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MacDon D1XL Series, Assembly Instructions Manual

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1

Safety

1.1

Signal Words

Three signal words,

DANGER

,

WARNING

, and

CAUTION

, are used to alert you to hazardous situations. The

appropriate signal word for each situation has been 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.

214017

1

Revision A

Summary of Contents for D1XL Series

Page 1: ...The harvesting specialists D1 XL Series Draper Header for Windrowers Unloading and Assembly Instructions North America 214017 Revision A 2016 Model Year Original Instruction...

Page 2: ...D1 XL Series Draper Header for Self Propelled Windrowers Published April 2016...

Page 3: ...tomers carefully follow the unload and assembly procedure from the beginning through to completion Some sections steps apply to multiple header configurations and sizes Refer to the instructions for y...

Page 4: ......

Page 5: ...0 4 7 Adding Tire Ballast 51 5 Performing Predelivery Checks 53 5 1 Checking Tire Pressure Transport and Stabilizer Wheels 53 5 2 Checking Wheel Bolt Torque 54 5 3 Checking Knife Drive Box 55 5 4 Chec...

Page 6: ...3 Flare Type Hydraulic Fittings 88 8 1 4 O Ring Boss ORB Hydraulic Fittings Adjustable 90 8 1 5 O Ring Boss ORB Hydraulic Fittings Non Adjustable 92 8 1 6 O Ring Face Seal ORFS Hydraulic Fittings 93 8...

Page 7: ...mminently hazardous situation that if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation that if not avoided could result in death or serious injury...

Page 8: ...er mask Figure 1 1 Safety Equipment Be aware that exposure to loud noises can cause hearing impairment or loss Wear suitable hearing protection devices such as ear muffs or ear plugs to help protect a...

Page 9: ...ten the machine s life To avoid bodily injury or death from unexpected startup of machine always shut down the engine and remove the key from ignition before leaving operator s seat for any reason Fig...

Page 10: ...e safety signs that are missing or become illegible If original parts on which a safety sign was installed are replaced be sure the repair part also bears the current safety sign Safety signs are avai...

Page 11: ...or machine damage IMPORTANT Forklifts are normally rated with the load centered 24 in 610 mm from the back end of forks To obtain forklift capacity for a load centered at 48 in 1220 mm check with your...

Page 12: ...rs may occur 4 Remove hauler s tie down straps chains and wooden blocks 5 Slowly raise header off trailer deck WARNING Be sure forks are secure before moving away from load Stand clear when lifting 6...

Page 13: ...Reel Header page 7 2 2 2 Lowering Double Reel Header page 9 2 2 1 Lowering Single Reel Header Reposition header in preparation for assembly and setup as follows 1 Choose an area with level ground 2 Ap...

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

Page 15: ...igure 2 5 Block at One End of Cutterbar 8 Lower header stand by pulling pin A lowering stand B and releasing pin A to secure stand in place 9 If ground is soft place a block under the stand 10 Lower h...

Page 16: ...tach a chain to shipping support A at center reel arm IMPORTANT Do NOT lift header at this location This procedure is only for laying the machine over into working position Figure 2 8 Shipping Support...

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

Page 18: ...Attach chain to center link anchor on frame tube and raise rear of header so that stand can be lowered Figure 2 10 Block at One End of Cutterbar 8 Lower the header stand pull pin A lower stand B and...

Page 19: ...ts A from shipping support Set draper header supports aside for reinstallation Figure 2 12 Straps Draper Header Supports and Shipping Supports 2 Single reel only Cut banding A securing reel to cutterb...

Page 20: ...Figure 2 15 Lower Support 5 Remove the four bolts A from the shipping stands at both outboard header legs and remove the shipping stands Figure 2 16 Outer Leg Shipping Supports 6 Remove reel anti rota...

Page 21: ...osen the two nuts B securing the shipping support to the endsheet 9 Slide shipping support C backward to remove 10 Tighten nuts B Figure 2 18 11 At the right hand side of the header loosen the two nut...

Page 22: ......

Page 23: ...m weighs approximately 120 lb 54 kg NOTE Hydraulic hoses were removed from the illustrations in this procedure to show clarity 1 Cut and remove the wire A securing the hydraulic hose management arm B...

Page 24: ...uts D from the plate support E 6 Retain bolts and nuts for use later Figure 3 3 Hydraulic Hose Management Arm Base Frame 7 30 35 Foot Headers With the sling supporting the hose management arm A remove...

Page 25: ...orting the hose management arm cut and remove the wire A that secure it to channel latch on top of header frame tube Figure 3 5 9 With the help of the sling position the hose management arm A as shown...

Page 26: ...shipping support B and reinstall the two bolts on the same location on the coupler holder to secure the hose cover Figure 3 8 Hose Management Arm Shipping Support Bracket 30 35 Foot Headers 13 Cut th...

Page 27: ...A Figure 3 10 Latch Support Assembly 16 Align the bolts A on the latch support assembly B to the holes on the support channel C of the windrower s outer leg and secure with the three nuts removed ear...

Page 28: ...hairpin and clevis pin B from the draper header support A Figure 3 12 Draper Header Support 2 Position the draper header support B on lift linkage A and reinstall clevis pin C NOTE To avoid catching t...

Page 29: ...y injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Stop windrower engine and remov...

Page 30: ...springs tension is fully released Figure 3 16 Float Springs 5 In the windrower cab press scroll knob A on Harvest Performance Tracker HPT to highlight QUICK MENU options 6 Rotate scroll knob A to high...

Page 31: ...ILT UP A and HEADER TILT DOWN B cylinder switches on the ground speed lever GSL to extend or retract center link cylinder until the hook is aligned with the header attachment pin 11 Stop engine and re...

Page 32: ...release and lower safety prop onto cylinder b Repeat for opposite lift cylinder IMPORTANT Ensure the safety props engage over cylinder piston rods If safety prop does not engage properly raise header...

Page 33: ...d press HEADER DOWN switch A on GSL to fully lower header 22 Stop engine and remove key Figure 3 26 GSL 3 3 2 Hydraulic Link with Optional Self Alignment Kit The following connection procedure applies...

Page 34: ...linkages when lowering header lift legs without a header or weight box attached to the windrower ensure the float springs tension is fully released Figure 3 28 Header Float Springs 4 In the windrower...

Page 35: ...t pin on the header IMPORTANT If the center link is too low it may contact the header as the windrower approaches the header for hookup Figure 3 31 GSL 9 Drive the windrower slowly forward until the d...

Page 36: ...C must be down to enable self locking mechanism If the release is open up manually push it down after hook engages header pin 12 Lower center link A onto the header with REEL DOWN switch on the GSL un...

Page 37: ...3 36 Cylinder Safety Prop 17 Install pin B through the header leg engaging U bracket in draper header support on both sides and secure with a hairpin A 18 Raise header stand D to storage position by...

Page 38: ...TO WINDROWER CAUTION Check to be sure all bystanders have cleared the area 21 Start engine and press HEADER DOWN switch A on GSL to fully lower header 22 Stop engine and remove key Figure 3 39 GSL 214...

Page 39: ...forward side of windrower Figure 3 40 Hydraulic Hose Management Arm 2 Connect hydraulic hose management arm A to windrower by securing the ball joint B on arm into the latch support C on windrower Fi...

Page 40: ...receptacles and secure by turning collar on electrical connector clockwise Figure 3 43 Draper Reel Multicoupler 9 Retrieve knife and reel drive multicoupler A from hose management arm 10 Push knob B...

Page 41: ...ATTACHING HEADER TO WINDROWER 14 Ensure hydraulic hose routing is as straight as possible and avoids potential rub wear points Figure 3 46 Hydraulic Multicouplers and Hose Routing 214017 35 Revision A...

Page 42: ......

Page 43: ...Attaching Reel Lift Cylinders CAUTION Bolts A with tags on reel arms keep the reel from sliding forward Ensure fore aft cylinders are attached before removing bolts Figure 4 1 Right Reel Arm Parts Rem...

Page 44: ...from the reel lift cylinder Figure 4 3 Reel Tube 3 Lift reel and remove two top bolts A on outboard reel arm supports Repeat for opposite side Figure 4 4 Outboard Reel Arm Support 4 Double reel heade...

Page 45: ...ine up with the lug on endsheet and the hole in the reel arm 7 Secure cylinder to endsheet and reel arm with pins as shown Insert cotter pin A OUTBOARD at reel arm Insert cotter pin B INBOARD at endsh...

Page 46: ...Remove socket head bolt and nut from cylinder rod end 13 Double reel only Attach rod end of cylinder to reel arm with socket head bolt and nut A Access hardware through holes in reel arm braces 14 Do...

Page 47: ...line up with the lug on endsheet and the hole in the reel arm 21 Secure cylinder to endsheet and reel arm with pins as shown Insert cotter pin A OUTBOARD at reel arm Insert cotter pin B INBOARD at end...

Page 48: ...ge center reel arm shipping support B from cutterbar and remove shipping support Figure 4 13 Center Reel Arm Shipping Support 24 Remove bolts A from reel arm support at endsheet and remove support Rep...

Page 49: ...HEADER 25 Remove brace bolts and tags A locking the reel fore aft position at outer reel arms Figure 4 15 Right Reel Arm Top Image Single Reel Bottom Image Double Reel Figure 4 16 Left Reel Arm 214017...

Page 50: ...uble reel only Remove the remaining three bolts A locking the reel fore aft position at the center reel arm and remove shipping channel B Figure 4 17 Center Reel Arm Shipping Channel Double Reel Heade...

Page 51: ...Endshield Cam End Shown Tail End Similar 2 Remove the two bolts A securing the disc segments to support tabs Retain for reinstallation later 3 Engage slots on disc segment B on endshield support tabs...

Page 52: ...s and endshields Figure 4 22 Hardware Bag Right Hand Reel 4 Rotate tine bar crank A and position link B so attachment holes in bar crank are aligned with hole in link 5 Install bolt C in link and posi...

Page 53: ...C to the bracket storage 2 Remove divider rods C from the bracket storage D and set aside for installation later 3 Return lock tab to its original position and tighten bolt B Figure 4 24 Crop Divider...

Page 54: ...n tip of crop divider as shown and tighten bolt A Figure 4 28 Divider Rod on Crop Divider 9 Check that divider does NOT move laterally Adjust bolts A as required to tighten divider and remove lateral...

Page 55: ...ADER 4 5 Positioning Transport Lights Transport lights are located on each of the outboard reel arms 1 Position lights A perpendicular to header Figure 4 30 Transport Light Perpendicular to Header 214...

Page 56: ...ASSEMBLING THE HEADER 4 6 Installing Options Retrieve the kits supplied as options with the header and install them according to the instructions supplied with each kit 214017 50 Revision A...

Page 57: ...377 Table 4 2 Recommended Ballast Recommended Ballast Level Ground Hills Header Size Rec Tire Size Per Tire U S Gal liters Both Tires lb kg 2 Per Tire U S Gal liters Both Tires lb kg 30 ft Single Reel...

Page 58: ......

Page 59: ...he final checks as listed on the Predelivery Checklist yellow sheet attached to this instruction Predelivery Checklist page 101 to ensure the machine is field ready Refer to the following pages for de...

Page 60: ...m the following procedure to ensure that transport and stabilizer wheel bolts are correctly torqued 1 Check wheel bolt torque is 80 90 ft lbf 110 120 N m Refer to bolt tightening sequence illustration...

Page 61: ...gine and remove key before making adjustments to machine 1 Press down the latch in the opening A on the inboard side of the endsheet 2 Pull endshield open using handle depression B Figure 5 2 Endshiel...

Page 62: ...ng normal operation Failure to do so can result in damage to the knife drive box 4 Check position of plug A and breather B at knife drive box Position MUST be as shown 5 Check oil level It should be b...

Page 63: ...hine IMPORTANT To prolong the belt and drive life do NOT overtighten the belt 1 Open the endshield 2 Loosen the two bolts A securing the motor assembly to the header endsheet 3 Turn the adjuster bolt...

Page 64: ...ORTANT Do NOT use the adjuster bolt at the drive pulley to adjust timing belt tension 1 Open the endshield 2 Loosen hex nuts A enough to allow the idler pulleys B to pivot Figure 5 7 LH Knife Drive 3...

Page 65: ...o the belt Figure 5 10 LH Knife Drive 7 Ensure there is a clearance of 0 10 0 14 in 2 5 3 5 mm between the lower belt A and lower guide B 8 If necessary loosen the three bolts C and adjust lower guide...

Page 66: ...2 Turn drawbolt B clockwise to tighten or counterclockwise to loosen belts C tension NOTE Tension is checked at mid span of the belts The belts should deflect 5 32 in 4 mm with 12 17 lbf 52 77 N of f...

Page 67: ...Reels page 62 5 5 1 Centering Double Reels 1 Measure clearances at locations A between reels and both endsheets The clearances should be the same if the reels are centered If not centered continue on...

Page 68: ...e if the reel is centered If not centered continue on the next step Figure 5 15 Single Reel Measurement Locations 2 Loosen bolt A on the brace B at both ends of the reel 3 Move the forward end of the...

Page 69: ...ep the draper from sagging below the cutterbar 1 Ensure the white indicator bar A is at the halfway point in the window WARNING Check to be sure all bystanders have cleared the area 2 Start the engine...

Page 70: ...e window 7 Turn the adjuster bolt A clockwise to tighten The white indicator bar B will move inboard in the direction of arrow E to indicate that the draper is tightening Tighten until the white indic...

Page 71: ...gap of 1 8 in 3 mm between the top of deck front track and cutterbar If deck height is acceptable skip the remaining steps and proceed to 5 8 Checking and Adjusting Skid Shoe Settings page 67 If deck...

Page 72: ...C to lower deck relative to supports and achieve the recommended setting Tap support B using a punch to raise deck relative to supports 6 Tighten deck support hardware A 7 Tension drapers Refer to 5 6...

Page 73: ...efore working under header or reel 1 Note the adjustment hole positions on the lugs A on each skid shoe They should be the same 2 If necessary adjust skid shoe as follows a Remove lynch pin B b Hold s...

Page 74: ...1 If the header is not level check the pressure of the windrower s tires to ensure they are properly inflated refer to your windrower s operator s manual 2 If the header is still not level adjust the...

Page 75: ...2 Finger to Guard Cutterbar Clearance X 1 8 in 3 mm at Reel Ends Header Width Single Reel Double Reel 30 ft 1 3 4 in 45 mm 35 ft 2 3 8 in 60 mm 40 ft 45 ft 3 4 in 20 mm Figure 5 27 Finger Clearance 5...

Page 76: ...reel flexing 6 Check all possible points of contact between points B and C Depending on the reel fore aft position minimum clearance can result at the guard tine hold down or cutterbar 7 Adjust the re...

Page 77: ...ance to cutterbar or turn cylinder rod into clevis to lower reel and decrease clearance c Tighten bolt A d Repeat at opposite side Figure 5 32 Outside Reel Arm 3 For Double Reel Only Adjust center arm...

Page 78: ...Temperatures page 72 Table 5 3 Endshield Gap at Various Temperatures Temperature in Degrees F C Gap X in Inches mm 25 4 1 1 10 28 45 7 1 24 65 18 13 16 20 85 29 5 8 16 105 41 1 2 12 125 52 5 16 8 145...

Page 79: ...l the endshield free of hinge tab A if additional clearance is required and swing shield towards the rear of the header 6 Engage safety catch B on hinge arm to secure the shield in fully open position...

Page 80: ...bolts A on latch assembly 11 Tighten the four bolts on the support tube bracket 12 Close endshield Figure 5 39 LH Endshield Latch Assembly Closing the endshield 13 Disengage lock B to allow endshield...

Page 81: ...reme pressure EP performance with 10 max molybdenum disulphide NLGI Grade 2 lithium base Driveline slip joints 5 12 1 Greasing Procedure Greasing points are marked on the machine by decals showing a g...

Page 82: ...eave excess grease on fitting to keep out dirt 4 Replace any loose or broken fittings immediately 5 Remove and thoroughly clean any fitting that will not take grease Also clean lubricant passageway Re...

Page 83: ...only 1 2 pumps of grease with a grease gun or just until the knifehead starts to move away from the arm Do NOT use an electric grease gun If more than 6 8 pumps of the grease gun are required to fill...

Page 84: ...aking grease OVERGREASING WILL DAMAGE U JOINT Six to eight pumps is sufficient at first grease factory As U joint wears and requires more than six pumps grease the joint more often Figure 5 45 Reel Sh...

Page 85: ...the cable tie on the manual case Figure 5 46 Manual Case 2 Confirm that the case contains the following manuals D1 XL Series Draper Header for Self Propelled Windrowers Operator s Manual D1 XL Series...

Page 86: ......

Page 87: ...y 1 Start the windrower and run header for 5 minutes watching and listening FROM THE OPERATOR S SEAT for binding or interfering parts NOTE Reels and drapers will not operate until oil flow fills the l...

Page 88: ......

Page 89: ...ath from unexpected startup of machine always stop engine and remove key before making adjustments to machine 1 Stop engine and remove the key 2 Check guards for signs of heating during run up due to...

Page 90: ...PERFORMING POST RUN UP ADJUSTMENTS 5 Adjust guard tips downward by positioning tool as shown and pushing down Figure 7 3 Guard Tips Downward Adjustment 214017 84 Revision A...

Page 91: ...tightness of bolts Understand torque categories for bolts and cap screws by using their identifying head markings 8 1 1 Metric Bolt Specifications Table 8 1 Metric Class 8 8 Bolts and Class 9 Free Spi...

Page 92: ...6 2 0 119 132 161 178 20 2 5 233 257 314 347 24 3 0 402 444 543 600 Figure 8 2 Bolt Grades Table 8 3 Metric Class 10 9 Bolts and Class 10 Free Spinning Nut Torque ft lbf in lbf Torque N m Nominal Size...

Page 93: ...ize A Min Max Min Max 3 0 5 12 13 1 3 1 5 3 5 0 6 19 21 2 1 2 3 4 0 7 28 31 3 1 3 4 5 0 8 56 62 6 3 7 6 1 0 95 105 10 7 11 8 8 1 25 19 21 26 29 10 1 5 38 42 51 57 12 1 75 66 73 90 99 14 2 0 106 117 14...

Page 94: ...for defects that might cause leakage 2 Align tube C with fitting D and thread nut E onto fitting without lubrication until contact has been made between the flared surfaces 3 Torque the fitting nut E...

Page 95: ...20 14 15 19 21 2 2 6 9 16 18 22 24 30 33 2 1 1 2 8 3 4 16 42 46 57 63 2 1 1 2 10 7 8 14 60 66 81 89 1 1 2 1 1 2 12 1 1 16 12 83 91 113 124 1 1 2 1 1 4 14 1 3 16 12 100 110 136 149 1 1 2 1 1 4 16 1 5 1...

Page 96: ...the threads and adjust if necessary 4 Apply hydraulic system oil to the O ring A Figure 8 7 Hydraulic Fitting 5 Install fitting B into port until back up washer D and O ring A contact the part face E...

Page 97: ...7 16 20 14 15 19 21 5 1 2 20 15 24 21 33 6 9 16 18 19 21 26 29 8 3 4 16 34 37 46 50 10 7 8 14 55 60 75 82 12 1 1 16 12 88 97 120 132 14 1 3 8 12 113 124 153 168 16 1 5 16 12 130 142 176 193 20 1 5 8...

Page 98: ...6 Check the final condition of the fitting Figure 8 9 Hydraulic Fitting Table 8 8 O Ring Boss ORB Hydraulic Fittings Non Adjustable Torque Value5 SAE Dash Size Thread Size in ft lbf in lbf N m 2 5 16...

Page 99: ...C comes in full contact with O ring B 4 Thread tube or hose nut D until hand tight The nut should turn freely until it is bottomed out 5 Torque fittings according to the values in Table 8 9 O Ring Fac...

Page 100: ...3 8 29 32 40 44 8 13 16 1 2 41 45 55 61 10 1 5 8 59 65 80 88 12 1 3 16 3 4 85 94 115 127 14 Note7 7 8 16 1 7 16 1 111 122 150 165 20 1 11 16 1 1 4 151 167 205 226 24 1 2 1 1 2 232 256 315 347 32 2 1 2...

Page 101: ...ways finish alignment of fitting in the tightening direction Never back off loosen pipe threaded connectors to achieve alignment 5 Clean all residue and any excess thread conditioner with the appropri...

Page 102: ...s are normally rated for a load center 24 in 610 mm ahead of back end of the forks To obtain the forklift capacity for a load center A at 48 in 1220 mm B check with your forklift distributor The minim...

Page 103: ...00689 megapascals MPa Pressure pounds per square inch psi 14 5038 bar Non SI bar pound feet or foot pounds ft lbf x 1 3558 Newton meters N m Torque pound inches or inch pounds in lbf x 0 1129 Newton...

Page 104: ...ion typical outside North America Finger tight Finger tight is a reference position where sealing surfaces or components are making contact with each other and the fitting has been tightened to a poin...

Page 105: ...n one of the mating parts SDD Single draper drive Self Propelled SP Windrower Self propelled machine consisting of a power unit with a header SK Single knife SKD Single knife drive Soft joint A joint...

Page 106: ...driven knives from a single hydraulic motor or two hydraulic motors Washer A thin cylinder with a hole or slot located in the center that is to be used as a spacer load distribution element or a locki...

Page 107: ...ng Knife Drive Box page 55 Check knife drive box lube level 5 3 Checking Knife Drive Box page 55 Check knife drive belt s tension 5 4 Checking and Adjusting Knife Drive Belt Tension page 57 Check if r...

Page 108: ...Tension page 57 Check knife sections for discoloration caused by misaligned components 7 1 Adjusting Knife page 83 Check for hot spots on the cutterbar above the draper seal Adjust deck height as requ...

Page 109: ......

Page 110: ...04 885 5590 f 204 832 7749 MacDon Inc 10708 N Pomona Avenue Kansas City Missouri United States 64153 1924 t 816 891 7313 f 816 891 7323 MacDon Australia Pty Ltd A C N 079 393 721 P O Box 243 Suite 3 1...

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