MacDon D1X Series, D1XL Series, D130XL, D115X, D135XL Unloading And Assembly Instructions

...
D1X and D1XL Series
Draper Header
Unloading and Assembly Instructions (North America)
214778 Revision A
Original Instruction
The harvesting specialists.
D1XL Draper Header for Self-Propelled Windrowers
Published: September 2018

Introduction

This instruction manual describes the unloading, setup, and predelivery requirements for the MacDon D1X and D1XL Series Draper Headers 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.
NOTE:
Keep your MacDon publications up-to-date. The latest version can be downloaded from our website (www.macdon.com)or from our Dealer portal (https://portal.macdon.com) (login required).
This document is currently available in English only.
214778 i Revision A

List of Revisions

Summary of Change Refer To
Updated illustrations to include outer leg shipping supports on 4.6–7.6 m (15–25 ft.) headers as well as 9.1–12.2 m (30– 40 ft.) headers.
2.3 Removing Shipping Supports, page 13
Included information regarding installing hose management arm on 4.6 m (15 ft.) D1X headers.
Added note about quick-disconnect couplers/hard plumb connections for M1 Series.
Increased detail, illustrations for topic. 4.1 Positioning Transport Lights, page 31
Included information regarding 9-bat reel arm shipping configuration.
Included additional D1X header sizes to table. 4.7 Adding Ballast, page 47
Added illustration. 5.13 Checking Manuals, page 75
3.1 Installing the Hydraulic Hose Management Arm, page 17
3.4 Connecting Hydraulics, page 28
4.4 Attaching Cam Arms, page 42
214778 ii Revision A
TABLE OF CONTENTS
Introduction ................................................................................................................................................i
List of Revisions...........................................................................................................................................ii
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Signal Words .........................................................................................................................................1
1.2 General Safety .......................................................................................................................................2
1.3 Safety Signs ...........................................................................................................................................4
Chapter 2: Unloading.................................................................................................................................. 5
2.1 Unloading Header from Trailer..................................................................................................................5
2.2 Lowering Header ....................................................................................................................................7
2.2.1 Lowering Single-Reel Header..... .......................................................................................................7
2.2.2 Lowering Double-Reel Header ........................................................................................................ 10
2.3 Removing Shipping Supports .................................................................................................................. 13
Chapter 3: Attaching Header to Windrower ........................................................................................... 17
3.1 Installing the Hydraulic Hose Management Arm ......................................................................................... 17
3.2 Attaching Draper Header Supports .......................................................................................................... 22
3.3 Connecting Center-Link.......................................................................................................................... 23
3.4 Connecting Hydraulics ........................................................................................................................... 28
Chapter 4: Assembling the Header .......................................................................................................... 31
4.1 Positioning Transport Lights ................................................................................................................... 31
4.2 Attaching Reel Lift Cylinders ................................................................................................................... 33
4.3 Installing Disc Segments of Outboard Reel Endshields ................................................................................. 41
4.4 Attaching Cam Arms ............................................................................................................................. 42
4.5 Installing Crop Dividers .......................................................................................................................... 44
4.6 Installing Options ................................................................................................................................. 46
4.7 Adding Ballast ...................................................................................................................................... 47
Chapter 5: Performing Predelivery Checks.............................................................................................. 49
5.1 Checking Tire Pressure – Transport and Stabilizer Wheels ............................................................................ 49
5.2 Checking Wheel Bolt Torque................................................................................................................... 50
5.3 Checking Knife Drive Box ... .................................................................................................................... 51
5.4 Checking and Adjusting Knife Drive Belt Tension ..... . .................................................................................. 53
5.4.1 Checking and Tensioning ............................................................................................................... 53
5.4.2 Tensioning Timed Knife Drive Belts ................................................................................................. 54
5.4.3 Tensioning Timed Knife Drive V-Belts............................................................................................... 56
5.5 Centering the Reel ................................................................................................................................ 57
5.5.1 Centering Double Reels ................................................................................................................. 57
5.5.2 Centering Single Reel .................................................................................................................... 58
5.6 Adjusting Draper Tension ....................................................................................................................... 59
214778 iii Revision A
TABLE OF CONTENTS
5.7 Checking and Adjusting Draper Seal ......................................................................................................... 61
5.8 Checking and Adjusting Skid Shoe Settings ................................................................................................ 63
5.9 Leveling the Header .............................................................................................................................. 64
5.10 Measuring and Adjusting Reel Clearance to Cutterbar ............................................................................... 65
5.10.1 Measuring Reel Clearance............................................................................................................ 65
5.10.2 Adjusting Reel Clearance ............................................................................................................. 67
5.11 Checking and Adjusting Endshields......................................................................................................... 68
5.12 Lubricating the Header . ....................................................................................................................... 72
5.12.1 Greasing Procedure .................................................................................................................... 72
5.12.2 Lubrication Points ...................................................................................................................... 73
5.13 Checking Manuals............................................................................................................................... 75
Chapter 6: Running up the Header .......................................................................................................... 77
Chapter 7: Performing Post Run-Up Adjustments .................................................................................. 79
7.1 Adjusting Knife ..................................................................................................................................... 79
Chapter 8: Reference................................................................................................................................ 81
8.1 Torque Specifications ............................................................................................................................ 81
8.1.1 SAE Bolt Torque Specifications ....................................................................................................... 81
8.1.2 Metric Bolt Specifications .............................................................................................................. 83
8.1.3 Metric Bolt Specifications Bolting into Cast Aluminum ........................................................................ 85
8.1.4 Flare-Type Hydraulic Fittings ..... ..................................................................................................... 86
8.1.5 O-Ring Boss (ORB) Hydraulic Fittings – Adjustable .............................................................................. 87
8.1.6 O-Ring Boss (ORB) Hydraulic Fittings – Non-Adjustable ....................................................................... 89
8.1.7 O-Ring Face Seal (ORFS) Hydraulic Fittings ........................................................................................ 90
8.1.8 Tapered Pipe Thread Fittings.......................................................................................................... 92
8.2 Lifting Equipment Requirements ............................................................................................................. 93
8.3 Conversion Chart .................................................................................................................................. 94
8.4 Definitions .......................................................................................................................................... 95
Predelivery Checklist ................................................................................................................................ 99
214778 iv Revision A

Chapter 1: Safety

1.1 Signal Words

Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words, IMPORTANT and NOTE identify non-safety related information. Signal words are selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be used to alert against unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may be used to alert against unsafe practices.
IMPORTANT:
Indicates a situation that, if not avoided, could result in a malfunction or damage to the machine.
NOTE:
Provides additional non-essential information or advice.
214778 1 Revision A
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1000005
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SAFETY

1.2 General Safety

CAUTION
The following are general farm safety precautions that should be part of your operating procedure for all types of machinery.
Protect yourself.
When assembling, operating, and servicing machinery, wear all protective clothing and personal safety devices that could be necessary for 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
Be aware that exposure to loud noises can cause hearing
impairment or loss. Wear suitable hearing protection devices such as earmuffs or earplugs to help protect against loud noises.
Provide a first aid kit for use in case of emergencies.
Keep a fire extinguisher on the machine. Be sure fire
extinguisher is properly maintained. Be familiar with its proper use.
Figure 1.1: Safety Equipment
Figure 1.2: Safety Equipment
Keep young children away from machinery at all times.
Be aware that accidents often happen when Operator is tired
or in a hurry. Take time to consider safest way. NEVER ignore warning signs of fatigue.
Figure 1.3: Safety Equipment
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1000008
1000009
SAFETY
Wear close-fitting clothing and cover long hair. NEVER wear
dangling items such as scarves or bracelets.
Keep all shields in place. NEVER alter or remove safety
equipment. Make sure driveline guards can rotate independently of shaft and can telescope freely.
Use only service and repair parts made or approved by equipment manufacturer. Substituted parts may not meet strength, design, or safety requirements.
Keep hands, feet, clothing, and hair away from moving parts. NEVER attempt to clear obstructions or objects from a machine while engine is running.
Do NOT modify machine. Unauthorized modifications may impair machine function and/or safety. It may also shorten machines life.
Figure 1.4: Safety around Equipment
To avoid bodily injury or death from unexpected startup of machine, ALWAYS stop the engine and remove the key from the ignition before leaving the operators seat for any reason.
Keep service area clean and dry. Wet or oily floors are slippery. Wet spots can be dangerous when working with electrical equipment. Be sure all electrical outlets and tools are properly grounded.
Keep work area well lit.
Keep machinery clean. Straw and chaff on a hot engine is a
fire hazard. Do NOT allow oil or grease to accumulate on service platforms, ladders, or controls. Clean machines before storage.
NEVER use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or flammable.
When storing machinery, cover sharp or extending components to prevent injury from accidental contact.
Figure 1.5: Safety around Equipment
Figure 1.6: Safety around Equipment
214778 3 Revision A

1.3 Safety Signs

1000694
Keep safety signs clean and legible at all times.
Replace safety signs that are missing or illegible.
If original part on which a safety sign was installed is
replaced, be sure the repair part displays the current safety sign.
Safety signs are available from your MacDon Dealer.
SAFETY
Figure 1.7: Operators Manual Decal
214778 4 Revision A

Chapter 2: Unloading

1013855
A
B
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Perform all procedures in this chapter in the order they are listed.

2.1 Unloading Header from Trailer

The following procedure assumes that two headers were shipped on the trailer.
CAUTION
To avoid injury to bystanders from being struck by machinery, do not allow people to stand in unloading area.
CAUTION
Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment may result in chain breakage, vehicle tipping, or machine damage.
IMPORTANT:
Forklifts are normally rated with the load centered 610 mm (24 in.) from the back end of forks. To obtain forklift capacity for a load centered at 1220 mm (48 in.), check with your forklift distributor.
Table 2.1 Lifting Vehicle
3178 kg (7000 lb.) load center

Minimum Lifting Capacity

(A) at 1220 mm (48 in.) (B)
from back of forks
Minimum Fork Length (C) 1981 mm (78 in.)
Figure 2.1: Minimum Lifting Capacity
A - Load Center of Gravity B - Load Center 1220 mm (48 in.) from Back of Forks C - Minimum Fork Length 1981 mm (78 in.)
To unload headers from a trailer, follow these steps:
1. Move trailer into position and block trailer wheels.
2. Lower trailer storage stands.
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UNLOADING
3. Approach one of the headers and slide forks (A) underneath the shipping support (B) as far as possible without contacting the shipping support of second header (C).
IMPORTANT:
Avoid lifting the second header and ensure the forks do not interfere with the shipping frame. If the forks contact the second header, the header could be damaged.
4. Remove haulers 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. Back up until header clears trailer and slowly lower to 150 mm (6 in.) from ground.
7. Take header to the storage or setup area. Ensure ground is flat and free of rocks or debris that could damage the header.
8. Repeat above steps for second header.
9. Check for shipping damage and missing parts.
Figure 2.2: Header Shipping Supports
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UNLOADING

2.2 Lowering Header

The procedure for lowering the header varies depending on whether the header has a single or double reel. Refer to the following:
2.2.1 Lowering Single-Reel Header, page 7
2.2.2 Lowering Double-Reel Header, page 10

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. Approach header from its underside and place forks under top of shipping frame (A).
3. Attach a chain (B) at each end of the shipping frame and secure other end to lifting vehicle.
Figure 2.3: Shipping Frame
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2
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CAUTION
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.
UNLOADING
Figure 2.4: Lowering the Header
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UNLOADING
5. Place 150 mm (6 in.) blocks (A) under each end and center of cutterbar, and then lower header onto blocks.
6. Remove chain and move lifting vehicle to rear of header.
7. Attach chain to center-link anchor on frame tube and raise rear of header so that stand can be lowered.
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 header onto stand.
Figure 2.5: Block under Cutterbar
Figure 2.6: Header Stand
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UNLOADING

2.2.2 Lowering Double-Reel Header

Reposition header in preparation for assembly and setup as follows:
1. Choose an area with level ground.
2. Drive lifting vehicle to approach header from its underside.
3. Attach 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 2.7: Underside of Header
Figure 2.8: Shipping Support
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2
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UNLOADING
CAUTION
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 Header
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UNLOADING
5. Place 150 mm (6 in.) blocks (A) under each end and center of cutterbar, and then lower header onto blocks.
6. Remove chain and move lifting vehicle to rear of header.
7. Attach chain to center-link anchor on frame tube and raise rear of header so that stand can be lowered.
8. Lower the header stand: pull pin (A), lower stand (B), and release pin (A) to secure stand in place.
9. If ground is soft, place a block under the stand.
10. Lower header onto stand.
Figure 2.10: Block under Cutterbar
11. Remove chain.
Figure 2.11: Header Stand
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UNLOADING

2.3 Removing Shipping Supports

NOTE:
Unless otherwise specified, discard all shipping materials and hardware.
1. Cut straps and remove draper header supports (A) from shipping support. Set draper header supports aside for installation.
Figure 2.12: Draper Header Supports and Shipping Supports
2. Single reel only: Cut banding (A) securing reel to cutterbar and backtube.
3. Remove four bolts (A) securing upper support (B) to header legs and remove support.
Figure 2.13: Single Reel
Figure 2.14: Upper Support
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UNLOADING
4. Remove six bolts (A) securing lower support (B) to header legs and remove support.
5. Remove the four bolts (A) from the shipping stands at both outboard header legs and remove the shipping stands.
Figure 2.15: Lower Support
Figure 2.16: Outer Leg Shipping Support – 9.1–12.2 m (30–40 ft.)
Figure 2.17: Outer Leg Shipping Support – 4.6–7.6 m (15–25 ft.)
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UNLOADING
6. Remove reel anti-rotation brace (A) from between reel and endsheet.
7. At the left side of the header, cut and remove the wire (A) securing the endshield to the panel. Repeat at the opposite side.
8. Loosen the three nuts (B) securing the shipping support to the endsheet.
Figure 2.18: Anti-Rotation Brace
9. Slide shipping support (C) backward to remove.
10. Tighten nuts (B).
11. At the right side of the header, loosen the two nuts (A) securing the shipping support (B) to the endsheet.
12. Slide shipping support (B) backward to remove.
13. Tighten nuts (A).
Figure 2.19: Endsheet Shipping Support
Figure 2.20: Endsheet Shipping Support
214778 15 Revision A

Chapter 3: Attaching Header to Windrower

1024555
A
B
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Perform all the procedures in this chapter in the order in which they are listed.

3.1 Installing the Hydraulic Hose Management Arm

The hydraulic hose management arm should be properly installed from shipping position to working position. Lifting equipment is required to complete this task; the hydraulic hose management arm weighs approximately 54 kg (120 lb.).
1. Disconnect harness connector (A) from the headers coupler holder (B).
NOTE:
The harness connector must be disconnected from the header prior to moving the hose management arm to field position.
Figure 3.1: Hoses and Connector Attached to the Header
2. Cut and remove the wire (A) securing the hydraulic hose management arm (B) to the diagonal brace (C).
Figure 3.2: Hydraulic Hose Management Arm
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C
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ATTACHING HEADER TO WINDROWER
NOTE:
Hydraulic hoses were removed from the illustrations in this procedure for clarity.
3. Position a sling (A) between the gas spring cylinder (B) and secure around the support arm (C).
NOTE:
Illustration shows hydraulic hose management arm in shipping position for a 7.6–10.6 m (25–35 ft.) header.
4. Attach sling (A) to forklift or lifting device.
5. 4.6 m (15 ft.) and 6.1 m (20 ft.) Headers: With the sling attached to the lifting device and supporting the hose management arm (A), lift the hydraulic hose management arm (A) out of the inboard shipping stand (B) and remove the two bolts and nuts (C) securing shipping stand (B) to center anchor (D). Retain hardware.
Figure 3.3: Hydraulic Hose Management Arm in Shipping Position
NOTE:
Sling not shown in illustration.
6. 7.6–10.6 m (25–35 ft.) Headers: Remove the two bolts and nuts (A) securing the base of the hose management arm (B) to the frame channel (C). Retain bolts and nuts for use later.
7. Remove the other two bolts and nuts (D) from the shipping plate (E). Retain bolts and nuts for use later. Discard shipping plate (E).
Figure 3.4: Hydraulic Hose Management Arm In Shipping Position – 4.6 m (15 ft.) and 6.1 m (20 ft.) Headers
214778 18 Revision A
Figure 3.5: Hydraulic Hose Management Arm Base Frame – 7.6–10.6 m (25– 35 ft.) Headers
1027044
A
B
B
B
B
C
D
D
E
E
C
1020181
A
C
B
ATTACHING HEADER TO WINDROWER
8. 4.6 m (15 ft.) and 6.1 m (20 ft.) Headers: With the sling
attached to the lifting device and supporting the hose management arm (A), remove the two bolts and nuts (B) securing the hose management arm to outboard shipping support (C). Retain hardware.
NOTE:
Sling not shown in illustration.
9. Remove bolts and nuts (D) securing shipping support (C) to the frame channel (E). Discard shipping support (C).
10. 7.6–10.6 m (25–35 ft.) Headers: With the sling attached to the lifting device and supporting the hose management arm (A), remove the two bolts and nuts (B) that secure the hose management arm to the shipping support (C).
Figure 3.6: Hydraulic Hose Management Arm In Shipping Position – 4.6 m (15 ft.) and 6.1 m (20 ft.) Headers
Figure 3.7: Hydraulic Hose Management Arm in Shipping Position – 7.6–10.6 m (25–35 ft.) Headers
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ATTACHING HEADER TO WINDROWER
11. 12.2–13.7 m (40–45 ft.) Headers: With the sling attached to
the lifting device and supporting the hose management arm, cut and remove the wire (A) that secures the hose management arm to channel latch on top of header frame tube.
12. With the help of the sling and lifting device, position the hose management arm (A) as shown.
NOTE:
Sling not shown in illustration.
Figure 3.8: Hose Management Arm in Shipping Position – 12.2–13.7 m (40–45 ft.) Headers
Figure 3.9: Hose Management Arm in Field Position
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B
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B
A
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ATTACHING HEADER TO WINDROWER
13. Secure the plate support (A) to the frame channel (B) using the four bolts and nuts previously removed.
14. Remove sling from the hose management arm.
15. 7.6–10.6 m (25–35 ft.) Headers: Remove the two bolts (A) and shipping support (B) from the coupler holder (C). Discard shipping support (B) and reinstall the two bolts at the same location on the coupler holder to secure the hose cover.
Figure 3.10: Hose Management Arm Plate Support
Figure 3.11: Hose Management Arm Shipping Support Bracket – 7.6–10.6 m (25–35 ft.) Headers
16. Connect harness connector (C) to the bulkhead on the headers coupler holder.
17. Cut the cable tie securing the hoses in position (A), and secure the hoses with the strap (B) bolted on the frame.
IMPORTANT:
Note the routing of the hoses in the hose management arm field position shown at right.
Figure 3.12: Hose Management Arm Hose Routing (Top View)
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ATTACHING HEADER TO WINDROWER

3.2 Attaching Draper Header Supports

WARNING
To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operators seat for any reason.
1. Retrieve header draper supports removed from shipping supports in Step 1, page 13.
2. Remove hairpin and clevis pin (B) from the draper header support (A).
3. Position the draper header support (B) on lift linkage (A), and reinstall clevis pin (C).
NOTE:
To avoid pin snagging the windrow, install the clevis pin on the outboard side of the draper header support.
4. Secure clevis pin (C) with hairpin (D).
5. Repeat for opposite lift linkage.
Figure 3.13: Draper Header Support
Figure 3.14: Draper Header Support
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ATTACHING HEADER TO WINDROWER

3.3 Connecting Center-Link

WARNING
To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operators seat for any reason.
1. Stop the engine and remove the key.
2. Hydraulic Center-Link without Self-Alignment: Relocate
pin (A) in frame linkage as required to raise the center­link (B) until the hook is above the attachment 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.
3. Remove hairpin (A) from pin (B), and remove pin (B) from header leg. Repeat on the opposite header leg.
CAUTION
Check to be sure all bystanders have cleared the area.
4. Start engine.
CAUTION
When lowering header lift legs without a header or weight box attached to the windrower, ensure the float springs tension is fully released to prevent damage to the header lift linkages.
NOTE:
If not prompted by the Harvest Performance Tracker (HPT) display to remove float, remove float manually by doing the following:
Figure 3.15: Center-Link without Self-Alignment
Figure 3.16: Header Leg
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Figure 3.17: Header Float Springs
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B
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C
D
E
F
ATTACHING HEADER TO WINDROWER
5. In the windrower cab, press scroll knob (A) on HPT to display the QuickMenu system.
6. Rotate scroll knob (A) to highlight the HEADER FLOAT symbol (B), and press scroll knob to select.
7. On Float Adjust page, press soft key 3 (A) to remove float.
Figure 3.18: HPT Display
8. Self-Aligning Hydraulic Center-Link:
a. Press HEADER DOWN switch on the ground speed lever
(GSL) to fully retract header lift cylinders.
b. Press REEL UP switch on the GSL to raise the center-link
until the hook is above the attachment 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 3.19: HPT Display
Figure 3.20: GSL Switches
A - Reel Down B - Reel Up C - Header Tilt Down D - Header Tilt Up E - Header Down F - Header Up
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