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Introduction

This instruction manual describes the unloading, setup, and predelivery requirements for the MacDon D1 XL-Series
Draper Header for Self-Propelled Windrowers.

To ensure the best performance of this product and the safety of your customers, carefully follow the unload and
assembly procedure from the beginning through to completion.

Some sections/steps apply to multiple header configurations and sizes. Refer to the instructions for your specific
header.

Carefully read all the material provided before attempting to unload, assemble, or use the machine.

Retain this instruction for future reference.

This instruction is available in the English language only.

214017

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Revision A

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Содержание D1XL Series

Страница 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...

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

Страница 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...

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 22: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 58: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 86: ......

Страница 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...

Страница 88: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 109: ......

Страница 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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