16 in.) S PR15 Pick-Up Reel Quantity of tine tubes 5, 6, or 9 — Center tube diameter 10.7 m (35 ft.) (single reel) only 254 mm (10 in.) — Center tube diameter All reel sizes (except 10.7 m [35 ft.] single reel) 203 mm (8 in.) — Finger tip radius Factory-set 800 mm (31 1/2 in.) — Finger tip radius Adjustment range 766–800 mm (30 3/16 – 31 1/2 in.) — Effective reel diameter (via cam profile) 1650 mm (65 in.) — Finger length 290 mm (11 in.) — Finger spacing (staggered on alternate bats) 150 mm (6 in.) — Reel drive Hydraulic S Reel speed (auto-adjust from cab using ground speed index) 0–85 rpm S PRODUCT OVERVIEW

Table 2.2 Header Attachments

Upper Cross Auger OD Outside diameter 305 mm (12 in.) Tube diameter All sizes 152 mm (6 in.) Stabilizer Wheel / Slow Speed Transport OD Wheels 38 cm (15 in.) Tires P205/75 R-15 Table 2.3 Header Weights Weight Estimated weight range with base header (variances are due to different package configurations) D115X – 4.6 m (15 ft.) header 1479–1538 kg (3260–3390 lb.) D120X – 6.0 m (20 ft.) header 1678–1640 kg (3615–3700 lb.) D125X – 7.6 m (25 ft.) header 1753 kg (3872 lb.) D130XL – 9.1 m (30 ft.) header 2318 kg (5110 lb.) D135XL – 10.7 m (35 ft.) header 2562–2730 kg (5649–6018 lb.) D140XL – 12.2 m (40 ft.) header 2823 kg (6224 lb.) D145XL – 13.7 m (45 ft.) header 2996 kg (6605 lb.) PRODUCT OVERVIEW

Here is a list of dimensions for D1X and D1XL windrower-configured headers.

The following symbol and letters are used in the table below: S: standard / OF: optional (factory installed) / OD: optional (dealer installed) / –: not available ������� � � � Figure 2.2: Header Width Table 2.4 Header Dimensions Header Width (Transport Mode, Reel Fore-Aft Fully Retracted) D1XL Series headers (B)2 (long dividers installed) 2845 mm (112 in.) S D1XL Series headers (A)2 (long dividers removed) 2667 mm (105 in.) S D1X Series headers (B)2 (long dividers installed) 2636 mm (104 in.) S D1X Series headers (A)2 (long dividers removed) 2452 mm (97 in.) S Header Height (Transport Mode, Reel Fore-Aft Fully Retracted) D1X Series headers (C)2 (long dividers installed) 2460 mm (97 in.) S D1XL Series headers (C)2 (long dividers installed) 2460 mm (97 in.) S PRODUCT OVERVIEW 2. Refer to Figure 2.2, page 31.

Safely operating your machine requires familiarizing yourself with its capabilities.

3.1 Owner/Operator Responsibilities Owning and operating heavy equipment comes with certain duties. CAUTION • It is your responsibility to read and understand this manual completely before operating the header. Contact your MacDon Dealer if an instruction is not clear to you. • Follow all safety messages in the manual and on safety decals on the machine. • Remember that YOU are the key to safety. Good safety practices protect you and the people around you. • Before allowing someone to operate the header, for however short a time or distance, make sure they have been instructed in its safe and proper use. • Review the manual and all safety related items with all Operators annually. • Be alert for other Operators not using recommended procedures or not following safety precautions. Correct these mistakes immediately, before an accident occurs. • Do NOT modify the machine. Unauthorized modifications may impair the function and/or safety of the machine and may reduce the length of service you receive from your machine. • The safety information given in this manual does not replace safety codes, insurance needs, or laws governing your area. Be sure your machine meets the standards set by these regulations.

Follow all the safety and operational instructions given in this manual.

������� Figure 3.1: No Riders CAUTION Adhere to the following safety precautions: • Follow all safety and operational instructions provided in your operator’s manuals. If you do not have a windrower manual, get one from your Dealer and read it thoroughly. • Never attempt to start the engine or operate the machine except from the operator’s seat. • Check the operation of all controls in a safe, clear area before starting work. • Do NOT allow riders on the windrower. ������� Figure 3.2: Bystander Safety CAUTION • Never start or move the machine until you are sure all bystanders have cleared the area. • Avoid travelling over loose fill, rocks, ditches, or holes. • Drive slowly through gates and doorways. • When working on inclines, travel uphill or downhill whenever possible. Be sure to keep transmission in gear when travelling downhill. • Never attempt to get on or off a moving machine. • Do NOT leave the operator’s station while the engine is running. • To avoid bodily injury or death from the unexpected startup of a machine, always stop the engine and remove the key before adjusting or removing plugged material from the machine. • Check for excessive vibration and unusual noises. If there is any indication of trouble, shut down and inspect the machine. Follow the proper shutdown procedure. For instructions, refer to 3.4 Shutting down the Windrower, page 44. • Operate only in daylight or good artificial light. 3.2.1 Header Safety Props The header safety props located on the header lift cylinders prevent the lift cylinders from unexpectedly retracting and lowering the header. For instructions on operating the safety props, refer to your windrower operator’s manual. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason. OPERATION

Reel Safety Props

The reel safety props are located on the reel support arms and prevent the reel from unexpectedly lowering. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason. IMPORTANT: To prevent damage to the reel support arms, do NOT transport the header with the reel safety props engaged. Engaging Reel Safety Props Engage the reel safety props anytime you are going to work on or around a raised reel. When engaged, the reel safety props prevent the reel from unexpectedly lowering. ������� � � Figure 3.3: Engaged Reel Safety Prop – Left Shown 1. Raise the reel fully. 2. Move reel safety props (A) to the engaged position. NOTE: Keep pivot bolt (B) sufficiently tight that the prop remains in the stored position when not in use, but can be engaged using hand force. 3. Repeat the previous step on the opposite reel arm. OPERATION

Figure 3.4: Reel Safety Prop – Center Arm

4. Use handle (A) to move the lock rod to inboard position (B), which engages pin (C) under the prop. 5. Lower the reel until the safety props contact the outer arm cylinder mounts and the center arm pins. Disengaging Reel Safety Props Disengage the reel safety props once you have completed working on or around a raised reel to ensure the proper operation of the reel and header. ������� � Figure 3.5: Left Reel Safety Prop 1. Raise the reel to its maximum height. 2. Move reel safety prop (A) back inside the reel arm. 3. Repeat the previous step on the opposite end of the reel. OPERATION

Figure 3.6: Reel Safety Prop – Center Arm

4. Use handle (B) on double-reel headers to move lock rod (A) to the outboard position. 3.2.3 Header Endshields A hinged, polyethylene endshield is fitted on each end of the header. Opening Endshields The endshields can be opened to access serviceable components or stored items. This procedure details the steps necessary to open the left endshield; the procedure for opening the right endshield is opposite. ������� � � Figure 3.7: Left Endshield 1. Locate the endshield. 2. From the back of the header, push release lever (A) to unlock the endshield. 3. Pull the endshield open using handle depression (B). OPERATION

Figure 3.8: Left Endshield

4. Pull the endshield at handle depression (A). NOTE: The endshield is retained by hinge tab (B) and will open in direction (C). ������� � � Figure 3.9: Left Endshield 5. If additional clearance is required, pull the endshield free of hinge tab (A) and swing the endshield toward the rear of the header. 6. Engage safety latch (B) on the hinge arm to secure the endshield in the fully open position. Closing Endshields Close and lock the endshields before moving the header. ������� � � Figure 3.10: Left Endshield 1. Disengage latch (B) to allow the endshield to move. 2. Insert the front of the endshield behind hinge tab (A) and into the divider cone. OPERATION

Figure 3.11: Left Endshield

3. Swing the endshield into the closed position (direction [A]). Engage the latch by pushing firmly on the endshield in the direction shown. 4. Ensure that the endshield is locked by pulling the endshield toward you; if it has successfully locked, it will not be possible to move the endshield. Removing Endshields To ensure the endshields are removed correctly, follow the recommended removal procedure provided here. NOTE: A D1X Series Draper Header is shown in the illustration. A D1XL Series Draper Header is similar. ������� � � � � Figure 3.12: Left Endshield on D1X Series Draper Header 1. Fully open the endshield. For instructions, refer to Opening Endshields, page 37. 2. Engage lock (A) to prevent endshield movement. 3. Remove self-tapping screw (B). 4. Slide the endshield upwards and remove it from hinge arm (C). Installing Endshields To ensure the endshields are installed correctly, follow the recommended installation procedure provided here. NOTE: A D1X Series Draper Header is shown in the illustration. A D1XL Series Draper Header is similar. OPERATION

Figure 3.13: Left Endshield on D1X Series

Draper Header 1. Guide the endshield onto hinge arm (C) and slowly lower it. NOTE: Ensure hinge arm (C) is installed in the outboard hole on the hinge bracket, as shown in the illustration at right. 2. Install self-tapping screw (B). 3. Disengage lock (A) to allow endshield movement. 4. Close the endshield. For instructions, refer to Closing Endshields, page 38. NOTE: Endshields may expand or contract when subjected to large temperature changes. The top pin and lower latch bracket positions can be adjusted to compensate for dimensional changes. For instructions, refer to Checking and Adjusting Endshields, page 40. Checking and Adjusting Endshields The header’s endshields are made from molded plastic and are therefore subject to expansion or contraction caused by variations in the ambient temperature. The position of the top pin and that of the lower latch can be adjusted to compensate for dimensional changes in the endshield. Checking the endshield ������� � Figure 3.14: Gap between Endshield and Header Frame 1. Measure gap (X) between the front end of the endshield and the header frame. Compare the measurement to the values provided in Table 3.1, page 40. Table 3.1 Endshield Gaps at Various Ambient Temperatures Ambient Temperature °C (°F) Expected Gap (X) 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 (5/32–11/32) OPERATION

Adjusting the endshield

������� � � � � � Figure 3.15: Left Endshield Support Tube on D1X Series Header 2. Inside the endshield, loosen four bolts (A) on support tube bracket (B). NOTE: A D1X Series Draper Header is shown in the illustration. The endshield on a D1XL Series Draper Header is similar. ������� � � Figure 3.16: Left Endshield Latch Assembly 3. Loosen three bolts (A) on latch assembly (B). 4. Adjust latch assembly (B) to achieve the desired gap between the front end of the endshield and the header frame. Refer to Table 3.1, page 40 for the recommended endshield gap at various ambient temperatures. 5. Tighten three bolts (A) on the latch assembly to 27 Nm (20 lbf·ft). ������� � � � � � Figure 3.17: Left Endshield Support Tube on D1X Series Header 6. Tighten four bolts (A) on support tube bracket (B) to 31 Nm (23 lbf·ft). NOTE: A D1X Series Draper Header is shown in the illustration; D1XL Series Draper Headers are similar. 7. Close the endshield. For instructions, refer to Closing Endshields, page 38. 8. Repeat Step 2, page 41 to Step 7, page 41 to adjust the right endshield. OPERATION

Daily Start-Up Check

Perform daily start-up checks daily before operating the machine. ������� Figure 3.18: Safety Devices CAUTION • Clear the area of other persons, pets, etc. Keep children away from machinery. Walk around the machine to be sure no one is under, on, or close to it. • Wear close-fitting clothing and protective shoes with slip- resistant soles. • Remove foreign objects from the machine and surrounding area. • Carry with you any protective clothing and personal safety devices that could be necessary through the day. Do NOT take chances. Personal safety devices that may be needed include a hard hat, protective glasses or goggles, heavy gloves, a respirator or filter mask, or wet weather gear. • Protect against noise. Wear a suitable hearing protective device such as ear muffs or ear plugs to protect against objectionable or uncomfortably loud noises. 1. Check the machine for leaks and any parts that are missing, broken, or not working correctly. NOTE: Use proper procedure when searching for pressurized fluid leaks. For instructions, refer to 5.3.5 Checking Hydraulic Hoses and Lines, page 119. 2. Clean all lights and reflectors on the machine. 3. Perform all daily maintenance. For instructions, refer to 5.3.1 Maintenance Schedule/Record, page 116. OPERATION

A brand-new machine must be operated gently when it is run for the first time.

NOTE: Until you become familiar with the sound and feel of your new header, be extra alert and attentive. WARNING Before investigating an unusual sound or attempting to correct a problem, shut off the engine and remove the key from the igniation. After attaching the header to the windrower for the first time, follow these steps: 1. Operate the machine with the reels, drapers, and knives running slowly for 5 minutes. Watch and listen FROM THE OPERATOR’S SEAT for binding or interfering parts. NOTE: The reels and side drapers will not operate until oil flow fills the lines. 2. Refer to 5.3.2 Break-In Inspection, page 117 and perform all specified tasks. OPERATION

Shutting down the Windrower

Before leaving the operator's seat for any reason, shut down the windrower. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. To shut down the windrower, do the following: 1. Park on level ground whenever possible. 2. Lower the header fully. 3. Place all controls in NEUTRAL or PARK. 4. Disengage the header drive. 5. Lower and fully retract the reel. 6. Shut down the engine, and remove the key from the ignition. 7. Wait for all movement to stop. OPERATION

The header is controlled from the windrower cab.

WARNING Be sure all bystanders are clear of the machine before starting the engine or engaging any header drives. For instructions, refer to your windrower operator’s manual for identification of the following in-cab controls: • Header engage/disengage control • Header height • Header angle • Ground speed • Reel speed • Reel height • Reel fore-aft position OPERATION

Perform the following procedures before operating the machine for optimal performance.

3.6.1 Header Attachments Optional attachments can improve performance in specific conditions or add features to the header. Optional attachments can be ordered and installed by your MacDon Dealer. Refer to 6 Options and Attachments, page 243 for descriptions of available items. 3.6.2 Header Settings The following tables provide guidelines for setting up D1X or D1XL Series Draper Headers for different crops and crop conditions; however, the suggested settings can be changed to suit crops and conditions not covered in the tables. Refer also to 3.6.3 Reel Settings, page 56. OPERATION

Table 3.2 Recommended D1X/D1XL Header Settings for Canola, Stubble Height 102–203 mm (4–8 in.)

Stabilizer Wheels3 Variable Float N (lbf)4 311–445 (70–100) Crop Condition Divider Rods Header Angle5 Skid Shoe Position6 Reel Cam7 Reel Speed %8 Knife Speed9 Reel Position10 Upper Cross Auger Light On 8–10 Variable 2 5–10 Medium 6 or 7 Not required Normal On 8–10 Middle or Down 1 10 Low 6 or 7 Not required Heavy On 8–10 Variable 1 10 Low 3 or 4 Recommended Lodged On 8–10 Middle or Down 2 5–10 Low 3 or 4 Recommended OPERATION 3. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing. 4. Force required to lift header at ends. Refer to your windrower operator’s manual for adjustment procedures. 5. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height. Refer to 3.7.3 Header Angle, page 63. 6. Skid shoe position is used in combination with header angle to determine the cutting height when cutting on or very close to the ground. Refer to Adjusting Skid Shoes, page 62. 7. Refer to Reel Cam Settings, page 68. 8. Percentage above ground speed. 9. Refer to 3.7.7 Knife Speed Information, page 66. 10. Refer to 3.7.9 Reel Fore-Aft Position, page 67.

Table 3.3 Recommended D1X/D1XL Header Settings for Canola, Stubble Height >203 mm (>8 in.)

Stabilizer Wheels11 Variable Float N (lbf)12 667 (150) Crop Condition Divider Rods Header Angle13 Skid Shoe Position14 Reel Cam15 Reel Speed %16 Knife Speed17 Reel Position18 Upper Cross Auger Light On 8–10 Not applicable 2 5–10 Medium 6 or 7 Not required Normal On 8–10 Not applicable 2 10 Low 6 or 7 Not required Heavy On 8–10 Not applicable 3 10 Low 3 or 4 Recommended Lodged On 8–10 Not applicable 3 5–10 Low 3 or 4 Recommended OPERATION 11. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing. 12. Force required to lift header at ends. Refer to your windrower operator’s manual for adjustment procedures. 13. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height. Refer to 3.7.3 Header Angle, page 63. 14. Skid shoe position is used in combination with header angle to determine the cutting height when cutting on or very close to the ground. Refer to Adjusting Skid Shoes, page 62. 15. Refer to Reel Cam Settings, page 68. 16. Percentage above ground speed. 17. Refer to 3.7.7 Knife Speed Information, page 66. 18. Refer to 3.7.9 Reel Fore-Aft Position, page 67.

Table 3.4 Recommended D1X/D1XL Header Settings for Cereals, Stubble Height <102 mm (<4 in.)

Stabilizer Wheels19 Storage Float N (lbf)20 311 (70) Crop Condition Divider Rods Header Angle21 Skid Shoe Position22 Reel Cam23 Reel Speed %24 Knife Speed25 Reel Position26 Upper Cross Auger Light On 0–3 Up or Middle 2 10–15 High 6 or 7 Not required Normal On 0–3 Up or Middle 2 10 Medium 6 or 7 Not required Heavy On 4–7 Up or Middle 2 10 Medium 6 or 7 Not required Lodged On 4–7 Up or Middle 3 5–10 Medium 4 or 5 Not required OPERATION 19. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing. 20. Force required to lift header at ends. Refer to your windrower operator’s manual for adjustment procedures. 21. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height. Refer to 3.7.3 Header Angle, page 63. 22. Skid shoe position is used in combination with header angle to determine the cutting height when cutting on or very close to the ground. Refer to Adjusting Skid Shoes, page 62. 23. Refer to Reel Cam Settings, page 68. 24. Percentage above ground speed. 25. Refer to 3.7.7 Knife Speed Information, page 66. 26. Refer to 3.7.9 Reel Fore-Aft Position, page 67.

Table 3.5 Recommended D1X/D1XL Header Settings for Cereals, Stubble Height 102–203 mm (4–8 in.)

Stabilizer Wheels27 Variable Float N (lbf)28 311 (70) Crop Condition Divider Rods Header Angle29 Skid Shoe Position30 Reel Cam31 Reel Speed %32 Knife Speed33 Reel Position34 Upper Cross Auger Light On 0–3 Middle or Down 2 10–15 High 6 or 7 Not required Normal On 0–3 Middle or Down 2 10 Medium 6 or 7 Not required Heavy On 4–7 Middle or Down 2 10 Medium 6 or 7 Not required Lodged On 4–7 Down 3 5–10 Medium 4 or 5 Not required OPERATION 27. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing. 28. Force required to lift header at ends. Refer to your windrower operator’s manual for adjustment procedures. 29. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height. Refer to 3.7.3 Header Angle, page 63. 30. Skid shoe position is used in combination with header angle to determine the cutting height when cutting on or very close to the ground. Refer to Adjusting Skid Shoes, page 62. 31. Refer to Reel Cam Settings, page 68. 32. Percentage above ground speed. 33. Refer to 3.7.7 Knife Speed Information, page 66. 34. Refer to 3.7.9 Reel Fore-Aft Position, page 67.

Table 3.6 Recommended D1X/D1XL Header Settings for Cereals, Stubble Height >203 mm (>8 in.)

Stabilizer Wheels35 Variable Float N (lbf)36 667 (150) Crop Condition Divider Rods Header Angle37 Skid Shoe Position38 Reel Cam39 Reel Speed %40 Knife Speed41 Reel Position42 Upper Cross Auger Light On 0–3 Not applicable 2 10–15 High 6 or 7 Not required Normal On 0–3 Not applicable 2 10 Medium 6 or 7 Not required Heavy On 4–7 Not applicable 2 10 Medium 6 or 7 Not required Lodged On 4–7 Not applicable 3 5–10 Medium 4 or 5 Not required OPERATION 35. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing. 36. Force required to lift header at ends. Refer to your windrower operator’s manual for adjustment procedures. 37. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height. Refer to 3.7.3 Header Angle, page 63. 38. Skid shoe position is used in combination with header angle to determine the cutting height when cutting on or very close to the ground. Refer to Adjusting Skid Shoes, page 62. 39. Refer to Reel Cam Settings, page 68. 40. Percentage above ground speed. 41. Refer to 3.7.7 Knife Speed Information, page 66. 42. Refer to 3.7.9 Reel Fore-Aft Position, page 67.

Table 3.7 Recommended D1X/D1XL Header Settings for Edible Beans, Ground Level Stubble Height (0 mm [0 in.])

Stabilizer Wheels43 Storage Float N (lbf)44 445 (100) Crop Condition Divider Rods Header Angle45 Skid Shoe Position46 Reel Cam47 Reel Speed %48 Knife Speed49 Reel Position50 Upper Cross Auger Light Off 8–10 Up or Middle 2 5–10 Medium 3 or 4 Not required Normal Off 8–10 Up or Middle 2 5–10 Medium 3 or 4 Not required Heavy Off 8–10 Up or Middle 2 5–10 Medium 3 or 4 Not required Lodged Off 8–10 Up or Middle 3 5–10 Medium 3 or 4 Not required OPERATION 43. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing. 44. Force required to lift header at ends. Refer to your windrower operator’s manual for adjustment procedures. 45. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height. Refer to 3.7.3 Header Angle, page 63. 46. Skid shoe position is used in combination with header angle to determine the cutting height when cutting on or very close to the ground. Refer to Adjusting Skid Shoes, page 62. 47. Refer to Reel Cam Settings, page 68. 48. Percentage above ground speed. 49. Refer to 3.7.7 Knife Speed Information, page 66. 50. Refer to 3.7.9 Reel Fore-Aft Position, page 67.

Table 3.8 Recommended D1X/D1XL Header Settings for Flax, Stubble Height 51–153 mm (2–6 in.)

Stabilizer Wheels51 Variable Float N (lbf)52 311–445 (70–100) Crop Condition Divider Rods Header Angle53 Skid Shoe Position54 Reel Cam55 Reel Speed %56 Knife Speed57 Reel Position58 Upper Cross Auger Light On 4–7 Middle or Down 2 5–10 High 6 or 7 Not required Normal On 0–3 Middle or Down 2 10 High 6 or 7 Not required Heavy On 4–7 Middle or Down 2 10 High 6 or 7 Not required Lodged On 8–10 Middle or Down 2 10 High 6 or 7 Not required OPERATION 51. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing. 52. Force required to lift header at ends. Refer to your windrower operator’s manual for adjustment procedures. 53. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height. Refer to 3.7.3 Header Angle, page 63. 54. Skid shoe position is used in combination with header angle to determine the cutting height when cutting on or very close to the ground. Refer to Adjusting Skid Shoes, page 62. 55. Refer to Reel Cam Settings, page 68. 56. Percentage above ground speed. 57. Refer to 3.7.7 Knife Speed Information, page 66. 58. Refer to 3.7.9 Reel Fore-Aft Position, page 67.

Table 3.9 Recommended D1X/D1XL Header Settings for Grass, Ground Level Stubble Height (0 mm [0 in.])

Stabilizer Wheels59 Storage Float N (lbf)60 311–445 (70–100) Crop Condition Divider Rods Header Angle61 Skid Shoe Position62 Reel Cam63 Reel Speed %64 Knife Speed65 Reel Position66 Upper Cross Auger Light On Variable Up or Middle 2 10 High 6 or 7 Not required Normal On Variable Up or Middle 2 10 High 6 or 7 Not required Heavy On Variable Up or Middle 2 10 High 6 or 7 Not required Lodged On Variable Up or Middle 2 10–15 High 6 or 7 Not required OPERATION 59. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing. 60. Force required to lift header at ends. Refer to your windrower operator’s manual for adjustment procedures. 61. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height. Refer to 3.7.3 Header Angle, page 63. 62. Skid shoe position is used in combination with header angle to determine the cutting height when cutting on or very close to the ground. Refer to Adjusting Skid Shoes, page 62. 63. Refer to Reel Cam Settings, page 68. 64. Percentage above ground speed. 65. Refer to 3.7.7 Knife Speed Information, page 66. 66. Refer to 3.7.9 Reel Fore-Aft Position, page 67.

Table 3.10 Recommended D1X/D1XL Header Settings for Alfalfa, Ground Level Stubble Height (0 mm [0 in.])

Stabilizer Wheels67 Storage Float N (lbf)68 311–445 (70–100) Crop Condition Divider Rods Header Angle69 Skid Shoe Position70 Reel Cam71 Reel Speed %72 Knife Speed73 Reel Position74 Upper Cross Auger Light On Variable Up or Middle 3 10 High 6 or 7 Not required Normal On Variable Up or Middle 2 10 High 6 or 7 Not required Heavy On Variable Up or Middle 2 10 High 6 or 7 Not required Lodged On Variable Up or Middle 3 10–15 High 6 or 7 Not required OPERATION 67. Stabilizer wheels are used to limit the side-to-side movement when cutting off the ground in rolling terrain and to minimize bouncing. 68. Force required to lift header at ends. Refer to your windrower operator’s manual for adjustment procedures. 69. Set header angle as shallow as possible (setting A) with center-link and skid shoes while maintaining cutting height. Refer to 3.7.3 Header Angle, page 63. 70. Skid shoe position is used in combination with header angle to determine the cutting height when cutting on or very close to the ground. Refer to Adjusting Skid Shoes, page 62. 71. Refer to Reel Cam Settings, page 68. 72. Percentage above ground speed. 73. Refer to 3.7.7 Knife Speed Information, page 66. 74. Refer to 3.7.9 Reel Fore-Aft Position, page 67.

The reel cam setting and reel position can be adjusted to produce different reel finger patterns.

Table 3.11, page 56 illustrates the profile of the reel at each cam or finger pitch setting as well as the reel position relative to the ground at different positions on the reel arm. Refer to 3.6.2 Header Settings, page 46 for the applicability of each finger pattern and reel position. Table 3.11 Recommended Reel Settings Cam Setting Number (Finger Speed Gain) Reel Position Number Reel Finger Pattern 1 (0) 6 or 7 ������� 2 (20%) 3 or 4 ������� OPERATION

Recommended Reel Settings (continued)

Cam Setting Number (Finger Speed Gain) Reel Position Number Reel Finger Pattern 3 (30%) 6 or 7 ������� 4 (35%) 2 or 3 ������� NOTE: • Adjust the reel forward to get closer to the ground while tilting the header back. Fingers/tines will dig into the ground at extreme reel-forward positions, so adjust skid shoes or header angle to compensate. Adjust the reel rearwards to position the reel farther away from the ground when tilting the header forward. • Header tilt can be increased to position the reel closer to the ground, or decreased to position the reel farther from the ground, while keeping material flowing onto drapers. • To leave the maximum amount of stubble behind in lodged crop, raise the header and increase the header tilt to keep the reel close to the ground. Position the reel fully forward. • The reel may have to be moved back to prevent lumps or plugging on the cutterbar in thinner crops. • Minimum crop carrying capacity (minimum area of exposed draper between the reel and the header backsheet) occurs with the reel in the farthest aft position. • Maximum crop carrying capacity (maximum area of exposed draper between the reel and the header backsheet) occurs with the reel in the farthest forward position. • The tip speed of the fingers/tines at the cutterbar becomes higher than the reel speed at higher cam settings due to the nature of the cam action. Refer to Table 3.11, page 56. OPERATION

Header Operating Variables

Satisfactory function of the header requires making proper adjustments to suit various crops and conditions. Correct operation reduces crop loss and increases productivity. As well, proper adjustments and timely maintenance will increase the length of service you receive from your machine. The variables listed in Table 3.12, page 58 and detailed on the following pages will affect the performance of your header. You will quickly become adept at adjusting the machine to achieve the results you desire. Most of the adjustments have been preset at the factory, but the settings can be changed to suit crop conditions. Table 3.12 Operating Variables Variable Refer to Cutting height 3.7.1 Cutting Height, page 58 Header float 3.7.2 Header Float, page 63 Header angle 3.7.3 Header Angle, page 63 Reel speed 3.7.4 Reel Speed, page 64 Ground speed 3.7.5 Ground Speed, page 65 Reel height 3.7.8 Reel Height, page 66 Reel fore-aft position 3.7.9 Reel Fore-Aft Position, page 67 Reel tine pitch 3.7.10 Reel Tine Pitch, page 68 Crop divider rods 3.7.12 Crop Divider Rods, page 75 3.7.1 Cutting Height The header design allows you to cut the crop above the ground at a desired stubble height or to cut the crop at ground level with the header on the ground. Cutting height will vary depending on a range of factors including crop type and crop conditions. Cutting off the Ground The stabilizer wheel system is designed to minimize bouncing at the header ends and may be used to float the header to achieve an even cutting height when cutting above ground level in cereal grains. The system produces an even stubble height and greatly reduces operator fatigue. Cutting height is controlled using a combination of the windrower header height control and a stabilizer wheel system (or stabilizer/slow speed transport wheel system). The header stabilizer wheel system (or stabilizer/slow speed transport wheel system) is available for all header widths. If stabilizer wheels are installed, refer to Adjusting Stabilizer Wheels, page 60 to change the wheel position. If stabilizer/slow speed transport wheels are installed, refer to Adjusting Stabilizer/Slow Speed Transport Wheels, page 58 to change the wheel position. Adjusting Stabilizer/Slow Speed Transport Wheels A properly adjusted header will achieve a balance between the amount of header weight carried by the float and the amount carried by the stabilizer/slow speed transport wheels. Refer to 3.6.2 Header Settings, page 46 for recommended use in specific crops and crop conditions. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. OPERATION

Raise the header so that the stabilizer wheels are off the ground.

2. Shut down the engine and remove the key. 3. Check that the float is working properly. Refer to your windrower operator’s manual for instructions. CAUTION Handle may be under tension, especially when the wheels are on the ground. Raise header so that wheels are off the ground before making adjustments. ������� � � � � Figure 3.19: Right Wheels 4. Remove hairpin (A) from the latch on the right wheel assembly. 5. Disengage latch (B), lift the wheel out of the hook, and place the wheel on the ground as shown. NOTE: This reduces the weight of the assembly and makes adjusting the wheel position easier. 6. Lift the left wheel slightly to support the weight of the wheel, and pull handle (C) upwards to release the lock. 7. Lift the left wheel to the desired height and engage the support channel into slot (D) in the upper support. 8. Push down on handle (C) to lock. 9. Lift the right wheel back into field position and ensure latch (B) is engaged. 10. Secure the latch with hairpin (A). ������� � � Figure 3.20: Left Wheels 11. Support the wheel weight by lifting slightly with one hand, and pull up on handle (A) to release the lock. 12. Lift the wheels to the desired height, and engage the support channel into slot (B) in the upper support. 13. Push down on handle (A) to lock. OPERATION

Figure 3.21: Load Indicator

14. Lower the header to the desired cutting height using the windrower controls. 15. Check the load indicator. ������� � Figure 3.22: Spring Compression IMPORTANT: Continuous operation with excessive spring compression (that is, a load indicator reading greater than 4 or a compressed length [A] less than 295 mm [11 5/8 in.]) can result in damage to the suspension system. 16. Adjust the header angle to the desired working angle using the windrower header angle controls. If header angle is not critical, set it to mid-position. 17. Use the windrower Harvest Performance Tracker (HPT) controls to automatically maintain cutting height. Refer to your windrower operator’s manual for details. Adjusting Stabilizer Wheels A properly adjusted header will achieve a balance between the amount of header weight carried by the float and the amount carried by the stabilizer wheels. Refer to 3.6.2 Header Settings, page 46 for recommended use in specific crops and crop conditions. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. CAUTION The handle may be under tension—especially when the wheels are on the ground. Raise the header until the wheels are off the ground before making adjustments. 1. Raise the header until the stabilizer wheels are off the ground. 2. Shut down the engine, and remove the key from the ignition. 3. Check that the float is working properly. Refer to your windrower manual for instructions. OPERATION

Figure 3.23: Stabilizer Wheel

4. Support the wheel weight by lifting slightly with one hand on handle (B), and pull up on handle (A) to release the lock. 5. Lift the wheel using handle (B), and engage the support channel into center slot (C) in the upper support. 6. Push down on handle (A) to lock. ������� Figure 3.24: Load Indicator 7. Lower the header to the desired cutting height using windrower controls. 8. Check the load indicator. ������� � Figure 3.25: Spring Compression IMPORTANT: Continuous operation with excessive spring compression (that is, a load indicator reading greater than 4 or a compressed length less than 295 mm [11 5/8 in.]) (A) can result in damage to the suspension system. 9. Adjust the header angle to the desired working angle with the windrower header angle controls. If header angle is not critical, set it to mid-position. 10. Use the Harvest Performance Tracker (HPT) controls to automatically maintain cutting height. Refer to your windrower operator’s manual for details. Cutting on the Ground Cutting on the ground is performed with the header fully lowered and the cutterbar on the ground. The orientation of the knife and knife guards relative to the ground (header angle) is controlled by the skid shoes and the center-link—it is NOT controlled by the header lift cylinders. The skid shoes and center-link allow you to adjust to field conditions and maximize the amount of material cut while reducing damage to the knife caused by stones and debris. OPERATION

The header float system floats the header over the surface to compensate for ridges, trenches, and other variations in

ground contour to prevent the cutterbar from pushing into the ground or leaving uncut crop. Refer to the following for additional information: • 3.6.2 Header Settings, page 46 • Adjusting Skid Shoes, page 62 • 3.7.2 Header Float, page 63 Adjusting Skid Shoes The skid shoes can be adjusted to optimize header performance and maximize the life of the skid shoes. To adjust the skid shoes, follow this procedure. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason. 1. Raise the header fully. 2. Engage the header’s safety props. 3. Shut down the engine, and remove the key from the ignition. 4. Raise the stabilizer wheels or slow speed transport wheels fully (if installed). For instructions, refer to the following: • Adjusting Stabilizer/Slow Speed Transport Wheels, page 58 • Adjusting Stabilizer Wheels, page 60 ������� � � � Figure 3.26: Inner Skid Shoe IMPORTANT: Note the adjustment hole position on support (A) and ensure each skid shoe is set to the same position. 5. Remove lynch pin (B) from each skid shoe. 6. Hold the shoe and remove pin (C) by disengaging it from the frame and pulling it away from the shoe. 7. Raise or lower the skid shoe to the desired position using the holes in support (A) as a guide. 8. Install pin (C), engage in frame, and secure with lynch pin (B). 9. Check that all of the skid shoes are adjusted to the same position. OPERATION

Figure 3.27: Outer Skid Shoe

10. Check the header float as described in your windrower operator’s manual. 3.7.2 Header Float Headers are designed to ride on skid shoes while cutting on the ground. The windrower float system, however, reduces the ground pressure at the cutterbar allowing the header to float over obstacles and follow ground contours instead of being supported by the windrower lift cylinders. Refer to your windrower operator’s manual for details about header float adjustments. 3.7.3 Header Angle Header angle is the angle between the header and the ground. The header angle is adjustable to accommodate different crop conditions and/or soil types and can be adjusted using the center-link between the windrower and the header. For in-cab adjustment details, refer to the windrower operator’s manual. ������� � � � � Figure 3.28: Header Angle The header angle (A) controls the distance (B) between the cutterbar knife and the ground and is a critical component for effective cutting crop at ground level. Adjusting the header angle pivots the header at the point of skid shoe/ground contact (C). Guard angle (D) is the angle between the upper surface of the cutterbar guards and the ground. OPERATION

Figure 3.29: Center-Link

Set the header angle according to the type and condition of crop and soil as follows: • Use shallower settings (A) (position A on the indicator) for normal cutting conditions and wet soil to reduce soil buildup at the cutterbar. Shallow angle settings also minimize damage to the knife in stony fields. • Use steeper settings (D) (position D on the indicator) for lodged crops and crops that are close to the ground such as soybeans. ������� � � Figure 3.30: Guard Angles The shallowest angle (A) (center-link fully retracted) produces the highest stubble when cutting on the ground. The steepest angle (D) (center-link fully extended) produces the lowest stubble when cutting on the ground. Choose an angle that maximizes performance for your crop and field conditions. Refer to the table below for a summary of adjustment ranges. Table 3.13 D1X/D1XL Series Header Angle Header Size Guard Angle 6.1–7.6 m (20 and 25 ft.) 7.0–12.4° 9.1–13.7 m (30–45 ft.) 2.0–7.4° For recommended header/guard angle settings for your particular crop conditions, refer to 3.6.2 Header Settings, page 46. Adjusting Header Angle Header angle can be adjusted using the center-link between the windrower and the header. Refer to the windrower operator’s manual for adjustment details. 3.7.4 Reel Speed Reel speed is one of the factors that determines how crop is moved from the cutterbar onto the drapers. The reel performs best when it appears to be driven by the ground. It should move the cut crop evenly through the cutterbar and onto the drapers without bunching and with minimal disturbance. In standing crop, reel speed should be slightly higher than, or equal to, ground speed. In flattened crop or crop that is leaning away from the cutterbar, the reel speed needs to be higher than the ground speed. To achieve this, either increase the reel speed or decrease the ground speed. Excessive shattering of grain heads or crop loss over the header backtube may indicate that the reel speed is too high. Excessive reel speed also increases reel component wear and overloads the reel drive. Slower reel speeds can be used with nine-bat reels, which is advantageous in shatter-prone crops. Refer to for recommended reel speeds in specific crops and crop conditions. OPERATION

The reel speed is adjustable using the controls in the windrower cab. Refer to the windrower operator’s manual for

adjustment details. Optional Reel Drive Sprockets Optional reel drive sprockets for use in special crop conditions are available as an alternative to the factory-installed sprocket. The header is factory-equipped with a 19-tooth sprocket that drives the reel and it is suitable for most crop conditions. Other sprockets are available that provide more torque to the reel in heavy cutting conditions or that allow for higher reel speeds in light crops when operating at increased ground speeds. See your MacDon Dealer for ordering information. For installation details, refer to 5.9.3 Reel Drive Sprocket, page 229. 3.7.5 Ground Speed Operating at the proper ground speed will cleanly cut crop and evenly distribute crop material in uniform windrows. For effects of ground speed on windrow formation, refer to 3.10 Windrow Types, page 80. Reduce ground speed in difficult cutting conditions to reduce loads on cutting components and drives. Use lower ground speeds in very light crops (e.g., short soybeans) to allow the reel to pull in short plants. Start at 4.8–5.8 km/h (3.0–3.5 mph) and adjust as required. Higher ground speeds may require heavier float settings to prevent excessive bouncing that causes uneven cutting and possible damage to the cutting components. If ground speed is increased, draper and reel speeds should generally be increased to handle the extra material. Figure 3.31, page 65 illustrates the relationship between ground speed and area cut for the various sized headers. ������� ������� � � � � � � � � � � Figure 3.31: Ground Speed versus Acres A - 4.6 m (15 ft.) B - 6.1 m (20 ft.) C - 7.6 m (25 ft.) D - 9.1 m (30 ft.) E - 10.7 m (35 ft.) F - 12.2 m (40 ft.) G - acres/hour H - miles/hour J - hectares per hour K - kilometers/hour OPERATION

Example: A 7.6 m (25 ft.) header operating at a ground speed of 9.7 km/h (6 mph) would produce a cut area of

approximately 7.3 hectares (18 acres) in one hour. 3.7.6 Draper Speed Operating with the correct draper speed is an important factor for achieving good flow of cut crop away from the cutterbar. The draper speed is controlled with the windrower Harvest Performance Tracker (HPT). For instructions, refer to your windrower operator’s manual. Adjust the draper speed to achieve good feeding of crop for a good windrow. Excessive draper speed will reduce draper life. 3.7.7 Knife Speed Information The header knife drive is powered by the windrower’s hydraulic pump and is controlled using the windrower’s Harvest Performance Tracker (HPT). The default speed is 1200 strokes per minute (spm). Table 3.14 D1X/D1XL Series Knife Speed Header Recommended Knife Speed Range (spm) D115X 1500–1900 D120X 1500–1900 D125X 1400–1700 D130XL 1200–1600 D135XL 1200–1400 D140XL 1100–1400 D145XL 1100–1400 NOTE: Refer to your windrower operator’s manual for information about using the HPT. 3.7.8 Reel Height The reel operating position depends on the type of crop and cutting conditions. You can create preset reel height positions using the Headland Management feature on an M1 Series Windrower. To set up this feature, refer to your windrower operator’s manual. Set the reel height and fore-aft position to carry material past the knife and onto the drapers with minimal damage to the crop. The reel height is controlled manually or with button presets on the ground speed lever (GSL) in the windrower cab. Refer to your windrower operator’s manual for instructions on controlling reel height or setting up auto reel height presets. For more information on fore-aft positioning, refer to 3.7.9 Reel Fore-Aft Position, page 67. The following conditions might result if the reel is set too low: • Crop loss over the header backtube • Crop disturbance on the drapers caused by the reel fingers • Crop pushed down by the tine tubes • Tall crop wrapped around the reel drive and ends The following conditions might result if the reel is set too high: • Cutterbar plugging • Crop lodging and being left uncut OPERATION

Grain stalks dropping ahead of the cutterbar

For recommended reel heights for specific crops and crop conditions, refer to 3.6.2 Header Settings, page 46. IMPORTANT: Maintain adequate clearance to prevent fingers contacting the knife or the ground. For instructions, refer to 5.8.1 Reel-to- Cutterbar Clearance, page 198. 3.7.9 Reel Fore-Aft Position Reel fore-aft position is a critical factor for achieving the best results in adverse conditions. The factory-set reel position suits normal conditions, but the fore-aft position can be adjusted as required using the controls inside the cab. You can create preset reel fore-aft positions using the Headland Management feature on an M1 Series Windrower. To set up this feature, refer to your windrower operator’s manual. ������� � � Figure 3.32: Fore-Aft Decal Use decal (A), on the right reel support arm, to identify your reel position. The aft edge of cam disc (B) is the reel fore-aft position marker. For straight standing crop, center the reel over the cutterbar (4–5 on decal). For crops that are down, tangled, or leaning, it may be necessary to move the reel ahead of the cutterbar (lower number on decal). NOTE: If experiencing difficulty picking up flattened crop, adjust to a steeper header angle. Refer to 3.7.3 Header Angle, page 63 for adjustment instructions. Adjust reel position only if header angle adjustments are not satisfactory. For recommended reel positions in specific crops and crop conditions, refer to 3.6.2 Header Settings, page 46. NOTE: In crops that are difficult to pick up such as rice or severely lodged crops that require full forward positioning of the reel, set the reel tine pitch to provide proper placement of the crop onto the drapers. Refer to 3.7.10 Reel Tine Pitch, page 68 for adjustment details. Adjusting Reel Fore-Aft Position Reel fore-aft position is a critical factor for achieving the best results in adverse conditions. The factory-set reel position suits normal conditions, but the fore-aft position can be adjusted as required using the controls inside the cab. 1. Use the in-cab controls to move the reel to the desired position. For more information on reel fore-aft position, refer to 3.7.9 Reel Fore-Aft Position, page 67. 2. Check the reel clearance to cutterbar after making changes to the cam setting. Refer to the following for measurement and adjustment procedures: • 5.8.1 Reel-to-Cutterbar Clearance, page 198 • Adjusting Reel Frown, page 202 IMPORTANT: Operating with the reel too far forward can result in the fingers contacting the ground. When operating with the reel in this position, lower the skid shoes or adjust the header tilt as required to prevent damaging the fingers. OPERATION

Reel Tine Pitch

The reel is designed to pick up flattened and severely lodged crops. Because the cam setting is mainly used to determine how the crop gets delivered onto the drapers, it is not always necessary to increase the tine pitch (select a higher cam setting) to pick up lodged crops. IMPORTANT: The following describes the conceptual and operational guidelines of the reel. Please read carefully before operating the machine. The positioning of the fingers relative to the ground (tine pitch) is not significantly affected by the cam setting. For example, with the cam position range at 33°, the corresponding finger pitch range is only 5° at the lowest point of the reel’s rotation. For the best results, use the minimum cam setting that delivers the crop past the rear edge of the cutterbar and onto the drapers. For more information, refer to 3.6.2 Header Settings, page 46. Reel Cam Settings The cam position is used to adjust the reel fingers release point of the crop at the back of the reel to the drapers. The following outlines the function of each cam position and provides set-up guidelines for various crop conditions. The setting numbers are visible above the slots on the cam disc. For instructions, refer to Adjusting Reel Cam, page 70. ������� Figure 3.33: Finger Profile – Position 1 Cam Position 1, Reel Position 6 or 7 delivers the most even crop flow onto the drapers without fluffing or disturbing the material. • This setting will release crop close to the cutterbar. It works best if the cutterbar is on the ground. • Some crops will not be delivered past the cutterbar when the cutterbar is raised off the ground and the reel is pushed forward; therefore, set the initial reel speed approximately equal to the ground speed. ������� Figure 3.34: Finger Profile – Position 2 Cam Position 2, Reel Position 3 or 4 is the recommended starting position for most crops and conditions. • If the crop is stalling on the cutterbar when the reel is in the forward position, increase the cam setting to push the crop past the rear edge of the cutterbar. • If the crop is getting fluffed or if there is a disruption to the flow across the drapers, decrease the cam setting. • This setting generates a fingertip speed that is approximately 20% faster than the reel speed. OPERATION

Figure 3.35: Finger Profile – Position 3

Cam Position 3, Reel Position 6 or 7 is mainly used to leave long stubble. • This position allows the reel to reach forward and lift the crop across the knife and onto the drapers. • This setting generates a fingertip speed that is approximately 30% faster than the reel speed. ������� Figure 3.36: Finger Profile – Position 4 Cam Position 4, Reel Position 2 or 3 is used with the reel fully forward to leave the maximum amount of stubble in lodged crops. • This position allows the reel to reach forward and lift the crop across the knife and onto the drapers. • This setting generates a fingertip speed that is approximately 35% faster than the reel speed. ������� Figure 3.37: Finger Profile – Position 4 Cam Position 4, Header Angle at Maximum, and Reel Fully Forward provides the maximum amount of reel reach below the cutterbar to pick up lodged crops. • This position leaves a significant amount of stubble when cutting height is set to approximately 203 mm (8 in.). In damp materials such as rice, it is possible to double the ground speed because of the reduction of cut material. • This setting generates a fingertip speed that is approximately 35% faster than the reel speed. NOTE: Higher cam settings with the reel fore-aft position set between 4–5 sharply decrease the draper capacity because the reel disrupts the crop flow across the drapers and the fingers engage the crop that is moving on the drapers. High cam settings are recommended only with the reel at, or close to, full forward settings. OPERATION

Adjusting Reel Cam

The reel is designed to pick up flattened and severely lodged crops. Adjustment may be required as crop conditions change. DANGER To prevent injury or death from the unexpected start-up of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. IMPORTANT: The reel-to-cutterbar clearance should always be checked following adjustments to reel tine pitch and reel fore-aft positions. For information, refer to 5.8.1 Reel-to-Cutterbar Clearance, page 198 and 3.6.2 Header Settings, page 46. NOTE: If there are multiple reel cams, the adjustments need to be made on all of the reel cams. 1. Shut down the engine, and remove the key from the ignition. ������� � � � Figure 3.38: Cam Disc Positions 2. Turn latch pin (A) counterclockwise using a 3/4 in. wrench to release the cam disc. 3. Use the wrench on bolt (B) to rotate the cam disc and align latch pin (A) with the desired cam disc hole position (C) (1 to 4). NOTE: Bolt (B) is positioned through the cam disc (transparent view shown in the illustration for improved clarity). 4. Turn latch pin (A) clockwise to engage and lock the cam disc. IMPORTANT: Ensure the cam is secured into position before operating the machine. 5. For double-reel headers, repeat the above procedure for the next reel. 3.7.11 Crop Dividers Crop dividers are used to help divide the crop when harvesting. They are removable to allow installation of vertical knives and to decrease transport width. Removing Crop Dividers with Latch Option from Header To correctly remove crop dividers with the latch option, follow the recommended removal procedure provided here. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason. 1. Lower the reel fully. For instructions, refer to your windrower operator’s manual. 2. Raise the header fully. For instructions, refer to your windrower operator’s manual. 3. Shut down the engine, and remove the key from the ignition. 4. Engage the safety props. For instructions, refer to your windrower operator’s manual. 5. Open the endshield. For instructions, refer to Opening Endshields, page 37. OPERATION

Figure 3.39: Crop Divider

6. Lift safety lever (A). 7. Hold onto crop divider (B), push lever (C) to open the latch, and lower the crop divider. ������� � � Figure 3.40: Stored Crop Divider 8. Lift the crop divider off of the endsheet and store it as follows: a. Insert pin (A) on the crop divider into the hole in the endsheet at the location shown. b. Lift the crop divider and position lugs (B) on the crop divider into the bracket on endsheet. Ensure the lugs engage the bracket. 9. Close the endshield. For instructions, refer to Closing Endshields, page 38. Removing Crop Dividers without Latch Option from Header To correctly remove crop dividers without the latch option, follow the recommended removal procedure provided here. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason. 1. Lower the reel fully. For instructions, refer to your windrower operator’s manual. 2. Raise the header fully. For instructions, refer to your windrower operator’s manual. 3. Shut down the engine, and remove the key from the ignition. 4. Engage the safety props. For instructions, refer to your windrower operator’s manual. 5. Open the endshield. For instructions, refer to Opening Endshields, page 37. OPERATION

Figure 3.41: Crop Divider

6. Remove bolt (A), the lock washer, and the flat washer. 7. Lower crop divider (B), then lift it to remove it from the endsheet. 8. Close the endshield. For instructions, refer to Closing Endshields, page 38. Installing Crop Dividers with Latch Option onto Header To correctly install crop dividers with the latch option, follow the recommended installation procedure provided here. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason. 1. Lower the reel fully. For instructions, refer to your windrower operator’s manual. 2. Raise the header fully. For instructions, refer to your windrower operator’s manual. 3. Shut down the engine, and remove the key from the ignition. 4. Engage the safety props. For instructions, refer to your windrower operator’s manual. 5. Open the endshield. For instructions, refer to Opening Endshields, page 37. ������� � � Figure 3.42: Stored Crop Divider 6. If the crop divider is stored on the header, remove the crop divider from its storage location by lifting the crop divider to disengage lugs (A) at the lower end. Then lower it slightly to disengage pin (B) from the endsheet. OPERATION

Figure 3.43: Crop Divider

7. Position the crop divider as shown by inserting lugs (A) into the holes in the endsheet. 8. Lift the forward end of the crop divider until pin (B) at top of the crop divider engages and closes latch (C). 9. Push safety lever (D) downwards to lock the pin into latch (C). ������� � Figure 3.44: Crop Divider 10. Pull the tip of the crop divider to ensure there is no lateral movement. If necessary, adjust bolts (A) to tighten the crop divider and eliminate any lateral movement. 11. Close the endshield. For instructions, refer to Closing Endshields, page 38. Installing Crop Dividers without Latch Option onto Header To correctly install crop dividers without the latch option, follow the recommended installation procedure provided here. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine, remove the key, and engage the safety props before going under the header for any reason. 1. Lower the reel fully. For instructions, refer to your windrower operator’s manual. 2. Raise the header fully. For instructions, refer to your windrower operator’s manual. 3. Shut down the engine, and remove the key from the ignition. 4. Engage the safety props. For instructions, refer to your windrower operator’s manual. OPERATION

Open the endshield. For instructions, refer to Opening Endshields, page 37.

������� � � Figure 3.45: Stored Crop Divider 6. If the crop divider is stored on the header, remove the crop divider from the storage location by lifting the crop divider to disengage lugs (A) at the lower end and then lowering it slightly to disengage pin (B) from the endsheet. ������� � Figure 3.46: Crop Divider 7. Position the crop divider as shown by inserting lugs (A) into the holes in the endsheet. ������� � � � Figure 3.47: Crop Divider 8. Lift the forward end of the crop divider and install bolt (A), and special stepped washer (B) (step towards divider). Tighten the bolt. 9. Pull on the tip of the crop divider to ensure there is no lateral movement. If necessary, adjust bolts (C) to tighten the crop divider and eliminate any lateral movement. 10. Close the endshield. For instructions, refer to Closing Endshields, page 38. OPERATION

Crop Divider Rods

Removable crop divider rods are used in conjunction with crop dividers to help divide the crop when harvesting. The rods are most useful when crop is bushy or down. In standing crops, using only crop dividers is recommended. Table 3.15 Crop Divider Rods Recommended Use With Divider Rods Without Divider Rods Alfalfa Lodged cereal Edible beans Canola Peas Milo Flax Soybeans Rice Grass seed Sudan grass Soybeans Lentils Winter forage Standing cereal Removing Crop Divider Rods To remove the crop divider rods and place them in their storage position, perform the removal procedure provided here. ������� � � Figure 3.48: Crop Divider Rod 1. Loosen bolt (A) and remove crop divider rod (B) from both sides of the header. ������� � Figure 3.49: Right Endsheet 2. Store both crop divider rods (A) inboard on the right endsheet. OPERATION

Installing Crop Divider Rods

To install the crop divider rods onto the crop dividers, perform the installation procedure provided here. ������� � Figure 3.50: Right Endsheet 1. Remove crop divider rods (A) from their storage location on the inboard of the side endsheet. ������� � � Figure 3.51: Divider Rod on Crop Divider 2. Position crop divider rod (B) on the tip of the crop divider as shown and tighten bolt (A). 3. Repeat procedure at opposite end of header. OPERATION

The width and location of the delivery opening affects the width and configuration of the windrow.

The decision to widen or narrow the center delivery opening, or to double windrow, should be based on the following factors: • Windrower pick-up capability • Type and yield of crop • Weather conditions • Available drying time Refer to 3.10 Windrow Types, page 80 for the pros and cons of various windrow configurations with respect to these factors, and also refer to 3.9 Double Windrowing, page 79. 3.8.1 Manually Adjusting Delivery Opening on Header Both draper decks can be moved manually to adjust the delivery opening between 1720 mm and 1950 mm (67 1/8 in. and 76 11/16 in.). ������� � Figure 3.52: Manual Deck Shift 1. Loosen bolts (A) on both decks. 2. Slide the decks the desired distance. Retighten bolts (A). OPERATION

Adjusting Delivery Opening on Header using Hydraulic Deck Shift

The width and position of the delivery opening affects the width and configuration of the windrow. Adjust the delivery opening by moving the inboard deck shift stops. Adjusting inboard deck shift stop ������� � � � � Figure 3.53: Inboard Hydraulic Deck Shift Stops 1. Remove two 1/4 in. hex head bolts (A) and nuts. 2. Slide stop (B) outboard to decrease the maximum opening size, or slide the stop inboard to increase the maximum opening size. IMPORTANT: Ensure that the deck shift stops are sufficiently adjusted to prevent the decks from contacting each other. 3. Install two 1/4 in. hex head bolts (A) and nuts, and tighten them. Adjusting outboard deck shift stop ������� � � � � Figure 3.54: Outboard Hydraulic Deck Shift Stops 4. Remove two 1/4 in. hex head bolts (A) and nuts. 5. Slide stop (B) inboard to move decks away from each other, or slide the stop outboard to move decks closer to each other. IMPORTANT: Ensure that the deck shift stops are sufficiently adjusted to prevent the decks from contacting each other. 6. Install two 1/4 in. hex head bolts (A) and nuts, and tighten them. OPERATION

Double windrowing involves laying two windrows side-by-side. Larger capacity combines or forage harvesters can then pick

up twice as much material in a single pass which saves time and fuel. Double windrowing is used for crops that don’t require conditioning such as grains, canola, and beans. Double windrowing is performed using the header’s deck shifting ability. For instructions, refer to 3.9.1 Shifting Decks Hydraulically, page 79. 3.9.1 Shifting Decks Hydraulically The hydraulic deck shift option allows you to select center, left, or right delivery from the windrower cab. It is available only on D130XL and D135XL Draper Headers. Refer to 6.4.10 Hydraulic Deck Shift Package, page 255 for ordering information. Refer to your windrower operator’s manual for identification and operation of the deck shift control. Laying a double windrow ������� � � Figure 3.55: Left and Right End Crop Delivery 1. Use the deck shift control in the windrower cab to position the decks at the left end of the header and deliver crop from right end (A), or shift the decks to the right end of the header and deliver crop from left end (B). ������� � Figure 3.56: Double Windrowing NOTE: Raise transport or stabilizer system wheels on D130XL and D135XL Draper Headers to avoid interference with windrows. 2. Shift the decks to the left end of the header to deliver crop from the right end (A). 3. Complete one round or one length of the field. 4. Complete the second round or length in the opposite direction to lay a double windrow. NOTE: The end delivery opening is designed to provide adequate clearance between the first windrow and standing crop while maintaining optimum space between the two windrows. OPERATION

Crops can be laid into six types of windrows depending on crop conditions, machine settings, and weather conditions.

The following criteria determine windrow quality: • Weight Distribution: Heads and stalks distributed evenly across full width of windrow. • Good Curing: A loose, open windrow for better drying. • Good Weatherability: A well-formed windrow that supports heads off the ground and holds together in extreme weather conditions. Table 3.16 Windrow Types Windrow Type Description Weight Distribution Curing Weatherability Machine Setting Guidelines Herringbone ������� The most desirable form of windrow, stalks are crossed and interwoven. Heads are distributed across full width of windrow. This windrow can be formed by center delivery only. Good Good Excellent • Reel and ground speed approximately equal • Medium draper speed • Center delivery Fantail ������� The stalks are crossed in the center and the heads are in line along outside edges. This windrow can be formed by center delivery only. Fair Fair Fair • Low draper speed • Low header angle • Center delivery Dovetail ������� The stalks are lined along outside edges of windrow and heads are crossed in center. This windrow can be formed by center delivery only. Poor Fair Poor • High draper speed • High header angle • Center delivery Parallel ������� The stalks are parallel to windrow and heads are evenly distributed across width of windrow. This windrow can be formed by center delivery or end delivery. Good Good Good • Medium draper speed • Medium header angle • Center or end delivery OPERATION

Windrow Types (continued)

Windrow Type Description Weight Distribution Curing Weatherability Machine Setting Guidelines 45° diagonal ������� The stalks are lined along one edge and heads are lined along opposite edge, 45° to windrow perpendicular. This windrow can be formed by end delivery or by center delivery if the crop is leaning to one side. Poor Fair Poor • Low reel speed • Less aggressive tine pitch • If crop is leaning, end delivery or center delivery 75° diagonal ������� The stalks are closer to parallel than the 45° windrow. Stalk tips are lined along one edge with heads opposite, 75° to windrow perpendicular. This windrow can be formed by end delivery or by center delivery if the crop is leaning to one side. Fair Good Fair • Low reel speed • Less aggressive tine pitch • If crop is leaning, end delivery or center delivery OPERATION

Refer to the following tips to optimize haying.

3.11.1 Curing Curing crops quickly helps maintain the highest quality because for each day that hay lies on the ground, 5% of the protein is lost. Leaving the windrow as wide and fluffy as possible results in the quickest curing. Cured hay should be baled as soon as possible. 3.11.2 Topsoil Moisture Topsoil moisture levels can be classified as wet, damp, or dry. Table 3.17 Topsoil Moisture Levels Level % Moisture Condition Wet Over 45% Soil is muddy Damp 25–45% Shows footprints Dry Under 25% Surface is dusty • On wet soil, the general rule of wide and thin does not apply. A narrower windrow will dry faster than hay left flat on wet ground. • When the ground is wetter than the hay, moisture from the soil is absorbed by the hay above it. Determine topsoil moisture level before cutting. Use a moisture tester or estimate level. • If ground is wet due to irrigation, wait until soil moisture drops below 45%. • If ground is wet due to frequent rains, cut when weather allows and let the forage lie on wet ground until it dries to the moisture level of the ground. • Cut hay will dry only to the moisture level of the ground beneath it, so consider moving the windrow to drier ground. 3.11.3 Weather and Topography Weather conditions and topography can greatly affect haying. • Cut as much hay as possible by midday when drying conditions are best. • Fields sloping south get up to 100% more exposure to the sun’s heat than do north-sloping fields. If hay is baled and chopped, consider baling the south-facing fields and chopping those facing north. • When relative humidity is high, the evaporation rate is low and hay dries slowly. • If there is no wind, saturated air becomes trapped around the windrow. Raking or tedding will expose the hay to fresh, less saturated air. • Cut hay perpendicular to the direction of the prevailing winds if possible. 3.11.4 Windrow Characteristics Producing windrows with the recommended characteristics will achieve the greatest results. Refer to 3.7 Header Operating Variables, page 58 for instructions on adjusting the header. OPERATION

Table 3.18 Recommended Windrow Characteristics

Characteristic Advantage High and fluffy Enables airflow through windrow which is more important to the curing process than direct sunlight Consistent formation (not bunching) Permits an even flow of material into the baler, chopper, etc. Even distribution of material across windrow Results in even and consistent bales to minimize handling and stacking problems Properly conditioned Prevents excessive leaf damage 3.11.5 Driving on Windrow Driving on previously cut windrows that will not be raked can extend drying time by a full day. If practical, set the forming shields to produce a narrower windrow that the machine can straddle. NOTE: Driving on the windrow in high-yield crops may be unavoidable if a full width windrow is necessary. 3.11.6 Raking and Tedding Raking or tedding speeds up drying; however, the resulting leaf loss may outweigh the benefits. There is little or no advantage to raking or tedding if the ground beneath the windrow is dry. Large windrows on damp or wet ground should be turned over when moisture levels reach 40–50%. Hay should not be raked or tedded at moisture levels below 25% or excessive yield loss will result. 3.11.7 Using Chemical Drying Agents Hay-drying agents work by removing wax from legume surfaces and allows water to escape and evaporate faster. However, treated hay lying on wet ground will absorb ground moisture faster. Before deciding to use a drying agent, carefully compare the relative costs and benefits for your area. OPERATION

Levelling the Header

The windrower linkages are factory-set to provide the proper level for the header and should not normally require adjustment. NOTE: The float springs are NOT used to level the header. If the header is not level, check the pressure of the windrower’s tires to ensure proper inflation (refer to your windrower operator’s manual). If the windrower’s tires are properly inflated and the header is still not level, adjust the windrower linkages as required (refer to the appropriate section in the windrower operator’s manual). OPERATION

Unplugging the Cutterbar

The cutterbar is located on the front of the header. It supports the knife and guards which are used to cut the crop. DANGER To prevent bodily injury or death from the unexpected start-up or fall of a raised machine, always stop the engine and remove the key before leaving the operator’s seat, and always engage the safety props before going under the machine for any reason. WARNING Wear heavy gloves when working around or handling knives. IMPORTANT: Lowering a rotating reel on a plugged cutterbar will damage the reel components. To unplug the cutterbar, reverse the windrower. If the cutterbar is still plugged, do the following: 1. Stop the forward movement of the machine and disengage the header drives. 2. Raise the header to prevent it from filling with dirt, and engage the header drive clutch. 3. If the plug does NOT clear, disengage the header drive clutch and fully raise the header. 4. Shut down the engine, and remove the key from the ignition. 5. Engage the header’s safety props. 6. Clean off the cutterbar by hand. NOTE: If cutterbar plugging persists, refer to 8 Troubleshooting, page 259. OPERATION

Upper Cross Auger

The upper cross auger (UCA) (A) improves delivery of very bulky crops across the header. ������� � Figure 3.57: Upper Cross Auger The UCA is available as an optional kit. For more information, refer to 6.4.3 Upper Cross Auger, page 253. NOTE: Optional wide draper deflectors are NOT compatible with the UCA. OPERATION

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