MacDon A40D Unloading And Assembly Instructions
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MacDon A40D Unloading And Assembly Instructions

Self-propelled windrower auger header
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Download this manual See also: Operator's Manual
A40D and A40DX
Self-Propelled Windrower Auger Header
Unloading and Assembly Instructions
214805 Revision A
Original Instruction
The harvesting specialists.

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Summary of Contents for MacDon A40D

  • Page 1 A40D and A40DX Self-Propelled Windrower Auger Header Unloading and Assembly Instructions 214805 Revision A Original Instruction The harvesting specialists.
  • Page 2 A40D Self-Propelled Windrower Auger Header Published October 2018...
  • Page 3 Introduction This instructional manual describes the unloading, setup, and predelivery requirements for the MacDon A40D and A40DX Self-Propelled Windrower Auger Headers, including a Grass Seed version for both models. Refer to the Table of Contents and follow the provided procedures in the order given.
  • Page 4 3.8 Installing and Adjusting Pan Extensions, page 17 Updated illustration and procedure steps. 3.9 Adjusting Transport Lights, page 19 Added reference to A40D SP Grass Seed Auger Conversion 3.13 Attaching A40DX Header to M1 Series Windrowers, kit (MD #B6384). page 45 Added content specific to A40DX GSS headers and A40DX 3.13 Attaching A40DX Header to M1 Series Windrowers,...

  • Page 5: Table Of Contents

    3.16 Routing Reverser Valve Jumper Hose – M Series ..................62 3.17 Hydraulic Drive Hose Routing – M Series Windrowers ................63 3.17.1 Hydraulic Drive Hose Routing – A40D and M Series Windrowers............63 3.18 Hydraulic Drive Hose Routing – M1 Series Windrowers................68 3.18.1 Hydraulic Drive Hose Routing –...
  • Page 6 TABLE OF CONTENTS 3.18.2 Hydraulic Drive Hose Routing (A40DX GSS and M1 Series Windrowers)..........70 3.19 Repositioning Knife Drive Box Breather....................73 Chapter 4: Lubricating the Machine ......................75 4.1 Greasing Procedure ..........................75 4.2 Lubrication Points – Left Side of Header ....................76 4.3 Lubrication Points –...
  • Page 7 TABLE OF CONTENTS 6.1.7 O-Ring Face Seal Hydraulic Fittings....................114 6.1.8 Tapered Pipe Thread Fittings......................116 6.2 Conversion Chart..........................117 6.3 Definitions ............................118 Predelivery Checklist ..........................121 214805 Revision A...

  • Page 9: Chapter 1: Safety

    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.

  • Page 10: General Safety

    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.
  • Page 11 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. •...

  • Page 12: Safety Signs

    • 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. Figure 1.7: Operator’s Manual Decal 214805 Revision A...

  • Page 13: Chapter 2: Unloading The Machine

    Chapter 2: Unloading the Machine Follow each procedure in this chapter in order. 2.1 Unloading the Header CAUTION To avoid injury to bystanders from being struck by machinery, do NOT allow anyone 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, machine damage or bodily harm to operators or bystanders.

  • Page 14: Unloading The Header From A Truck Flatbed

    UNLOADING THE MACHINE 2.1.1 Unloading the Header from a Truck Flatbed IMPORTANT: Do NOT unload using lean bar for lifting. Chain hook slots in lean bar are only for laying the machine over into working position after it is on the ground. NOTE: Take care not to bend parts on backtube.

  • Page 15: Chapter 3: Assembling The Machine

    Chapter 3: Assembling the Machine Once all unloading procedures have been completed, it is time to set up the machine. Follow each procedure in this chapter in order. 3.1 Removing Underside Shipping Stand CAUTION Keep feet clear when removing final bolts. 1.

  • Page 16: Installing Skid Shoes

    ASSEMBLING THE MACHINE 3.2 Installing Skid Shoes If the Skid Shoes kit is NOT supplied, proceed to 3.3 Installing Gauge Rollers, page 9. Otherwise, proceed as follows: NOTE: This kit may be installed later in the header assembly sequence, but it may be easier prior to laying the header down. 1.

  • Page 17: Installing Gauge Rollers

    ASSEMBLING THE MACHINE 3.3 Installing Gauge Rollers If the Gauge Rollers kit is NOT supplied, proceed to 3.4 Lowering the Header, page 11. Otherwise, proceed as follows. NOTE: This kit may be installed later in the header assembly sequence, but it may be easier prior to laying the header down. 1.
  • Page 18 ASSEMBLING THE MACHINE 8. Remove locking pin (A) and adjust rollers to desired height. Reinstall both locking pins (A). 9. Ensure that nut (B) on each pin registers in adjacent hole in support bracket. 10. Secure pins with hairpins (C). 11.

  • Page 19: Lowering The Header

    ASSEMBLING THE MACHINE 3.4 Lowering the Header To lower the header to the ground, follow these steps: 1. Attach either a spreader bar or chain to forks. CAUTION Ensure spreader bar or chain is secured to the forks so that it cannot slide off the forks or towards the mast as the header is lowered to the ground.
  • Page 20 ASSEMBLING THE MACHINE NOTE: Do NOT lift at lean bar when unloading from trailer. This procedure is only for laying the machine over into working position. 4. Raise forks until lift chains are fully tensioned. 1008870 Figure 3.10: Header with Crane A - 1.2 m (48 in.) Minimum 5.
  • Page 21 ASSEMBLING THE MACHINE 7. Attach chain to center-link anchor (A) on frame tube and raise rear of header approximately 305 mm (12 in.) off the ground. Figure 3.12: Center-Link Anchor 8. Remove lynch pin from clevis pin (A) in header stand at right side of header.

  • Page 22: Removing Shipping Stands

    1. Remove bolts (A) from shipping stands (B) at right and left sides of header. NOTE: For A40D headers only: Discard hardware (A) from right and left side shipping stands. NOTE: For A40DX headers only: Discard hardware (A) from right side shipping stand.

  • Page 23: Installing Tall Crop Divider Kit

    ASSEMBLING THE MACHINE 3.6 Installing Tall Crop Divider Kit If the Tall Crop Divider kit is NOT supplied, proceed to 3.7 Adjusting Lean Bar, page 16. Otherwise, proceed as follows: 1. Unpack kit and disassemble hardware from divider. NOTE: If tall crop extension angles are not required, proceed to Step 5, page 2.

  • Page 24: Adjusting Lean Bar

    ASSEMBLING THE MACHINE 3.7 Adjusting Lean Bar The lean bar is fully retracted for shipping. Adjust as follows: NOTE: If optional tall crop divider kit is supplied, it can be installed prior to reinstalling the lean bar. Refer to 3.6 Installing Tall Crop Divider Kit, page 1.

  • Page 25: Installing And Adjusting Pan Extensions

    ASSEMBLING THE MACHINE 3.8 Installing and Adjusting Pan Extensions To install the pan extensions, do the following: 1. Remove deflectors (A) from their shipping positions on the header and unwrap. Figure 3.21: Shipping Configuration 2. Remove nut and bolt (A), nut and washers (B), and nuts (C) from the pan extension.
  • Page 26 ASSEMBLING THE MACHINE 3. Install left side deflector (A) using nuts and bolts (B) and nut, bolt, and five washers (C) retained from the previous step. Torque all nuts to 11.5 Nm (102 lbf·in). NOTE: Do NOT install nut (D) if the pan extension’s width will be adjusted.

  • Page 27: Adjusting Transport Lights

    ASSEMBLING THE MACHINE 3.9 Adjusting Transport Lights 1. Position amber light support (A) perpendicular to the header. 2. Check that pivot bolt (B) is tight enough to hold light support (A) in upright position, yet allows the light to pivot out of the way of obstructions.

  • Page 28: Assembling Forming Shield

    ASSEMBLING THE MACHINE 3.10 Assembling Forming Shield 1. Unpack and remove shipping material. 2. Remove bolts (A) from side deflectors (B). 1022367 Figure 3.27: Forming Shield in Shipping Configuration 3. Install rubber strap (A) to side bracket (B) using bolt (C), washer (D), and nut (E).
  • Page 29 ASSEMBLING THE MACHINE 7. Assemble side deflectors (C) to cover with bolt (B), jam nut (E), washer (D), and nut (A) from previous step. 8. Tighten flange nut (A) enough to hold deflectors (C) in position, but still allow deflectors to move. 9.
  • Page 30 ASSEMBLING THE MACHINE 12. Invert forming shield to installation position as shown. Figure 3.32: Forming Shield in Installation Position 214805 Revision A...

  • Page 31: Installing Forming Shield

    ASSEMBLING THE MACHINE 3.11 Installing Forming Shield NOTE: Do NOT install the two triangular-shaped plates from the forming shield kit. Triangular plates are used with rotary headers. Figure 3.33: Triangular Plate 1. Install bolt (A) with spacer (B) and nut on each windrower leg in the upper hole.
  • Page 32 ASSEMBLING THE MACHINE 3. Position forming shield (A) under windrower frame. Figure 3.36: Forming Shield under Windrower 4. Position forming shield onto bolts (A) in windrower legs and secure with clevis pins (B) and hairpin. Figure 3.37: Forming Shield Attached to Windrower Legs 214805 Revision A...
  • Page 33 ASSEMBLING THE MACHINE 5. Lift aft end of the forming shield and attach straps (B) to pins (A) on the windrower frame. Install washer and hairpin to secure strap. Use the middle hole and adjust height to suit the crop. Figure 3.38: Forming Shield Attached to Windrower Frame 6.

  • Page 34: Attaching A40D Headers To M Series Sp Windrowers

    M150, M155, M155E4, and M200 Windrowers with M Series Reverser kit (MD #B4656) installed need to have the reverser valve hose plumbing changed if switching between a D Series Draper Header with a conditioner to an A40D Auger Header. Changing this plumbing prevents improper operation and damaging the reel drive motor.
  • Page 35 ASSEMBLING THE MACHINE 1. Disengage rubber latch (A) and open driveline shield (B). Figure 3.41: Driveline Shield 2. Remove cap (A) from the electrical connector and remove the connector from the support bracket. 3. Disengage and rotate lever (B) counterclockwise to fully up position to release the hose bundle (C).
  • Page 36 NOTE: Hoses attached to connectors not shown in illustrations at right. Figure 3.44: A40D Header – 4.3 m and 4.9 m (14 ft. and 16 ft.) Header Shown (5.5 m [18 ft.] Header Similar) A - Reel Pressure...
  • Page 37 ASSEMBLING THE MACHINE 11. Route auger return and reel pressure hose bundle (A) from header to windrower, and position bundle above existing hose support (C) as shown. 12. Secure with three straps (D), and lower lever (B). Figure 3.46: Auger Return and Reel Pressure Hose Bundle 13.
  • Page 38 B - Auger Motor 16. For procedure to change hose routing for M100 or M105 3.17.1 Hydraulic Drive Hose Routing – Windrowers, refer to A40D and M Series Windrowers, page Figure 3.51: Modified Routing M100, M105, and M205 214805 Revision A...

  • Page 39: Attaching A40D To M150, M155, Or M155E4

    ASSEMBLING THE MACHINE 3.12.2 Attaching A40D to M150, M155, or M155E4 CAUTION To prevent accidental movement of windrower, return ground speed lever (GSL) to Park, center steering wheel to lock, shut off engine, and remove key. M150, M155, and M155E4 self-propelled windrowers are factory-equipped with four header drive hoses (A) on the left side.
  • Page 40 NOTE: Hoses attached to connectors not shown in illustrations at right. Figure 3.56: A40D Header – 4.3 m and 4.9 m (14 ft. and 16 ft.) Header Shown (5.5 m [18 ft.] Header Similar) A - Reel Pressure...
  • Page 41 ASSEMBLING THE MACHINE Figure 3.57: Grass Seed Header Hose Connectors A - Reel and Auger Pressure B - Knife and Conditioner Return C - Case Drain D - Knife and Conditioner Pressure 11. Route auger return and reel pressure hose bundle (A) from header to windrower and position bundle above existing hose support (C) as shown.
  • Page 42 ASSEMBLING THE MACHINE Figure 3.60: M150/M155/M155E4 without Reverser Valve 14. Locate the auger pressure (A) and auger/reel return (B) hoses. Figure 3.61: Auger Pressure and Auger/Reel Return Hose Couplers – 4.3 m and 4.9 m (14 ft. and 16 ft.) Header Shown (5.5 m [18 ft.] Header Similar) 15.
  • Page 43 ASSEMBLING THE MACHINE Figure 3.63: M150/M155/M155E4 without Reverser Valve 214805 Revision A...

  • Page 44: Attaching A40D To M200

    Figure 3.64: Drive Hoses If only three drive hoses are present, before following the procedure below, configure the M200 to run an A40D Auger Header by installing kit MD #B4651. The kit includes an additional hose (A), hardware, and installation instructions.
  • Page 45 NOTE: Hoses attached to connectors not shown in illustrations at right. Figure 3.69: A40D Header – 4.3 m and 4.9 m (14 ft. and 16 ft.) Header Shown (5.5 m [18 ft.] Header Similar) A - Reel Pressure...
  • Page 46 ASSEMBLING THE MACHINE Figure 3.70: Grass Seed Header Hose Connectors A - Reel and Auger Pressure B - Knife and Conditioner Return C - Case Drain D - Knife and Conditioner Pressure 11. Route auger return and reel pressure hose bundle (A) from header to windrower, and position bundle above existing hose support (C) as shown.
  • Page 47 ASSEMBLING THE MACHINE Figure 3.73: M200 without Reverser Valve 14. Locate the auger pressure (A) and auger/reel return (B) hoses. Figure 3.74: Auger Pressure and Auger/Reel Return Hose Couplers – 4.3 m and 4.9 m (14 ft. and 16 ft.) Header Shown (5.5 m [18 ft.] Header Similar) 15.
  • Page 48 ASSEMBLING THE MACHINE Figure 3.76: M200 without Reverser Valve 3.16 Routing Reverser Valve Jumper Hose – M Series, page 16. Proceed to 214805 Revision A...

  • Page 49: Attaching A40D To M205

    1. Disengage rubber latch (A), and open driveline shield (B). Figure 3.78: Driveline Shield 2. Reverser kit is optional and not required, although most A40D Headers have a Reverser kit (MD #B5492) ordered for the windrower. Install prior to hook-up if required.
  • Page 50 NOTE: Hoses attached to connectors not shown in illustrations at right. Figure 3.81: A40D Header – 4.3 m and 4.9 m (14 ft. and 16 ft.) Header Shown (5.5 m [18 ft.] Header Similar) A - Reel Pressure...
  • Page 51 ASSEMBLING THE MACHINE Figure 3.82: Grass Seed Header Hose Connectors A - Reel and Auger Pressure B - Knife and Conditioner Return C - Case Drain D - Knife and Conditioner Pressure 11. Route auger return and reel pressure hose bundle (A) from header to windrower, and position bundle above existing hose support (C) as shown.
  • Page 52 B - Auger Motor 15. For the procedure to change hose routing for M205 3.17.1 Hydraulic Drive Hose Routing – windrowers, refer to A40D and M Series Windrowers, page Figure 3.86: Modified Routing M100, M105, and M205 214805 Revision A...

  • Page 53: Attaching A40Dx Header To M1 Series Windrowers

    This procedure is for A Series Headers equipped with the Auger Header Compatibility kit (MD# B5998) or the A40D SP Grass Seed Auger Conversion kit (MD #B6384). Kits B5998 and B6384 include a new manifold and hose bundle required for operation with an M1 Series Windrower, and effectively convert an A40D header into an A40DX header.
  • Page 54 ASSEMBLING THE MACHINE 3. If attaching to a disc-ready windrower, ensure knife drive hose (A) is connected to coupler (B). NOTE: Hose (A) provides power to run the knife/conditioner. 1022401 Figure 3.89: M1170/M1240 – Disc Header Configured NOTE: M1170 Windrowers with standard auger/draper configuration don’t require the knife drive hose;...
  • Page 55 ASSEMBLING THE MACHINE 9. Remove cover from receptacle (A) and connect electrical harness from header. Figure 3.92: Windrower Electrical Connector A40DX GSS headers and A40DX headers equipped with Reel Speed Control kit (MD #B6604) A40DX GSS headers have a factory-installed reel speed kit and includes a second electrical connection required for attaching to an M1 Series windrower.

  • Page 56: Modifying Hydraulics - A40D

    ASSEMBLING THE MACHINE 3.14 Modifying Hydraulics – A40D The windrower hydraulics must be modified to work correctly with an A40D Auger Header. Follow the instructions in the relevant section for your windrower model: • 3.14.1 Modifying Hydraulics – M100, M105, page 48 •...
  • Page 57 ASSEMBLING THE MACHINE 4. Remove and discard cap (C) and adapter fitting (B) with O-ring from the large coupler (A). Figure 3.96: Large Coupler Assembly 5. Install large coupler (A) onto the fitting at port R1 on valve block (B). IMPORTANT: Make sure the O-ring is on JIC threads in port R1 to ensure a proper seal with coupler (A).

  • Page 58: Modifying Hydraulics - M150, M155, M155E4

    ASSEMBLING THE MACHINE 7. Install small coupler subassembly (A) onto tee (B) on valve block (C). NOTE: Position of adjacent hoses may require slight adjustment to allow access for new hoses. Figure 3.99: Valve Block Configured for Auger Header 3.14.2 Modifying Hydraulics – M150, M155, M155E4 1.
  • Page 59 ASSEMBLING THE MACHINE 3. Remove female coupler assemblies (A) and (B) from hoses in bundle (C) from header, and remove caps. Figure 3.102: Header Hose Bundle 4. Install smaller coupler assembly (C) in port R2 on valve block (A) and the larger coupler assembly (D) in port R2 on valve block (B).

  • Page 60: Modifying Hydraulics - M200 With Reverser Valve

    For windrowers with Reverser kit (MD #B4656), to prevent draper header reel damage and improper operation, hose plumbing to reverser valve must be changed to suit the header type if switching between A40D Auger Header and draper header. Refer to kit installation instruction for proper plumbing procedures for each header type.

  • Page 61: Modifying Hydraulics - M200 Without Reverser Valve

    ASSEMBLING THE MACHINE 4. Install smaller coupler assembly (C) in port R2 on valve block (A) and the larger coupler assembly (D) in port R2 on valve block (B). NOTE: Position of adjacent hoses may require slight adjustment to allow access for new hoses. Align larger coupler assembly (D) with R1 hose (E).
  • Page 62 ASSEMBLING THE MACHINE 3. Remove female coupler assemblies (A) and (B) from hoses in bundle (C) from header. Figure 3.109: Header Hose Bundle 4. Remove and discard cap (A) and adapter fitting (B) (including O-ring) from the large coupler (C). Figure 3.110: Large Coupler Assembly 5.

  • Page 63: Modifying Hydraulics - M205

    3.14.5 Modifying Hydraulics – M205 The M205 hydraulics need to be modified to accept an A40D Auger Header. Kits MD #B5491, MD #B5492, and MD #B5497 should have been supplied with your header. If required, these kits can be ordered from your MacDon Dealer.

  • Page 64: Attaching Hydraulics - M Series

    ASSEMBLING THE MACHINE 3.15 Attaching Hydraulics – M Series WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason. 1. Disengage rubber latch (A) and open driveline shield (B). Figure 3.113: Driveline Shield 2.
  • Page 65 ASSEMBLING THE MACHINE 6. Route hoses (A) from the windrower through support (B) and access hole (C) in the header frame alongside hose bundle (D). NOTE: Hose bundle (D) will be attached later in the procedure. 7. Remove the cover on header electrical receptacle (E). 8.
  • Page 66 ASSEMBLING THE MACHINE • Reel/auger pressure (A) • Knife and conditioner return (B) • Case drain (C) • Knife and conditioner pressure (D) Figure 3.119: Hose Connections on Standard Header – 5.4 m (18 ft.) Header Shown • Knife return (male fitting not visible) (A) •...
  • Page 67 ASSEMBLING THE MACHINE 12. If not already installed, retrieve the package of three adjustable straps shipped with the header. 13. Position adjustable strap (A) through the slot and under bracket (B) on the hose support. 14. Attach the strap to the bracket with 1/2 in. carriage bolt (C) and locking nut.
  • Page 68 ASSEMBLING THE MACHINE 18. Connect the auger/reel pressure and reel/auger return hoses from the header to the receptacles on the windrower valve block. Refer to the relevant illustration for your equipment. Figure 3.123: M100/M105 A - Reel/Auger Return B - Auger/Reel Pressure Figure 3.124: M150/M155/M155E4 with Reverser Valve A - Auger Pressure...
  • Page 69 ASSEMBLING THE MACHINE Figure 3.126: M200 with Reverser Valve A - Auger Pressure B - Reel/Auger Return Figure 3.127: M200 without Reverser Valve A - Auger Pressure B - Reel/Auger Return Figure 3.128: M205 A - Reel/Auger Return B - Auger/Reel Pressure 214805 Revision A...

  • Page 70: Routing Reverser Valve Jumper Hose - M Series

    2. Route jumper hose (B) from C2 conveyor circuit (C) to port CR on reverser block (A) as shown. Figure 3.129: Jumper Hose Position – A40D on M200 Shown (M150, M155, and M155E4 Similar) IMPORTANT: For draper headers, port CR is routed to port R4 (as shown in image at right) on reverser block.

  • Page 71: Hydraulic Drive Hose Routing - M Series Windrowers

    IMPORTANT: If attempting to attach an A40D Header to an M1170 or M1240 Windrower, the M1 Series Conversion kit (MD #B5998) or the A40D SP Grass Seed Auger Conversion kit (MD #B6384) must first be installed. These kits include a new manifold and hydraulic hose bundle required for operation with an M1 Series Windrower, and effectively converts an A40D header into an A40DX header.
  • Page 72 ASSEMBLING THE MACHINE 2. Disengage rubber latch (A), and open driveline shield (B). Figure 3.132: Driveline Shield 3. Loosen bulkhead nut (A) on auger and reel pressure coupler (B). This allows auger and reel pressure hose (C) to rotate freely. Figure 3.133: Auger and Reel Pressure Coupler and Hose –...
  • Page 73 ASSEMBLING THE MACHINE Hydraulic hose connections: 4. Disconnect hoses as follows: Disconnect hose (A) from tee (B). b. Disconnect tee (B) from the reel motor upper port. Disconnect hose (C) from the reel motor lower port. 5. Cut cable ties (D) at locations shown in illustration. Figure 3.135: Factory Configuration –...
  • Page 74 ASSEMBLING THE MACHINE Electrical harness routing: 7. Secure electrical harness (B), motor case drain hose (C), and hose (D) together with cable ties (A), as shown. IMPORTANT: Ensure there is at least 25 mm (1 in.) clearance between hose bundle (E) and knife drive timing belt (F). Figure 3.137: Adjusted Configuration –...
  • Page 75 ASSEMBLING THE MACHINE 9. Close driveline shield (B) and engage rubber latch (A). 10. Close driveshield before engaging header. Figure 3.140: Driveline Shield 214805 Revision A...

  • Page 76: Hydraulic Drive Hose Routing - M1 Series Windrowers

    IMPORTANT: If attempting to attach an A40D Header to an M1170 or M1240 Windrower, the M1 Series Conversion kit (MD #B5998) or the A40D SP Grass Seed Auger Conversion kit (MD #B6384) must first be installed. These kits include a new manifold and hydraulic hose bundle required for operation with an M1 Series Windrower, and effectively converts an A40D header into an A40DX header.
  • Page 77 ASSEMBLING THE MACHINE For 4.9 m (16 ft.) header only: • Auger/reel pressure (A) – Connects to tee on port PR2 • Auger/reel return (B) – Connects to port RET2 • Case drain (C) – Connects to tee on knife motor case drain port •...

  • Page 78: Hydraulic Drive Hose Routing (A40Dx Gss And M1 Series Windrowers)

    IMPORTANT: If attempting to attach an A40D GSS Header to an M1170 or M1240 Windrower, the A40D SP Grass Seed Auger Conversion kit (MD #B6384) must first be installed. This kit includes a new manifold and hydraulic hose bundle required for operation with an M1 Series Windrower, and effectively converts an A40D GSS header into an A40DX GSS header.
  • Page 79 ASSEMBLING THE MACHINE • Reel reverse (A) • Reel return (B) • Reel/auger pressure (C) • Reel/auger return (D) • Case drain (E) Figure 3.146: M1170/M1240 Configuration • Reel pressure (A) – Connects to tee (B) on top of the manifold •...
  • Page 80 ASSEMBLING THE MACHINE • Hose (A) – Connects to elbow fitting (D) in knife return port OR2 on manifold • Hose (B) – Connects to elbow fitting (E) tee on knife pressure port KP on manifold • Hose (C) – Connects to elbow fitting (F) in drain port OR1 on manifold •...

  • Page 81: Repositioning Knife Drive Box Breather

    ASSEMBLING THE MACHINE 3.19 Repositioning Knife Drive Box Breather There is one knife drive box at each end of the auger header. The knife drive box sits at different angles when in shipping and field positions. When the position is changed, the breather has to be moved to make sure oil does not leak from the knife drive box.

  • Page 83: Chapter 4: Lubricating The Machine

    Chapter 4: Lubricating the Machine 4.1 Greasing Procedure DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key, and engage safety props before going under machine. 1. Wipe grease fitting with a clean cloth before greasing to avoid injecting dirt and grit.

  • Page 84: Lubrication Points - Left Side Of Header

    LUBRICATING THE MACHINE 4.2 Lubrication Points – Left Side of Header NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI Grade 2) lithium base. To prevent binding and/or excessive wear caused by knife pressing on guards, do NOT over-grease. If more than 6 to 8 pumps of grease gun are required to fill the cavity, replace the seal in the knifehead.

  • Page 85: Lubrication Points - Right Side Of Header

    LUBRICATING THE MACHINE 4.3 Lubrication Points – Right Side of Header NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI Grade 2) lithium base. To prevent binding and/or excessive wear caused by knife pressing on guards, do NOT over-grease. If more than 6 to 8 pumps of grease gun are required to fill the cavity, replace the seal in the knifehead.

  • Page 86: Lubrication Points - Hay Conditioner

    LUBRICATING THE MACHINE 4.4 Lubrication Points – Hay Conditioner NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI Grade 2) lithium base. Figure 4.4: Hay Conditioner A - Roll Pivot (1 Place - Both Sides) B - Roll Shaft Bearings (2 Places) C - Roll Shaft Bearings (2 Places) 214805...

  • Page 87: Lubrication Points - Drivelines

    LUBRICATING THE MACHINE 4.5 Lubrication Points – Drivelines NOTE: Use high temperature extreme pressure (EP2) performance with 1% max molybdenum disulphide (NLGI Grade 2) lithium base. Figure 4.5: Drivelines A - Driveline Shafts (2 Places) 3 B - Cross Shafts (2 Places) C - Driveline Universals (2 Places) D - Driveline Universals (2 Places) 3.

  • Page 88: Knife And Gearbox Oil

    LUBRICATING THE MACHINE 4.6 Knife and Gearbox Oil Figure 4.6: Knife and Gearbox Oil C - Knife Drive Box (2 Places) 4 A - Oil Knife Daily Except in Sandy Soil (SAE 30) B - Check Roll Gearbox (1 Place) 5 4.

  • Page 89: Chapter 5: Performing Predelivery Checks

    2. Check knife drive timing belt (A). It should deflect 14 mm (0.55 in.) when a load of 22–30 N (5–6.5 lbf) is applied mid span. Figure 5.1: A40D Header Right Side 3. Open shield on header left side. 4. Check knife drive timing belt (A). It should deflect 14 mm (0.55 in.) when a load of 22–30 N (5–6.5 lbf) is applied...

  • Page 90: Checking Auger Stripper Bar Clearance

    PERFORMING PREDELIVERY CHECKS 5.2 Checking Auger Stripper Bar Clearance 1. Check for signs of auger flighting (A) rubbing stripper bars (B) after run-up. Figure 5.3: Auger 2. Check clearance between auger flighting (A) and stripper bars (B). NOTE: The auger flighting (A) should clear the stripper bars (B) on the auger pan by approximately 1–4 mm (1/32–5/32 in.).

  • Page 91: Checking Reel Tine To Header Pan Clearance

    PERFORMING PREDELIVERY CHECKS 5.3 Checking Reel Tine to Header Pan Clearance IMPORTANT: The dimensions provided are guidelines only. Tines may slightly contact the guards, but NOT the knife sections or the auger pan. 1. Rotate reel slowly by hand and check tine clearance at knife and pan.

  • Page 92: Checking And Adjusting Float - M Series

    PERFORMING PREDELIVERY CHECKS 5.4 Checking and Adjusting Float – M Series The windrower float springs are NOT used to level the header. CAUTION To prevent accidental movement of windrower, return ground speed lever (GSL) to Park, center steering wheel to lock, shut off engine, and remove key.

  • Page 93: Checking And Adjusting Float - M1 Series

    PERFORMING PREDELIVERY CHECKS 5.5 Checking and Adjusting Float – M1 Series Header float on M1170 and M1240 Windrowers is completely adjustable from the cab through the Harvest Performance Tracker (HPT). The windrower float springs are NOT used to level the header. 5.5.1 Checking Float –...

  • Page 94: Setting The Float

    PERFORMING PREDELIVERY CHECKS 5.5.2 Setting the Float The float can be set for windrowing with the cutterbar on the ground. The optimum float setting lets the header follow the contour of the terrain. Proceed as follows: 1. Set center-link to mid-range position (5.0 on the Harvest Performance Tracker [HPT]).

  • Page 95: Removing And Restoring Float

    PERFORMING PREDELIVERY CHECKS 5.5.3 Removing and Restoring Float Follow these steps to remove and restore the header float settings: 1. Press rotary scroll knob (A) on Harvest Performance Tracker (HPT) to display the QuickMenu system or press F1 on the console. 2.

  • Page 96: Leveling The Header - M Series

    PERFORMING PREDELIVERY CHECKS 5.6 Leveling the Header – M Series Windrower linkages are factory-set to provide the proper level for the header and should not normally require adjustment. If the header is NOT level, do the following steps before adjusting the levelling linkages. The float springs are NOT used to level the header.
  • Page 97 15. If additional levelling is required, install the removed shim on the opposite linkage. NOTE: If required, additional shims (MD #110854) can be ordered from your MacDon Dealer. NOTE: Figure 5.17: Shims Float does NOT require adjustment after levelling header.

  • Page 98: Leveling The Header - M1 Series

    PERFORMING PREDELIVERY CHECKS 5.7 Leveling the Header – M1 Series The windrower lift linkages are factory-set to provide the proper header level, and should not normally require adjustment. If leveling is required, follow these steps: 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 operator’s seat for any reason.
  • Page 99 PERFORMING PREDELIVERY CHECKS 4. Park the windrower on level ground. 5. Press the header raise button (A) on the ground speed lever (GSL). When the header reaches maximum height, continue to hold the header raise button momentarily to allow the lift cylinders to rephase.
  • Page 100 PERFORMING PREDELIVERY CHECKS 12. On the side that is higher, remove nut, washer, and bolt (A) that attaches shims (B) to the linkage. 13. Remove one or both of the shims (B) and reinstall the hardware (A). CAUTION Check to be sure all bystanders have cleared the area. 14.

  • Page 101: Checking Conditioner Rolls

    PERFORMING PREDELIVERY CHECKS 5.8 Checking Conditioner Rolls WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator’s seat for any reason. 1. Lower header fully, stop engine, and remove key. 2.
  • Page 102 PERFORMING PREDELIVERY CHECKS If required, adjust the roll timing as follows: 6. Loosen four bolts (A) in slots of yoke plate on lower roll universal shaft. 7. Turn rolls to achieve best timing. 8. When roll timing is satisfactory, tighten bolts (A) to secure the position.

  • Page 103: Checking Conditioner Gearbox Oil Level

    PERFORMING PREDELIVERY CHECKS 5.9 Checking Conditioner Gearbox Oil Level 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 operator’s seat for any reason. 1.

  • Page 104: Checking Skid Shoes / Gauge Rollers

    PERFORMING PREDELIVERY CHECKS 5.10 Checking Skid Shoes / Gauge Rollers DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key, and engage safety props before going under machine. 1. Raise header and engage safety props. 2.

  • Page 105: Checking Lights

    PERFORMING PREDELIVERY CHECKS 5.11 Checking Lights Hazard lights, which are mounted on both ends of the header, are activated by switches in the windrower cab. 1. Check that pivot bolt (A) is tight enough to hold light support (B) in an upright position, but will still allow the light to pivot out of the way of obstructions.

  • Page 106: Running Up Header

    PERFORMING PREDELIVERY CHECKS 5.12 Running up Header CAUTION • Never start or move the machine until you are sure all bystanders have cleared the area. • Clear the area of other persons, pets etc. Keep children away from machinery. Walk around the machine to be sure no one is under, on, or close to it.

  • Page 107: Checking Knife Speed

    For optimum performance, set the knife speed within the range specified. Refer to Table 5.1, page NOTE: When attaching an A40D Auger Header to an M100 or M105 Windrower for the first time, knife speed should be set to the MAXIMUM setting. Table 5.1 A40D Auger Header Knife Speed...

  • Page 108: Setting Knife Speed With Expansion Module (Md #B4666)

    PERFORMING PREDELIVERY CHECKS Setting Knife Speed with Expansion Module (MD #B4666) 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 operator’s seat for any reason. 1.

  • Page 109: Setting Knife Speed Without Expansion Module (Md #B4666)

    PERFORMING PREDELIVERY CHECKS 6. Loosen jam nut (A). 7. Turn adjuster screw (B) clockwise (screw in) to decrease knife speed, and counterclockwise (screw out) to increase the knife speed. NOTE: One turn of adjuster screw (B) will change the knife speed by approximately 116 strokes per minute (spm), or the knife drive box pulley speed by 58 revolutions per minute (rpm).

  • Page 110: Adjusting Knife And Guards

    PERFORMING PREDELIVERY CHECKS 5.14 Adjusting Knife and Guards WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before adjusting machine. 1. Stop engine and remove key. 2. Check guards for signs of heating during run-up due to insufficient clearance between guard and knife.

  • Page 111: Checking Manuals

    1. Open the right endshield (A) and remove cable tie (B) from manual case (C). Figure 5.40: Manual Case 2. A40D/A40DX manuals are shipped with shipping documents and auger header unloading and assembly instructions. Be sure to place the following manuals in the manual case: •...

  • Page 113: Chapter 6: Reference

    Chapter 6: Reference 6.1 Torque Specifications The following tables provide correct torque values for various bolts, cap screws, and hydraulic fittings. • Tighten all bolts to torque values specified in charts (unless otherwise noted throughout this manual). • Replace hardware with same strength and grade of bolt. •...
  • Page 114 REFERENCE Table 6.2 SAE Grade 5 Bolt and Grade F Distorted Thread Nut Torque (Nm) Torque (lbf·ft) (*lbf·in) Nominal Size (A) Max. Max. Min. Min. 1/4-20 16.7 18.5 5/16-18 *149 *164 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 Figure 6.2: Bolt Grades 3/4-10 A - Nominal Size B - SAE-8...

  • Page 115: Metric Bolt Specifications

    REFERENCE Table 6.4 SAE Grade 8 Bolt and Grade 8 Free Spinning Nut Torque (Nm) Torque (lbf·ft) (*lbf·in) Nominal Size (A) Min. Max. Min. Max. 16.8 18.6 *150 *165 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 Figure 6.4: Bolt Grades 3/4-10 A - Nominal Size B - SAE-8...
  • Page 116 REFERENCE Table 6.6 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (lbf·ft) (*lbf·in) Torque (Nm) Nominal Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 8-1.25 18.8 20.8 *167 *185 10-1.5 Figure 6.6: Bolt Grades 12-1.75 14-2.0 16-2.0...

  • Page 117: Metric Bolt Specifications Bolting Into Cast Aluminum

    REFERENCE Table 6.8 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (lbf·ft) (*lbf·in) Torque (Nm) Nominal Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 10.7 11.8 *105 8-1.25 10-1.5 Figure 6.8: Bolt Grades 12-1.75 14-2.0 16-2.0 20-2.5...

  • Page 118: Flare-Type Hydraulic Fittings

    REFERENCE 6.1.4 Flare-Type Hydraulic Fittings 1. Check flare (A) and flare seat (B) 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 flared surfaces.

  • Page 119: O-Ring Boss Hydraulic Fittings - Adjustable

    REFERENCE 6.1.5 O-Ring Boss Hydraulic Fittings – Adjustable 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Back off lock nut (C) as far as possible. Ensure that washer (D) is loose and is pushed toward lock nut (C) as far as possible.
  • Page 120 REFERENCE Table 6.11 O-Ring Boss (ORB) Hydraulic Fittings – Adjustable Torque Value SAE Dash Size Thread Size (in.) lbf·ft (*lbf·in) 5/16–24 6–7 *53–62 3/8–24 12–13 *106–115 7/16–20 19–21 14–15 1/2–20 21–33 15–24 9/16–18 26–29 19–21 3/4–16 46–50 34–37 7/8–14 75–82 55–60 1 1/16–12 120–132...

  • Page 121: O-Ring Boss Hydraulic Fittings - Non-Adjustable

    REFERENCE 6.1.6 O-Ring Boss Hydraulic Fittings – Non-Adjustable 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Check that O-ring (A) is NOT on threads and adjust if necessary. 3. Apply hydraulic system oil to O-ring. 4.

  • Page 122: O-Ring Face Seal Hydraulic Fittings

    REFERENCE 6.1.7 O-Ring Face Seal Hydraulic Fittings 1. Check components to ensure that sealing surfaces and fitting threads are free of burrs, nicks, scratches, or any foreign material. Figure 6.14: Hydraulic Fitting 2. Apply hydraulic system oil to O-ring (B). 3.
  • Page 123 REFERENCE Table 6.13 O-Ring Face Seal (ORFS) Hydraulic Fittings Torque Value SAE Dash Size Thread Size (in.) Tube O.D. (in.) lbf·ft – – Note 3/16 25–28 18–21 9/16 – – Note 5/16 40–44 29–32 11/16 55–61 41–45 13/16 80–88 59–65 1 3/16 115–127 85–94...

  • Page 124: Tapered Pipe Thread Fittings

    REFERENCE 6.1.8 Tapered Pipe Thread Fittings Assemble pipe fittings as follows: 1. Check components to ensure that fitting and port threads are free of burrs, nicks and scratches, or any form of contamination. 2. Apply pipe thread sealant (paste type) to external pipe threads. 3.

  • Page 125: Conversion Chart

    REFERENCE 6.2 Conversion Chart Table 6.15 Conversion Chart Quantity SI Units (Metric) Factor US Customary Units (Standard) Unit Name Abbreviation Unit Name Abbreviation acre acres Area x 2.4710 = hectare Flow liters per minute x 0.2642 = US gallons per minute L/min Force Newton...

  • Page 126: Definitions

    6.3 Definitions The following terms and acronyms may be used in this instruction: Term Definition A Series header MacDon A30S, A30D, A40D, A40DX, and Grass Seed auger headers American Petroleum Institute ASTM American Society of Testing and Materials Bolt A headed and externally threaded fastener that is designed to be paired with a nut...
  • Page 127 REFERENCE Term Definition O-ring face seal: A style of fitting commonly used for connecting hoses and tubes. This ORFS style of fitting is also commonly called ORS, which stands for O-ring seal RoHS (Reduction of A directive by the European Union to restrict use of certain hazardous substances (such as Hazardous Substances) hexavalent chromium used in some yellow zinc platings) Revolutions per minute...

  • Page 129: Predelivery Checklist

    Carefully follow the instructions given. Be alert for safety-related messages that bring your attention to hazards and unsafe practices. Header Serial Number: Table .16 A40D, A40DX Predelivery Checklist ü ü Item Reference Check for shipping damage or missing parts. Be sure all —...
  • Page 130 REFERENCE 5.12 Running up Header, page 98 RUN-UP PROCEDURE Check hydraulic hose and wiring harness routing for — clearance when raising or lowering header and when retracting or extending center-link. 5.13 Checking Knife Speed, page 99 Check knife speed. Check that amber flasher and signal lights are functional. 5.11 Checking Lights, page 97 —...
  • Page 132 MacDon Industries Ltd. MacDon Brasil Agribusiness Ltda. 680 Moray Street Rua Grã Nicco, 113, sala 404, B. 04 Winnipeg, Manitoba Mossunguê, Curitiba, Paraná Canada R3J 3S3 CEP 81200-200 Brasil t. (204) 885-5590 f. (204) 832-7749 t. +55 (41) 2101-1713 f. +55 (41) 2101-1699 MacDon, Inc.

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