MacDon D1XL Series User manual

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

D1 XL-Series Draper Header for Self-Propelled Windrowers
Published: April 2016

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 iRevision A

TABLE OF CONTENTS
Introduction...................................................................................................................................... i
1 Safety.................................................................................................................................................... 1
1.1 Signal Words................................................................................................................................... 1
1.2 General Safety ................................................................................................................................ 2
1.3 Safety Signs.................................................................................................................................... 4
2 Unloading Header.................................................................................................................................. 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..................................................................................................9
2.3 Removing Shipping Supports ......................................................................................................... 13
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
3.3.1 Hydraulic Link without Self-Alignment Kit ................................................................................. 23
3.3.2 Hydraulic Link with Optional Self-Alignment Kit......................................................................... 27
3.4 Connecting Hydraulics................................................................................................................... 33
4 Assembling the Header....................................................................................................................... 37
4.1 Attaching Reel Lift Cylinders........................................................................................................... 37
4.2 Installing Disc Segments of Outboard Reel Endshields..................................................................... 45
4.3 Attaching Cam Arms...................................................................................................................... 46
4.4 Installing Crop Dividers .................................................................................................................. 47
4.5 Positioning Transport Lights ........................................................................................................... 49
4.6 Installing Options........................................................................................................................... 50
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 Checking and Adjusting Knife Drive Belt Tension............................................................................. 57
5.4.1 Tensioning Non-Timed Knife Drive Belts .................................................................................. 57
5.4.2 Tensioning Timed Knife Drive Belts.......................................................................................... 58
5.4.3 Tensioning Timed Knife Drive V-Belts ...................................................................................... 60
5.5 Centering the Reel......................................................................................................................... 61
5.5.1 Centering Double Reels.......................................................................................................... 61
5.5.2 Centering Single Reels........................................................................................................... 62
5.6 Adjusting Draper Tension ............................................................................................................... 63
5.7 Checking and Adjusting Draper Seal...............................................................................................65
5.8 Checking and Adjusting Skid Shoe Settings .................................................................................... 67
5.9 Levelling the Header...................................................................................................................... 68
5.10 Measuring and Adjusting Reel Clearance to Cutterbar ..................................................................... 69
5.10.1 Measuring Reel Clearance...................................................................................................... 69
5.10.2 Adjusting Reel Clearance ....................................................................................................... 71
5.11 Checking and Adjusting Endshields................................................................................................ 72
5.12 Lubricating the Header................................................................................................................... 75
5.12.1 Greasing Procedure ............................................................................................................... 75
5.12.2 Lubrication Points................................................................................................................... 77
5.13 Checking Manuals......................................................................................................................... 79
6 Running up the Header ....................................................................................................................... 81
7 Performing Post Run-Up Adjustments................................................................................................83
7.1 Adjusting Knife .............................................................................................................................. 83
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TABLE OF CONTENTS
8 Reference............................................................................................................................................ 85
8.1 Torque Specifications..................................................................................................................... 85
8.1.1 Metric Bolt Specifications........................................................................................................ 85
8.1.2 Metric Bolt Specifications Bolting into Cast Aluminum............................................................... 88
8.1.3 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
8.1.7 Tapered Pipe Thread Fittings ..................................................................................................95
8.2 Lifting Equipment Requirements..................................................................................................... 96
8.3 Conversion Chart........................................................................................................................... 97
8.4 Definitions..................................................................................................................................... 98
Predelivery Checklist ....................................................................................................................101
214017 iv Revision A

1Safety
1.1 Signal Words
Three signal words, DANGER,WARNING,andCAUTION, 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
Indicatesapo
tentially hazardous situation that, if not avoided, could result in death or serious injury. It
mayalsobeuse
d 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.
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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 the protective clothing and personal safety
devices that could be necessary for the job at hand.
Don’t 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 1.1: 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 against objectionable or loud noises.
Figure 1.2: Safety Equipment
•Provideafirst aid kit for use in case of emergencies.
•Keepafire extinguisher on the machine. Be sure the
fire extinguisher is properly maintained. Be familiar with
its proper use.
• Keep young children away from the machinery at
all times.
• Be aware that accidents often happen when the
Operator is tired or in a hurry. Take the time to
consider the safest way. Never ignore the warning
signs of fatigue.
Figure 1.3: Safety Equipment
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SAFETY
•Wearclose-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 the shaft and can telescope freely.
• Use only service and repair parts made or approved by
the equipment manufacturer. Substituted parts may not
meet strength, design, or safety requirements.
Figure 1.4: 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.
•DoNOT modify the machine. Non-authorized
modifications may impair machine function and/or
safety. It may also shorten 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.
Figure 1.5: Safety around Equipment
• Keep the 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 1.6: Safety around Equipment
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SAFETY
1.3 Safety Signs
• Keep safety signs clean and legible at all times.
• Replace 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 available from MacDon Parts.
Figure 1.7: Operator’s Manual Decal
214017 4Revision A

2 Unloading Header
Perform all procedures in this chapter in the order in which 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 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 forklift distributor.
Table 2.1 Lifting Vehicle
Minimum Lifting
Capacity
7000 lb. (3178 kg)
load center (A) at
48 in. (1220 mm) (B)
from back of forks
Minimum Fork
Length (C)
78 in. (1981 mm)
Figure 2.1: Minimum Lifting Capacity
A - Center of Gravity of the Load
B - Load Center 48 in. (1220 mm) from Back of Forks
C - Minimum Fork Length 78 in. (1981 mm)
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 HEADER
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
opposite 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, damage to the headers
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. Back up until unit clears trailer and slowly lower to 6 in.
(150 mm) from ground.
Figure 2.2: Header Shipping Supports
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.
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UNLOADING HEADER
2.2 Lowering Header
The procedure for lowering the header from the trailer 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 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. Approach header from its underside and place forks
under top of shipping frame (A).
3. Attach a chain (B) at each end of frame and secure
other end to lifting vehicle.
Figure 2.3: Shipping Frame
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UNLOADING HEADER
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 2.4: Lowering the Header
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UNLOADING HEADER
5. Place 6 in. (150 mm) 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.
Figure 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 header onto stand.
Figure 2.6: Header Stand
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.
Figure 2.7: Lift Location
214017 9Revision A

UNLOADING HEADER
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 2.8: Shipping Support
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UNLOADING HEADER
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 HEADER
5. Place 6 in. (150 mm) 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.
Figure 2.10: Block at One End of Cutterbar
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.
11. Remove chain.
Figure 2.11: Header Stand
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UNLOADING HEADER
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 reinstallation.
Figure 2.12: Straps, Draper Header Supports,
and Shipping Supports
2. Single reel only: Cut banding (A) securing reel to
cutterbar and backtube.
Figure 2.13: Single Reel
3. Remove four bolts (A) securing upper support (B) to
header legs and remove support.
Figure 2.14: Upper Support
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UNLOADING HEADER
4. Remove six bolts (A) securing lower support (B) to
header legs and remove support.
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-rotation brace (A) from between reel
and endsheet.
Figure 2.17: Anti-Rotation Brace
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