MacDon A40D Operator's Manual
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MacDon A40D Operator's Manual

Self-propelled windrower auger header
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A40D and A40DX
Self-Propelled Windrower
Auger Header
Operator's Manual
214804 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 Operator’s Manual 214804 Revision A Original Instruction The harvesting specialists.
  • Page 2 MacDon A40D Self-Propelled Windrower Auger Header Published: November 2018...
  • Page 3 EC Declaration of Conformity Figure 1. EC Declaration of Conformity Page 1 214804 Revision A...
  • Page 4 Figure 2. EC Declaration of Conformity Page 2 214804 Revision A...
  • Page 5 M1 Series Windrower. NOTE: A40D auger header grass seed (GSS) version can be used on an M1 Series Windrower ONLY if conversion kit MD #B5998 and MD #318022 have been installed on the auger header. This kit is optional when converting the A40D for use on M1 Series windrowers.
  • Page 6 (www. macdon.com) or from our Dealer-only site (https://portal.macdon.com) (login required). NOTE: A Russian translation of this manual can be ordered from MacDon, downloaded from the MacDon Dealer Portal (https://portal.macdon.com) (login required), or downloaded from the MacDon international website (http://www. macdon.com/world).

  • Page 7: List Of Revisions

    3.2 Detaching A40DX Header from M1 Series Windrower, page 29 3.6.9 Checking/Adjusting Float – M Series, page 72 Updated procedure Updated illustration 3.3.5 Configuring Reverser Valve Jumper Hose for A40D, page 49 Updated illustration Adjusting Reel Vertical Position, page 66 Updated unload and assembly...

  • Page 8: Model And Serial Number

    Model and Serial Number Record the model number, serial number, and model year of the header in the spaces below. The header serial number plate is located on the top of the left end frame (A). Header Model Number: ____________ Header Serial Number: ____________ Year: ______ Figure 3.

  • Page 9: Table Of Contents

    3.1 Attaching A40DX Header to M1 Series Windrowers ................25 3.2 Detaching A40DX Header from M1 Series Windrower................29 3.3 Attaching A40D Headers to M Series SP Windrowers ................31 3.3.1 Attaching A40D to M100 or M105 ....................31 3.3.2 Attaching A40D to M150, M155, or M155E4 ................36 3.3.3 Attaching A40D to M200 ......................40...
  • Page 10 TABLE OF CONTENTS Adjusting Reel Fore-Aft Position ....................64 Adjusting Reel Vertical Position ....................66 Checking Reel Tine to Header Pan Clearance ................69 3.6.6 Setting Tine Aggressiveness ......................69 3.6.7 Adjusting Header Angle ......................70 3.6.8 Setting Cutting Height........................71 3.6.9 Checking/Adjusting Float – M Series...................72 3.6.10 Checking/Adjusting Float –...
  • Page 11 TABLE OF CONTENTS 4.4.1 Maintenance Schedule/Record ....................104 4.4.2 Break-In Inspection ......................... 105 4.4.3 Preseason Checks ........................105 4.4.4 Storage ..........................106 4.5 Lubrication ............................107 4.5.1 Greasing Procedure ........................ 107 4.5.2 Lubrication Points........................107 Lubrication Points: Auger Header .................... 108 Lubrication Points: Hay Conditioner ..................
  • Page 12 TABLE OF CONTENTS Removing Timing Belt from Right Side ..................146 Installing Timing Belt on Right Side ..................147 4.8.2 Header Reel Drive........................148 4.8.3 Header Auger Drive......................... 148 4.9 Reel Tines and Tine Bar Bearings ..................... 149 4.9.1 Replacing Tine and Bearing: Cam End – Disc #1 ............... 149 4.9.2 Replacing Tine and Bearing: Disc #2 ..................
  • Page 13 TABLE OF CONTENTS Chapter 6: Unloading and Assembly.....................197 Chapter 7: Troubleshooting ......................199 7.1 Header Performance ........................199 7.2 Mechanical ............................204 Chapter 8: Reference .........................207 8.1 Recommended Torques ........................207 8.1.1 Torque Specifications ......................207 SAE Bolt Torque Specifications....................207 Metric Bolt Specifications ......................

  • Page 15: Chapter 1: Safety

    1 Safety 1.1 Safety Alert Symbols This safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. This symbol means: • ATTENTION! • BECOME ALERT! • YOUR SAFETY IS INVOLVED! Carefully read and follow the safety message accompanying this symbol.

  • Page 16: Signal Words

    SAFETY 1.2 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.

  • Page 17: General Safety

    SAFETY 1.3 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 18 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 19: Maintenance Safety

    SAFETY 1.4 Maintenance Safety To ensure your safety while maintaining machine: • Review operator’s manual and all safety items before operation and/or maintenance of machine. • Place all controls in Neutral, stop the engine, set the park brake, remove the ignition key, and wait for all moving parts to stop before servicing, adjusting, and/or repairing.

  • Page 20: Hydraulic Safety

    SAFETY 1.5 Hydraulic Safety • Always place all hydraulic controls in Neutral before dismounting. • Make sure that all components in hydraulic system are kept clean and in good condition. • Replace any worn, cut, abraded, flattened, or crimped hoses and steel lines. •...

  • Page 21: Safety Signs

    • Replacement safety signs are available from your MacDon Dealer Parts Department. Figure 1.14: Operator’s Manual Decal 1.6.1 Installing Safety Decals 1. Clean and dry installation area. 2. Decide on exact location before you remove decal backing paper.

  • Page 22: Safety Sign Locations: Self-Propelled Windrower Header

    SAFETY 1.7 Safety Sign Locations: Self-Propelled Windrower Header Figure 1.15: Left Side of Header A - MD #174632 B - MD #184422 C - MD #166452 D - MD #174436 E - MD #171288 F - MD #184372 G - MD #194464 H - MD #194521 J - MD #36651 Figure 1.16: Decals on Left Side of Header...
  • Page 23 SAFETY Figure 1.17: Right Side of Header A - MD #184422 B - MD #170638 C - MD #166452 Figure 1.18: Decals on Right Side of Header 214804 Revision A...

  • Page 24: Understanding Safety Signs

    SAFETY 1.8 Understanding Safety Signs MD #36651 Rotating driveline DANGER • Rotating driveline contact can cause death—keep away! Do NOT operate without: • Stopping the engine and removing the key before opening shield. • All driveline guards, tractor, and equipment shields in place.
  • Page 25 SAFETY MD #166452 Hand and arm entanglement hazard WARNING • Do NOT open or remove safety shields while the engine is running. • To avoid injury, stop the engine and remove the key before opening shield. Figure 1.21: MD #166452 MD #166466 High-pressure oil hazard WARNING...
  • Page 26 SAFETY MD #171279 Crushing hazard DANGER • Read the operator’s manual and follow all safety instructions. • Rest header on ground or engage hydraulic lock-out valves before going under unit. Figure 1.24: MD #171279 MD #171281 Hot fluid under pressure CAUTION •...
  • Page 27 SAFETY MD #174436 High-pressure oil hazard WARNING • Do not go near leaks. • High-pressure oil easily punctures skin, causing serious injury, gangrene, or death. • If injured, seek emergency medical help. Immediate surgery is required to remove oil. • Do not use finger or skin to check for leaks.
  • Page 28 SAFETY • Disengage header drive, put transmission in Neutral, and wait for all movement to stop before leaving operator’s position. • Stop the engine and remove the key from the ignition before servicing, adjusting, lubricating, cleaning, or unplugging machine. • Engage safety props to prevent lowering of raised unit before servicing in the raised position.
  • Page 29 SAFETY MD #194521 Auger entanglement hazard CAUTION • To avoid injury from entanglement with rotating auger, stand clear of header/mower while machine is running. General hazard pertaining to machine operation and servicing. CAUTION • Read the operator’s manual and follow safety instructions.

  • Page 30: Owner/Operator Responsibilities

    SAFETY 1.9 Owner/Operator Responsibilities CAUTION • It is your responsibility to read and understand this manual completely before operating the header. Contact your Dealer if an instruction is not clear to you. • Follow all safety messages in the manual and on safety signs on the machine. •...

  • Page 31: Operational Safety

    SAFETY 1.10 Operational Safety CAUTION • Follow all safety and operational instructions given in your operator's manual. If you do not have a windrower manual, get one from your Dealer and read it thoroughly. • Never attempt to start windrower engine or operate the machine, except from the operator’s seat. •...

  • Page 33: Chapter 2: Product Overview

    2.1 Definitions The following terms and acronyms may be used in this manual: Term Definition A Series header MacDon 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 34 PRODUCT OVERVIEW Term Definition North American header Header configuration typical in North America National Pipe Thread: A style of fitting used for low-pressure port openings. Threads on NPT fittings are uniquely tapered for an interference fit An internally threaded fastener that is designed to be paired with a bolt O-ring boss: A style of fitting commonly used in port openings on manifolds, pumps, and motors O-ring face seal: A style of fitting commonly used for connecting hoses and tubes.

  • Page 35: Product Specifications

    PRODUCT OVERVIEW 2.2 Product Specifications NOTE: Specifications and design are subject to change without notice, or obligation to revise previously sold units. Table 2.1 A40D, A40DX Self-Propelled Windrower Auger Header Specifications Cutterbar Effective cutting width 4.3 m (14 ft.) header 4496 mm (14 ft.
  • Page 36 PRODUCT OVERVIEW Table 2.1 A40D, A40DX Self-Propelled Windrower Auger Header Specifications (continued) Rubber feed fingers Standard Stripper bars (three per side) Standard Hydraulic, 15.9 cu in. (261 cc) per rev Auger drive Standard direct mounted motor Auger speed SP windrower 230–320 rpm...
  • Page 37 PRODUCT OVERVIEW Table 2.1 A40D, A40DX Self-Propelled Windrower Auger Header Specifications (continued) Swath Forming Shield 915 mm (36 in.) to Swath width range 2540 mm (100 in.) Header-mounted adjustable baffle Standard Attachment Windrower Adjustable side deflectors Standard Frame And Structure...

  • Page 39: Chapter 3: Operation

    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 hose bundle required for operation with an M1 Series Windrower, and effectively converts an A40D header into an A40DX header.
  • Page 40 OPERATION 2. Insert hose support (B) into hole (A) in the windrower left leg, and route header hose bundle (C) under the windrower to the hydraulic and electrical couplers. Figure 3.2: Hose Support 3. If attaching to a disc-ready windrower, ensure knife drive hose (A) is connected to coupler (B).
  • Page 41 OPERATION 4. Clean multicouplers and receptacles to prevent contamination. 5. Push button (A) on rear multicoupler receptacle and pull handle (B) away from windrower. 6. Open cover (C) and position multicoupler (D) onto receptacle. Align pins in coupler with slots in handle (B), and push handle toward windrower so that coupler is locked onto receptacle and button (A) snaps out.
  • Page 42 OPERATION 10. Remove cover from receptacle (A) on windrower and connect electrical harness (B) from header. Figure 3.7: Electrical Connection 214804 Revision A...

  • Page 43: Detaching A40Dx Header From M1 Series Windrower

    OPERATION 3.2 Detaching A40DX Header from M1 Series Windrower Refer to your windrower operator’s manual for procedures to mechanically detach the auger header from the M1 Series Windrower. To detach an A40DX header’s hydraulics and electrical from an M1 Series Windrower, follow these steps: CAUTION To prevent accidental movement of windrower, return ground speed lever (GSL) to Park, center steering...
  • Page 44 OPERATION 8. Remove hose support (B) from hole (A) in windrower left leg, and remove header hose bundle (C) from the windrower. Figure 3.10: Hose Support 9. Keeping hose bundle (A) in hose guide (B), store hose bundle on top of header walkway (C), away from the windrower.

  • Page 45: 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. Refer to 3.3.5 Configuring Reverser Valve Jumper Hose for A40D, page 49...
  • Page 46 OPERATION 1. Disengage rubber latch (A) and open driveline shield (B). Figure 3.13: 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 47 NOTE: Hoses attached to connectors not shown in illustrations at right. Figure 3.16: 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 B - Knife and Conditioner Return...
  • Page 48 13. If valve blocks are NOT configured as shown (A), install required fittings as described in the unloading and assembly instructions that were supplied with your A40D Auger Header. Figure 3.19: Valve Block Configuration 14. Push auger/reel pressure (A) and auger/reel return (B) hose couplers onto mating receptacles on valve block until collar on receptacle snaps into lock position.
  • Page 49 M200 A - Reel Motor B - Auger Motor 16. For procedure to change hose routing for M100 or M105 Windrowers, refer to 3.3.6 Routing A40D Hydraulic Drive Hoses, page Figure 3.23: Modified Routing M100, M105, and M205 214804...

  • Page 50: Attaching A40D To M150, M155, Or M155E4

    OPERATION 3.3.2 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 51 NOTE: Hoses attached to connectors not shown in illustrations at right. Figure 3.28: 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 B - Knife and Conditioner Return...
  • Page 52 Figure 3.30: Auger Return and Reel Pressure Hose Bundle 13. If valve blocks are NOT configured as shown at right, install required fittings as described in the A40D Self- Propelled Windrower Auger Header Unloading and Assembly Instructions, which were supplied with your A40D Auger Header.
  • Page 53 (B) hoses. 15. Proceed to 3.3.5 Configuring Reverser Valve Jumper Hose for A40D, page Figure 3.33: 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) 16.

  • Page 54: Attaching A40D To M200

    OPERATION Figure 3.35: M150/M155/M155E4 without Reverser Valve 3.3.3 Attaching A40D to M200 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. The M200 Windrower requires four drive hoses (A) to run an A40D Auger Header.
  • Page 55 OPERATION 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. Figure 3.37: Auger Header Drive and Draper...
  • Page 56 NOTE: Hoses attached to connectors not shown in illustrations at right. Figure 3.41: 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 B - Knife and Conditioner Return...
  • Page 57 Figure 3.43: Auger Return and Reel Pressure Hose Bundle 13. If valve blocks are NOT configured as shown at right, install required fittings as described in the unloading and assembly instructions supplied with your A40D Auger Header. Figure 3.44: M200 with Reverser Valve 214804...
  • Page 58 16. If valve blocks are NOT configured as shown above, install required fittings as described in the unloading and assembly instructions supplied with your A40D Auger Header. Figure 3.47: M200 with Reverser Valve...

  • Page 59: Attaching A40D To M205

    MD #B5497 Figure 3.49: Auger Drive Basic Kit and Completion Kit Installed 1. 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. 214804...
  • Page 60 OPERATION 1. Disengage rubber latch (A), and open driveline shield (B). Figure 3.50: 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 61 NOTE: Hoses attached to connectors not shown in illustrations at right. Figure 3.53: 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 B - Knife and Conditioner Return...
  • Page 62 OPERATION 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 3.55: Auger Return and Reel Pressure Hose Bundle 13.

  • Page 63: Configuring Reverser Valve Jumper Hose For A40D

    Drive Hoses, page Figure 3.58: Modified Routing M100, M105, and M205 3.3.5 Configuring Reverser Valve Jumper Hose for A40D An optional reverser valve block (A) to reverse the header drive in the event of plugging may have been installed on M150, M155, and M200 Self-Propelled Windrowers.

  • Page 64: Routing A40D Hydraulic Drive Hoses

    Figure 3.61: Connected Jumper Hose 3.3.6 Routing A40D Hydraulic Drive Hoses The A40D Auger Header hydraulic drive hose routing depends on the windrower model to which the header is being attached. A40D Headers are factory-configured for M150, M155, M155E4, and M200 SP Windrowers as shown in Figure 3.66, page...
  • Page 65 OPERATION 1. Press screwdriver against latch in opening (A) and lift to open header left driveshield. Shield will latch at location (B) to stay open. Figure 3.62: Left Driveshield 2. Disengage rubber latch (A), and open driveline shield (B). Figure 3.63: Driveline Shield 3.
  • Page 66 OPERATION Figure 3.65: Auger and Reel Pressure Coupler and Hose – 5.5 m (18 ft.) Header Shown Hydraulic hose connections: 4. Disconnect hoses as follows: a. Disconnect hose (A) from tee (B). b. Disconnect tee (B) from reel motor upper port. c.
  • Page 67 OPERATION e. Confirm orientation of upper port 45 degree fitting, back-off tee (B), and tighten upper port fitting in position determined. Tighten hose (A). Check orientation of lower port 45 degree fitting and tighten. g. Connect tee (B) to lower port 45 degree fitting and tighten.
  • Page 68 OPERATION Figure 3.70: Auger and Reel Pressure Coupler and Hose – 5.5 m (18 ft.) Header Shown 9. Close driveline shield (B) and engage rubber latch (A). 10. Close driveshield before engaging header. Figure 3.71: Driveline Shield 214804 Revision A...

  • Page 69: Detaching A40D Header From M Series Self-Propelled Windrower

    OPERATION 3.4 Detaching A40D Header from M Series Self-Propelled Windrower 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. 1. Move left cab-forward platform to rear of windrower.
  • Page 70 OPERATION Figure 3.74: M150 without Reverser Valve (M155 and M155E4 Similar) Figure 3.75: M200 with Reverser Valve Figure 3.76: M200 without Reverser Valve 214804 Revision A...
  • Page 71 OPERATION Figure 3.77: M205 3. Raise lever (B) on hose support (C), and undo three adjustable straps (D). 4. Move hose bundle (A) to store on header walkway. Figure 3.78: Hose Bundle 5. Install caps on connectors and hose ends (if equipped). 6.
  • Page 72 OPERATION Figure 3.80: Grass Seed Header A - Knife Return (Male Fitting at Header) (Not Shown in This Image) B - Auger and Reel Pressure C - Knife Pressure (Female Fitting at Header) D - Case Drain 8. Move hose bundle (A) from header, and position on windrower left side with hose ends in support (B) and under lever (C).

  • Page 73: Header Lift Cylinder Lock-Out Valves

    OPERATION 3.5 Header Lift Cylinder Lock-Out Valves Refer to your windrower operator’s manual for information about the lift cylinder lock-out valves. 214804 Revision A...

  • Page 74: Operating Variables

    OPERATION 3.6 Operating Variables Satisfactory function of the header in all situations requires making proper adjustments to suit various crops and conditions. Correct operation reduces crop loss and allows cutting of more acres. As well, proper adjustments and timely maintenance will increase the length of service you receive from the machine. The variables listed below and detailed on the following pages will affect the performance of the header.

  • Page 75: Setting Lean Bar

    OPERATION 3.6.1 Setting Lean Bar Use the lean bar adjustment to accommodate different crop heights. The lean bar (A) should strike the upper portion of the crop (roughly 2/3 of the crop height), leaning it away from the header, and exposing the stalks to the knife. IMPORTANT: To prevent structural damage to the header, do NOT operate with lean bar removed.

  • Page 76: Adjusting Auger Fore-Aft Position

    2. Open left endshield. 3. Loosen four nuts (A). 4. Loosen jam nut on adjuster bolt (B), and turn bolt (B) to adjust auger fore-aft position. 5. Tighten jam nut. 6. Tighten nuts (A). Figure 3.84: A40D Left Side 214804 Revision A...

  • Page 77: Adjusting Vertical Position

    10. Tighten jam nut. 11. Tighten nuts (A). 12. Close shields before engaging header. Figure 3.85: A40D Right Side Adjusting Vertical Position 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 78: Setting Reel Position

    OPERATION 3.6.5 Setting Reel Position Reel position has been found to be a critical factor in achieving good results in adverse conditions. Reel position is factory-set for average straight standing crop. It can be adjusted both vertically and horizontally (fore-aft) for different crop conditions.
  • Page 79 OPERATION 1. Shut off engine and remove key. 2. Open left endshield. 3. Loosen four nuts (A). 4. Loosen jam nut on adjuster bolt (B), and turn bolt (B) to adjust reel fore-aft position. 5. Tighten jam nut. 6. Tighten nuts (A). Figure 3.89: Auger Header Left Side 7.

  • Page 80: Adjusting Reel Vertical Position

    OPERATION Adjusting Reel Vertical Position 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. 1. Shut off engine and remove key. 2. Open left endshield. 3.
  • Page 81 OPERATION 6. Tighten nuts (A). Figure 3.93: Auger Header Left Side 7. Open right endshield. 8. Loosen four nuts (A). Figure 3.94: Auger Header Right Side 9. Loosen jam nuts on adjuster bolts (A), and turn bolts (A) to adjust reel vertical position. NOTE: The factory setting at forward adjuster bolt should be 12 mm (15/32 in.) lower than at rear adjuster bolt.
  • Page 82 OPERATION 11. Tighten nuts (A). 12. Close shields before engaging header. 13. Check that the reel rotates freely. NOTE: Manually rotate reel, and ensure that tines do not contact header pan, otherwise damage to pan will result. If necessary, grind off excessive length from tine if tine length varies considerably.

  • Page 83: Checking Reel Tine To Header Pan Clearance

    OPERATION Checking Reel Tine to Header Pan Clearance IMPORTANT: The dimensions at right are provided as 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 84: Adjusting Header Angle

    OPERATION 4. Loosen jam nuts on bolts (A), and turn bolts to rotate cam to desired position. Viewed from right side, rotate cam clockwise to obtain more aggressive tine action. NOTE: The factory setting at forward adjuster bolt should be 12 mm (0.47 in.) lower than at rear adjuster bolt.

  • Page 85: Setting Cutting Height

    OPERATION 3.6.8 Setting Cutting Height 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. 1. Raise header, and engage header lift cylinder lock-out valves. 2.

  • Page 86: Checking/Adjusting Float - M Series

    OPERATION 3.6.9 Checking/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. IMPORTANT: Always check the float with the header set in working position (with the header fully lowered to the ground and the header angle set to the desired cutting height per crop type and conditions).

  • Page 87: Checking Float - M1 Series Windrower

    OPERATION Checking Float – M1 Series Windrower 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. CAUTION Before starting the machine, check to be sure all bystanders have cleared the area.

  • Page 88: Removing And Restoring Float

    OPERATION 3. Press rotary scroll knob (A) on the HPT to display the QuickMenu system. 4. Rotate scroll knob (A) to highlight header float icon (B) and press scroll knob to select. Figure 3.107: HPT Run Screen 5. Turn scroll knob (A) to highlight left (B) or right (C) float and press knob (A) to activate selection.

  • Page 89: Setting Feed Pan And Rock Drop Tine Position

    OPERATION 3. Press soft key 3 (A) to remove or restore the header float. NOTE: If the header float is active, the icon at soft key 3 will say REMOVE FLOAT; if header float has been removed, the icon will say RESTORE FLOAT. Figure 3.110: HPT Display –...

  • Page 90: Adjusting Conditioner Roll Gap

    OPERATION 4. Tighten hardware on both sides. 5. Disengage safety props. 3.6.12 Adjusting Conditioner Roll Gap The roll gap determines the amount of conditioning: • To reduce conditioning, increase roll gap. • To increase conditioning, decrease roll gap. The conditioner roll gap is factory-set at 6 mm (1/4 in.). 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 91 OPERATION 5. Loosen bolt (A), and rotate cover (B) to expose access port (C). 6. Inspect space between roll bars at both ends of the rolls at access port (C). IMPORTANT: Roll timing and alignment are critical when the roll gap is decreased because •...

  • Page 92: Adjusting Conditioner Roll Tension

    OPERATION 3.6.13 Adjusting Conditioner Roll Tension The roll tension (the force holding the rolls together) is factory-set, and is adjustable. There is a spring for each end of the roll. Figure 3.114: Conditioner Roll Tension Springs Table 3.2 Conditioner Roll Tension Factory Settings 81–91 mm (3 3/16 –...

  • Page 93: Positioning The Forming Shields

    OPERATION 1. Lower header fully. 2. Stop engine, and remove key. 3. To increase the roll tension, loosen jam nut (B) at spring insert, and turn spring drawbolt (C) clockwise to tighten the spring. Tighten jam nut (B). 4. To decrease the roll tension, loosen jam nut (B) at spring insert, and turn spring drawbolt (C) counterclockwise to loosen the spring.

  • Page 94: Positioning Rear Deflector (Fluffer Shield)

    OPERATION 1. Set forming shield side deflectors to desired width by repositioning adjuster bars as follows: a. Remove lynch pin (A). b. Move adjuster bar (B) to another hole. c. Reinstall lynch pin (A). Figure 3.116: Forming Shield Side Deflector 2.
  • Page 95 OPERATION 1. Shut off engine and remove key. 2. For more crop control in light material, lower the deflector (A) by pushing down on one side of the deflector, and then on the other side. Locking handles (B) are located at either end of deflector, and may be loosened slightly.

  • Page 96: Recommended Operating Settings

    OPERATION 3.7 Recommended Operating Settings These settings are intended as a starting point. Operators should fine-tune to crop and field conditions. Refer to Table 3.3, page 214804 Revision A...
  • Page 97 214804 Revision A...
  • Page 98 OPERATION 214804 Revision A...
  • Page 99 OPERATION 214804 Revision A...

  • Page 100: Unplugging Conditioner And Knife

    Exercise caution when working around the cutterbar. Blades are sharp and can cause serious injury. Wear heavy gloves when working around or handling knife. 6. Clean off cutterbar and area under reel by hand. 7. Retrieve wrench (A) from storage inside the left drive compartment. Figure 3.119: Wrench Location – A40D 214804 Revision A...
  • Page 101 OPERATION 8. Use wrench on left end of primary driveshaft (A) to turn rolls forward until plug clears. 9. Return wrench to storage location, and secure in place with pin. WARNING Return unplug wrench to storage location, and close left side driveshield before restarting machine.

  • Page 102: Grass Seed Special

    OPERATION 3.9 Grass Seed Special The grass seed auger header has several features to adapt it to this special application. These features include: • 3.9.1 Stub Guards and Hold-Downs, page 88 • 3.9.2 Special Auger Design for Grass Seed Special, page 89 •...

  • Page 103: Special Auger Design For Grass Seed Special

    OPERATION 3.9.2 Special Auger Design for Grass Seed Special The center beaters and beater supports have been removed to reduce auger wrapping. Figure 3.122: Grass Seed Auger 3.9.3 Seven-Bat Reel A seventh bat is added to the reel body, for smoother reel action and better crop feed into the header.

  • Page 104: Auger Pan Extensions

    OPERATION 3.9.4 Auger Pan Extensions The grass seed header is equipped with adjustable auger pan extensions that allow adjustment of delivery opening to vary the windrow characteristics. Installing and Adjusting Pan Extensions To install the pan extensions, do the following: 1.
  • Page 105 OPERATION 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 106: Windrow Forming Rods

    OPERATION 3.9.5 Windrow Forming Rods Forming rods are provided to assist in forming the narrow windrows preferred for this application. Bend rods to modify the windrow shape. Use forming rods in conjunction with auger pan extensions to achieve the width and shape of windrows you desire. Figure 3.129: Windrow Forming Rods 214804 Revision A...

  • Page 107: Selecting Ground Speed

    OPERATION 3.10 Selecting Ground Speed CAUTION Reduce speed when turning, crossing slopes, or when travelling over rough ground. Windrower ground speed SHOULD NOT EXCEED 13 km/h (8 mph). For most crop conditions a ground speed of 8 km/h (5 mph) has been found satisfactory. Choose a ground speed that allows the knife to cut the crop smoothly and evenly.

  • Page 108: Tall Crop Dividers

    OPERATION 3.11 Tall Crop Dividers The tall crop dividers attach to the ends of the header for clean crop dividing, and reel entry in tall crops. They can be easily adjusted to suit the crop, or removed when not required. 3.11.1 Adjusting Tall Crop Dividers 1.

  • Page 109: Removing Tall Crop Dividers

    OPERATION 3.11.2 Removing Tall Crop Dividers 1. Remove U-bolt (A) and bolts (B), and remove divider. Repeat for other divider. 2. Remove bolts attaching lean bar to header. Figure 3.132: Tall Crop Divider 3. Remove bolts (A) attaching extensions (B) to lean bar (C), and remove extensions.
  • Page 110 OPERATION 4. Reposition lean bar on header at desired height, and install existing carriage bolts (A)—two per side. Tighten bolts. Figure 3.134: Lean Bar 214804 Revision A...

  • Page 111: Haying

    OPERATION 3.12 Haying 3.12.1 Haying Tips Curing Curing crops quickly helps maintain the highest quality of crop material as 5% of protein is lost from hay for each day that it lays on the ground after cutting. Leaving the windrow as wide and fluffy as possible results in the quickest curing. Cured hay should be baled as soon as possible.

  • Page 112: Windrow Characteristics

    OPERATION Windrow Characteristics Producing windrows with the recommended characteristics will achieve the best results. Refer to 3.6 Operating Variables, page 60 for instructions on adjusting the header. Table 3.5 Recommended Windrow Characteristics Characteristic Advantage Enables airflow through windrow, which is more important to the curing High and fluffy process than direct sunlight Consistent formation (not bunching)

  • Page 113: Chapter 4: Maintenance And Servicing

    4 Maintenance and Servicing The following instructions are provided to assist you in the use of the header. Detailed maintenance and service information is contained in the technical service manual that is available from your Dealer. A parts catalog is provided with your shipment.

  • Page 114: Opening/Closing Driveshield

    MAINTENANCE AND SERVICING 4.2 Opening/Closing Driveshield This procedure is for opening and closing the driveshield over the conditioner drivelines. Opening driveshield 1. Disengage rubber latch (A). 2. Open shield (B). Figure 4.1: Driveline Shield Figure 4.2: Driveline Shield Open 214804 Revision A...
  • Page 115 MAINTENANCE AND SERVICING Closing driveshield 1. Lower shield (B). 2. Engage rubber latch (A). Figure 4.3: Driveline Shield 214804 Revision A...

  • Page 116: Endshields

    MAINTENANCE AND SERVICING 4.3 Endshields This procedure is for opening and closing the endshields at each end of the machine. To open endshields: CAUTION Ensure shield lock engages in the open position as shown at (B) before letting go of shield. 1.

  • Page 117: Maintenance Requirements

    MAINTENANCE AND SERVICING 4.4 Maintenance Requirements Periodic maintenance requirements are organized according to service intervals. Regular maintenance is the best insurance against early wear and untimely breakdowns. Following the maintenance schedule will increase your machine’s life. When servicing the machine, refer to the specific headings in this section and use only fluids and lubricants specified in chart on the inside back cover of this manual.

  • Page 118: Maintenance Schedule/Record

    MAINTENANCE AND SERVICING 4.4.1 Maintenance Schedule/Record Self-Propelled Windrower Header Maintenance ü ü - Check S S - Lubricate p p - Change Action: Record Hour meter reading Date Serviced by Break-in Refer to 4.4.2 Break-In Inspection, page 105. 100 Hours or Annually Conditioner drive gearbox ü...

  • Page 119: Break-In Inspection

    MAINTENANCE AND SERVICING Self-Propelled Windrower Header Maintenance ü ü - Check S S - Lubricate p p - Change Action: Record Conditioner universal shafts Roll pivots Conditioner shaft bearings Knife drive cross-shaft Knife drive box oil - First 50 hours only 1000 Hours or 3 Years Conditioner drive gearbox lubricant...

  • Page 120: Storage

    MAINTENANCE AND SERVICING 4.4.4 Storage Do the following at the end of each operating season: CAUTION Never use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or flammable. CAUTION Cover cutterbar and knife guards to prevent injury from accidental contact. 1.

  • Page 121: Lubrication

    MAINTENANCE AND SERVICING 4.5 Lubrication CAUTION To avoid personal injury, before servicing header or opening drive covers, follow procedures in Preparing for Servicing, page CAUTION Refer to inside back cover for recommended greases. Log hours of operation and use the Maintenance Checklist provided to keep a record of scheduled maintenance. Refer to 4.4.1 Maintenance Schedule/Record, page 104.

  • Page 122: Lubrication Points: Auger Header

    MAINTENANCE AND SERVICING Lubrication Points: Auger Header NOTE: 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. 214804 Revision A...
  • Page 123 MAINTENANCE AND SERVICING Figure 4.6: A40D, A40DX Header Right Side A - Knife Drive Bearing (1 Place) (50 Hours) B - Reel Shaft Bearing (1 Place) (50 Hours) C - Auger Shaft Bearing (1 Place) (50 Hours) D - Knifehead Bearing (1 Place) (25 Hours)
  • Page 124 MAINTENANCE AND SERVICING Figure 4.7: A40D, A40DX Header Left Side A - Tine Bar Bearing (4 Places Each Tine Bar) (50 Hours) B - Knifehead Bearing (1 Place) (25 Hours) C - Gauge Roller Bearings (2 Places) Both Sides - if Installed (50 Hours)

  • Page 125: Lubrication Points: Hay Conditioner

    MAINTENANCE AND SERVICING Lubrication Points: Hay Conditioner NOTE: High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base. Figure 4.8: Hay Conditioner A - Roll Pivot (1 Place - Both Sides) B - Roll Shaft Bearings (2 Places) C - Roll Shaft Bearings (2 Places) 214804 Revision A...

  • Page 126: Lubrication Points: Drivelines

    MAINTENANCE AND SERVICING Lubrication Points: Drivelines NOTE: 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. Figure 4.9: Drivelines A - Driveline Shafts (2 Places) (50 hours) - NOTE: 10% Moly Grease Is Recommended For Driveline Shaft Slip Joints ONLY.
  • Page 127 MAINTENANCE AND SERVICING 214804 Revision A...

  • Page 128: Knife And Gearbox Oil

    MAINTENANCE AND SERVICING 4.5.3 Knife and Gearbox Oil Refer to the following illustration to identify the various locations that require lubrication. Refer to the inside back cover of this manual for proper oil. Figure 4.10: Knife and Gearbox Oil C - Knife Drive Box (2 Places) 3 A - Oil Knife Daily Except in Sandy Soil (SAE 30) B - Check Roll Gearbox (1 Place) 4 3.

  • Page 129: Installing Sealed Bearings

    MAINTENANCE AND SERVICING 4.5.4 Installing Sealed Bearings Follow these steps to install sealed bearings: 1. Clean shaft and coat with rust preventative. 2. Install flangette (A), bearing (B), second flangette (C), and lock collar (D). NOTE: The locking cam is only on one side of the bearing. 3.

  • Page 130: Hydraulics

    MAINTENANCE AND SERVICING 4.6 Hydraulics For hydraulics information about self-propelled windrower headers, contact your Dealer. 4.6.1 Servicing Header Hydraulics Refer to your windrower operator’s manual for hydraulic system maintenance procedures for self-propelled windrower headers. 4.6.2 Checking Hoses and Lines Check hydraulic hoses and lines daily for signs of leaks. WARNING •...

  • Page 131: Cutterbar

    MAINTENANCE AND SERVICING 4.7 Cutterbar CAUTION To avoid personal injury, before servicing header or opening drive covers, follow procedures in . WARNING Exercise caution when working around the cutterbar. Blades are sharp and can cause serious injury. Wear heavy gloves when working around or handling knife. WARNING Keep hands clear of the area between guards and knife at all times.

  • Page 132: Removing Knife

    MAINTENANCE AND SERVICING 4.7.2 Removing Knife WARNING To avoid bodily injury or death from unexpected start-up or fall of raised machine, always stop engine, remove key, and engage safety props before going under machine for any reason. WARNING Stand to rear of knife during removal to reduce risk of injury from cutting edges. Wear heavy gloves when handling knife.

  • Page 133: Removing Knifehead Bearing

    MAINTENANCE AND SERVICING 2. Slide the knife into place and align the knifehead with the output arm. 3. For ease of removing or installing knifehead pin, remove grease fitting from pin. 4. Install knifehead pin (A) through the output arm and into the knifehead.

  • Page 134: Installing Knifehead Bearing

    MAINTENANCE AND SERVICING 4.7.5 Installing Knifehead Bearing 1. Place O-ring (E) and plug (D) into knifehead. IMPORTANT: Install the bearing with the stamped end (the end with the identification markings) facing up. NOTE: It may be necessary to temporarily remove the grease fitting from the knifehead during installation of the knifehead pin.

  • Page 135: Guards

    MAINTENANCE AND SERVICING CAUTION 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. Remove bolts (A) from lean bar end cap. 2. Pull out end cap and plastic storage tube assembly with the knife inside.
  • Page 136 MAINTENANCE AND SERVICING Figure 4.23: Guard Configurations A - Pointed Standard (MD #118344) B - Pointed Drive End (No Ledger) (MD #118345) C - Pointed Right Outboard (MD #118302) D - Pointed Left Outboard (MD #118301) E - Pointed Center (MD #124338) F - Stub Standard (MD #118346) G - Stub Drive End (No Ledger) (MD #118347) H - Stub Center (MD #124775)

  • Page 137: Aligning Guard

    MAINTENANCE AND SERVICING Aligning Guard Check daily that guards are aligned to obtain proper shear cut between knife section and guard. Knife sections should contact shear surface of each guard. 1. Retrieve tool (A) from left side of header. Figure 4.24: Wrench Location 2.

  • Page 138: Replacing Pointed Guards And Hold-Downs

    MAINTENANCE AND SERVICING Replacing Pointed Guards and Hold-Downs Check daily that guards are firmly bolted to the cutterbar, and not worn or broken. Replace as required. A worn or broken guard can be replaced without removing knife from cutterbar. This procedure describes the replacement of pointed guards and hold-downs on single- and double-knife headers.
  • Page 139 MAINTENANCE AND SERVICING Double knife pointed center guard and hold-down IMPORTANT: Ensure center guard (B) has offset (A) in ledgers and that hold-down accommodates overlapping knives. NOTE: Replace adjacent guards when replacing center guard. Figure 4.29: Pointed Center Guard 1. Remove two nuts (A), and carriage bolts (B) that attach guard (C), adjuster bar (D), and hold-down (E) to the cutterbar.

  • Page 140: Replacing Pointed Center Guard On Double-Knife Header

    MAINTENANCE AND SERVICING Replacing Pointed Center Guard on Double-Knife Header Check daily that guards are firmly bolted to the cutterbar, and not worn or broken. Replace as required. A worn or broken guard can be replaced without removing knife from cutterbar. This procedure applies to the center guard where the two knives overlap on a double-knife header.
  • Page 141 MAINTENANCE AND SERVICING 1. Stroke the knife so that knife sections are spaced midway between the guards. 2. Remove two nuts (A) and bolts (B) that attach center guard (C) and hold-down (D) to cutterbar. 3. Remove guard (C), hold-down (D), and adjuster bar (E). 4.

  • Page 142: Replacing Center Stub Guard On Double-Knife Header

    MAINTENANCE AND SERVICING Replacing Center Stub Guard on Double-Knife Header Check daily that guards are firmly bolted to the cutterbar, and not worn or broken. Replace as required. A worn or broken guard can be replaced without removing knife from cutterbar. This procedure applies to the center guard where the two knives overlap on a double-knife header.
  • Page 143 MAINTENANCE AND SERVICING 1. Remove two nuts (A) and bolts that attach center guard (B) and top guide (C) to cutterbar. 2. Remove guard, top guide, and adjuster bar (D). Figure 4.39: Stub Guard Replacement IMPORTANT: Ensure center guard (B) has offset cutting surfaces. Refer to illustration.

  • Page 144: Hold-Downs

    MAINTENANCE AND SERVICING 4.7.8 Hold-Downs Hold-downs (also referred to as guides) keep the knife in contact with the guard cutting surface. It is important that the hold-downs are adjusted properly. Hold-downs are designed to accommodate specific guard locations and guard types: •...

  • Page 145: Adjusting Knife Hold-Down: Center Guard - Double-Knife Header

    MAINTENANCE AND SERVICING Adjusting Knife Hold-Down: Center Guard – Double-Knife Header 1. Torque nuts (A) to 46 Nm (35 lbf·ft). 2. Turn adjuster bolts (B). Using feeler gauge, clearance from hold-down to knife section (C) should be: • 0.1–0.4 mm (0.004–0.016 in.) at the guide tip (C) •...

  • Page 146: Knife Drive Box

    MAINTENANCE AND SERVICING 4.7.9 Knife Drive Box The knife drive box converts rotational motion from the windrower header driveshaft to reciprocating motion for the knife. The heavy-duty oil bath knife drive box (A) uses tapered roller bearings on the input shaft and yoke for increased durability.

  • Page 147: Removing Knife Drive Box

    MAINTENANCE AND SERVICING Removing Knife Drive Box 1. Loosen knife drive belt (A), and slip off knife drive box pulley. Refer to the following sections: • Checking/Adjusting Timing Belt Tension on Left Side, page 141 • Checking/Adjusting Timing Belt Tension on Right Side, page 145 Figure 4.47: Knife Drive Box 2.

  • Page 148: Installing Knife Drive Box

    MAINTENANCE AND SERVICING 9. Remove bolts (A) attaching knife drive box to frame. 10. Remove knife drive box. Figure 4.50: Knife Drive Box Bolts Installing Knife Drive Box 1. Position knife drive box as shown, and install four bolts (A). Torque side bolts, and then torque bottom bolts to 270 Nm (200 lbf·ft).
  • Page 149 MAINTENANCE AND SERVICING 6. Slide pitman arm (C) up or down on shaft until it just contacts knifehead (B), (0.25 mm [0.010 in.]) gap. 7. Install bolt (E) and nut, and torque to 217 Nm (160 lbf·ft). 8. Align knifehead (B) with pitman arm (C). 9.

  • Page 150: Removing Pulley

    MAINTENANCE AND SERVICING Removing Pulley 1. Remove knife drive box. Refer to Removing Knife Drive Box, page 133. 2. Loosen nut and bolt (A) from pulley. 3. Remove pulley using a three-jaw puller. Figure 4.55: Knife Drive Box Pulley Installing Pulley 1.

  • Page 151: Changing Knife Drive Box Oil

    MAINTENANCE AND SERVICING Changing Knife Drive Box Oil Change knife drive box lubricant after the first 50 hours operation, and every 1000 hours (or 3 years) thereafter. To change lubricant, follow these steps: CAUTION 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.
  • Page 152 MAINTENANCE AND SERVICING 2. Rotate the left side knife drive box driven pulley (A) clockwise until the left side knife is at the center of the inboard stroke (moving towards center of header). NOTE: Center stroke is when the knife points are centered between guard points.
  • Page 153 MAINTENANCE AND SERVICING 6. Check for correct knife timing by rotating the driveshaft (A) slowly with the unplugging wrench (B), and observe where knives overlap at the center of the header. IMPORTANT: Knives must move in opposite directions, and must begin moving at exactly the same time.

  • Page 154: Header Drive Systems

    MAINTENANCE AND SERVICING 4.8 Header Drive Systems 4.8.1 Header Knife Drive The A40D and A40DX double-knife headers have a windrower-powered hydraulic motor that drives each knife on the header with two belt-driven knife drive boxes. Checking/Adjusting V-Belt Tension on Left Side...

  • Page 155: Installing Double V-Belts

    MAINTENANCE AND SERVICING 3. Loosen three nuts (A) and jam nut on adjuster bolt (B). 4. Turn adjuster bolt (B) so that drive belts (C) can be slipped off pulleys (D) and (E). Figure 4.66: Left Side V-Belt Installing Double V-Belts IMPORTANT: Belts are a matched set.

  • Page 156: Removing Timing Belt From Left Side

    MAINTENANCE AND SERVICING 1. Turn off engine, and remove key. 2. Open left endshield. 3. Apply a force of 22–30 N (5–6.5 lbf) on belt (A) at midspan. Belt should deflect 14 mm (9/16 in.). If necessary, adjust as follows: a.
  • Page 157 MAINTENANCE AND SERVICING 9. Open the access panel (A) located beside the knife drive box. Line up the belt with the notch machined into the knife drive box pulley. Rotate the pulley with the belt in the notch until it is free for removal. Figure 4.71: Knife Drive Belt Access Panel NOTE: Mark the ports and hoses and place port caps or plastic...

  • Page 158: Installing Timing Belt On Left Side

    MAINTENANCE AND SERVICING Installing Timing Belt on Left Side CAUTION 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. Route knife drive timing belt from inboard side of endsheet through opening (A).

  • Page 159: Checking/Adjusting Timing Belt Tension On Right Side

    MAINTENANCE AND SERVICING 8. Install cover (B) in endsheet and secure with bolt (A). 9. Close endshield. NOTE: Readjust tension of a new belt after a short run-in period (5 hours). Figure 4.76: Left Side Inboard Cover Checking/Adjusting Timing Belt Tension on Right Side IMPORTANT: To prolong belt and drive life, do NOT over-tighten belt.

  • Page 160: Removing Timing Belt From Right Side

    MAINTENANCE AND SERVICING Removing Timing Belt from Right Side CAUTION 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. Remove bolt (A) and remove cover (B) in right endsheet.

  • Page 161: Installing Timing Belt On Right Side

    MAINTENANCE AND SERVICING Installing Timing Belt on Right Side CAUTION 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. Route knife drive timing belt from inboard side of endsheet through opening (A).

  • Page 162: Header Reel Drive

    The reel drive gearbox is a sealed, factory-assembled unit on an A40D and A40DX header. The reel drive gearbox requires no scheduled maintenance, but if service is required, see your Dealer. 4.8.3 Header Auger Drive The auger on an A40D and A40DX Header is driven directly from a hydraulic motor that is powered by the windrower hydraulics. 214804...

  • Page 163: Reel Tines And Tine Bar Bearings

    MAINTENANCE AND SERVICING 4.9 Reel Tines and Tine Bar Bearings Separate procedures are required to replace reel tines, depending on their location on the reel. Refer to the following topics for these procedures: • 4.9.1 Replacing Tine and Bearing: Cam End – Disc #1, page 149 •...
  • Page 164 MAINTENANCE AND SERVICING 2. Remove cam follower bearing bolt (A), bearing (B), and nut. 3. Disengage cam arm (C) from the cam track with a pry bar. 4. Remove flangette mounting bolts (D). Figure 4.85: Cam Follower 5. Remove nuts (A), keepers (B), and shoulder bolts (C) that connect cam arm (D) and end tines (E) to tine bar.
  • Page 165 MAINTENANCE AND SERVICING 7. Replace bearing (A). Refer to 4.5.4 Installing Sealed Bearings, page 115. Figure 4.88: Cam Arm Assembly 8. Replace tines as follows: a. Remove bolt (A) and keeper (B) on tine to be replaced. b. Remove bolts and keepers on tines as required to facilitate replacement of damaged or worn tine.
  • Page 166 MAINTENANCE AND SERVICING IMPORTANT: Replace hardware at cam end of tine bar with hardware as specified in the following steps. 13. Position tines as shown and install bolts (A) with keepers, spacers (B), and nuts (C). 14. Install bolts (D), spacers (B), and nuts (C) between tines as shown.

  • Page 167: Replacing Tine And Bearing: Disc #2

    MAINTENANCE AND SERVICING 17. Reposition cover (A) on cam, and tighten bolt. Figure 4.94: Cover 4.9.2 Replacing Tine and Bearing: Disc #2 Replace tine and bearing at disc #2 (A) as follows: IMPORTANT: Tine attachment hardware and configuration may vary between Tine Bar Type A and Tine Bar Type B.
  • Page 168 MAINTENANCE AND SERVICING 5. Remove bearing (A) from tine bar connecting shaft (B). Refer to 4.5.4 Installing Sealed Bearings, page 115. 6. Remove nuts (C), shoulder bolts (D), keepers (E) from left tine bar (F) and remove tines (G). Figure 4.97: Tine Bar Type A 7.
  • Page 169 MAINTENANCE AND SERVICING 10. Slip new tine onto center tine bar (E). 11. Assemble left tine bar (D) to center tine bar (E) and secure with shoulder bolts (B), keeper (C), and nuts. 12. Install tine bar onto reel disc with hardware (A). Tighten bolts to 31–36 Nm (23–26 lbf·ft).
  • Page 170 MAINTENANCE AND SERVICING 19. Install new tine (G) onto left tine bar (F) with shoulder bolt (D), keeper (E), and nut (C). 20. Assemble new bearing (A) with flangettes onto connecting shaft (B). Refer to 4.5.4 Installing Sealed Bearings, page 115.

  • Page 171: Replacing Tine And Bearing: Center Section X

    MAINTENANCE AND SERVICING 4.9.3 Replacing Tine and Bearing: Center Section X Replace tine and bearings at center section X (X) as follows: Figure 4.106: Center Section X A - Disc #2 B - Disc #3 C - Disc #4 X - Section X Y - Section Y 1.
  • Page 172 MAINTENANCE AND SERVICING 5. Remove tine as follows: a. Remove bolt (A) and keeper (B) on tine to be replaced. b. Remove bolts and keepers on tines as required to facilitate replacement of damaged or worn tine. c. Slide tines off tine bar. d.

  • Page 173: Replacing Tine And Bearing: Opposite Cam - Section Y

    MAINTENANCE AND SERVICING 4.9.4 Replacing Tine and Bearing: Opposite Cam – Section Y Replace tine and bearings at center section Y (Y) as follows: Figure 4.112: Opposite Cam – Section Y A - Disc #3 B - Disc #4 Y - Section Y Z - Section Z 1.
  • Page 174 MAINTENANCE AND SERVICING 5. Replace tine as follows: a. Remove bolt (A) and keeper (B) on tine to be replaced. b. Remove bolts and keepers on tines as required to facilitate replacement of damaged or worn tine. c. Slide tines off tine bar. d.

  • Page 175: Replacing Tine: Tine Bar Extension - Section Z

    MAINTENANCE AND SERVICING 4.9.5 Replacing Tine: Tine Bar Extension – Section Z Replace tine and bearings at center section Z (Z) as follows: Figure 4.116: Tine Bar Extension – Section Z A - Disc #3 B - Disc #4 Y - Section Y Z - Section Z 1.

  • Page 176: Straightening Auger Pans

    MAINTENANCE AND SERVICING 4.10 Straightening Auger Pans The high density polyethylene auger pans are repairable and replaceable. Refer to your Dealer for details on replacing the pans. IMPORTANT: To prolong the life of the auger pan, be sure to check that reel tines do NOT contact the pans when adjusting the reel position or tine pitch.

  • Page 177: Replacing Rubber Fingers

    MAINTENANCE AND SERVICING 4.11 Replacing Rubber Fingers Rubber fingers should be replaced if missing or damaged. To replace a rubber finger, follow these steps: 1. Remove nut and bolt (A), and then remove finger (B). 2. Position new finger in holder, and then install bolt and nut.

  • Page 178: Stripper Bar

    MAINTENANCE AND SERVICING 4.12 Stripper Bar Stripper bars help prevent the crop from wrapping around the auger and improve crop flow into the conditioner. To maintain 1–4 mm (1/32–5/32 in.) clearance (B) between auger (A) flighting and stripper bars, bars may need replacing due to wear or damage.

  • Page 179: Replacing Stripper Bars

    MAINTENANCE AND SERVICING 4.12.2 Replacing Stripper Bars WARNING 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. Remove four nuts and bolts (A) that secure each stripper bar (B) (both left and right side) to the pan, and remove bars.
  • Page 180 MAINTENANCE AND SERVICING 4. Position extension (A) at inboard end of front stripper bars, and mark locations of the two holes onto the pan. 5. Drill two 8 mm (5/16 in.) holes at these locations. 6. Install extension (A) with carriage bolts (C) retained from Step 3, page 165.

  • Page 181: Conditioner

    MAINTENANCE AND SERVICING 4.13 Conditioner CAUTION To avoid personal injury, before servicing header or opening drive covers, follow procedures in . 4.13.1 Changing Gearbox Oil CAUTION 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.
  • Page 182 MAINTENANCE AND SERVICING 4. Place a suitable container under gearbox drain to collect oil. 5. Remove breather (A) and check plug (B). Figure 4.126: Gearbox Breather Figure 4.127: Check Plug 6. Remove drain plug (A) and allow oil to drain. Replace drain plug once oil has drained.

  • Page 183: Removing Forming Shield

    MAINTENANCE AND SERVICING 7. Add oil at (A) to required level. Refer to inside back cover for recommended lubricant. 8. Oil is at required level when it runs out of check plug (B). Figure 4.129: Gearbox Breather Figure 4.130: Check Plug 4.13.2 Removing Forming Shield 1.

  • Page 184: Disassembling Forming Shield

    MAINTENANCE AND SERVICING 4. Remove two clevis pins (B) from forming shield forward end. 5. Lift forming shield off bolts (A) in windrower legs, and lower to ground. Replace clevis pins in forming shield. 6. Slide forming shield out from under windrower, or drive windrower away from forming shield.
  • Page 185 MAINTENANCE AND SERVICING 3. Disassemble nut (A) from bolt (B), and lift deflector (C) and washer (D) off forming shield. Repeat for other deflector. Figure 4.134: Forming Shield 4. Disassemble locking handles (A), and remove bolts. 5. Disassemble fluffer shield (B) from forming shield cover. Figure 4.135: Cover 214804 Revision A...

  • Page 186: Assembling Forming Shield

    MAINTENANCE AND SERVICING 6. Remove bolts (A) to remove deflector fins (B) from cover. Figure 4.136: Cover 4.13.4 Assembling Forming Shield To assemble the forming shield, follow these steps: 1. Attach deflector fins (B) to forming shield cover with bolts (A). Figure 4.137: Cover 2.
  • Page 187 MAINTENANCE AND SERVICING 4. Attach deflectors (C) and washers (D) to forming shield cover with nuts (A) and bolts (B). Figure 4.139: Forming Shield 5. Attach adjuster rods (B) to side deflectors (C) with lynch pin (A). Figure 4.140: Forming Shield 214804 Revision A...

  • Page 188: Installing Forming Shield

    MAINTENANCE AND SERVICING 4.13.5 Installing Forming Shield 1. If attached, remove header from the windrower for ease of installing the forming shield. Refer to windrower operator’s manual for procedure. NOTE: Do NOT install the two triangular-shaped plates from the forming shield kit. Triangular plates are used with rotary headers.
  • Page 189 MAINTENANCE AND SERVICING 4. Position forming shield (A) under windrower frame. Figure 4.144: Forming Shield under Windrower 5. Position forming shield onto bolts (A) in windrower legs and secure with clevis pins (B) and hairpin. Figure 4.145: Forming Shield Attached to Windrower Legs 214804 Revision A...

  • Page 190: Removing Header Drive Motor

    Deflector (Fluffer Shield), page Figure 4.147: Side Deflectors and Fluffer Shield 4.13.6 Removing Header Drive Motor This procedure applies to A40D and A40DX (excluding Grass Seed A40D and Grass Seed A40DX) double-knife headers. CAUTION 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.

  • Page 191: Installing Header Drive Motor

    Figure 4.148: Header Drive Motor 4.13.7 Installing Header Drive Motor This procedure applies to A40D, and A40DX (excluding Grass Seed A40D and Grass Seed A40DX) double-knife headers. CAUTION 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.

  • Page 192: Removing Conditioner Gearbox

    MAINTENANCE AND SERVICING 4.13.8 Removing Conditioner Gearbox 1. Open the conditioner drive shield and header left endshield. 2. Remove two bolts (A) securing channel (B) to frame. Figure 4.150: Conditioner Drive 3. Remove two hex bolts (A), and one carriage bolt (B) securing channel (C) to endsheet and remove channel (C).
  • Page 193 MAINTENANCE AND SERVICING 6. Remove two bolts (A) in upper driveline (B). 7. Pull driveline (B) off gearbox. If necessary, use a screwdriver or equivalent to spread yoke. Move driveline clear of work area. 8. Remove four bolts (C) from flange on lower driveline (D) and remove driveline from gearbox.

  • Page 194: Installing Conditioner Gearbox

    MAINTENANCE AND SERVICING 4.13.9 Installing Conditioner Gearbox 1. Position gearbox (B) as shown, picking up the three holes in the endsheet and secure with three flanged lock nuts (A). Do NOT fully tighten. Figure 4.156: Conditioner Gearbox 2. Locate key (A) in shaft. 3.
  • Page 195 MAINTENANCE AND SERVICING 9. Install knife drive V-belts (A). Refer to Installing Double V-Belts, page 141. Figure 4.159: Header Drive 10. Remove oil level check plug (A) in gearbox. If oil does not run out, add oil to required level. If oil is required, refer to the chart on the inside back cover of this manual.
  • Page 196 MAINTENANCE AND SERVICING 14. Apply a light coat of silicone to motor flange. 15. Position hydraulic motor (A) onto gearbox as shown and secure with two hex head bolts (B) with thread locking compound, two flat washers (C), and two lock washers (D).

  • Page 197: Checking/Adjusting Roll Alignment

    MAINTENANCE AND SERVICING 4.13.10 Checking/Adjusting Roll Alignment Rolls are aligned at the factory, but adjustment is provided in case the rolls become misaligned during operation. 1. Lower header until it rests on the ground. CAUTION 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.
  • Page 198 MAINTENANCE AND SERVICING 5. Examine roll bar spacing (X) at each end of the rolls. The rolls are aligned if (X) varies less than 1.6 mm (1/16 in.) from one end to the other. Figure 4.167: Roll Bar Spacing 6. If roll bar spacing (X) (as shown in Step 5, page 184) varies more than 1.6 mm (1/16 in.), align rolls as...

  • Page 199: Checking/Adjusting Roll Timing

    MAINTENANCE AND SERVICING 4.13.11 Checking/Adjusting Roll Timing The rolls must be correctly timed with each steel bar on one roll centered between two bars of the other roll. WARNING To avoid bodily injury or death from fall of raised machine, always lock-out lift cylinders before going under header for any reason.
  • Page 200 MAINTENANCE AND SERVICING 4. If required, adjust the roll timing as follows: a. Loosen four bolts (A) in slots of yoke plate on lower driveline. b. Turn rolls to achieve best timing. c. When roll timing is satisfactory, tighten bolts (A) to secure the position.

  • Page 201: Replacing Skid Shoe Wear Plate

    MAINTENANCE AND SERVICING 4.14 Replacing Skid Shoe Wear Plate Skid shoes are equipped with replaceable wear plates that can be reversed for increased service life. It is recommended that wear plates be replaced when the skid shoe support bracket becomes exposed. CAUTION 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.
  • Page 202 MAINTENANCE AND SERVICING 8. Insert tabs on skid shoe into slots (A) on cutterbar at inboard mounting locations on frame, and secure with clevis pin (B). Figure 4.176: Inboard Cutterbar Mounting Location 9. Reinstall clips (A) with bolts and nuts removed at Step 3, page 187 to secure skid shoe to cutterbar.

  • Page 203: Gauge Rollers

    MAINTENANCE AND SERVICING 4.15 Gauge Rollers Gauge rollers can be removed for replacement or repair. 4.15.1 Removing Gauge Rollers CAUTION 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.
  • Page 204 MAINTENANCE AND SERVICING 2. Secure with two pins (B) at lowest position. 3. Attach clips (A) with bolts and nuts to secure roller assembly to cutterbar. NOTE: Use a socket and ratchet wrench to access the nuts. 4. Tighten nuts. Figure 4.180: Gauge Roller Assembly 5.

  • Page 205: Maintaining The Electrical System

    Keep lights clean, and replace defective bulbs. To replace light bulbs, follow these steps: 1. Using a Phillips screwdriver, remove screws (A) from fixture, and remove plastic lens. 2. Replace bulb, and reinstall plastic lens and screws. Figure 4.182: A40D Hazard Light 214804 Revision A...

  • Page 207: Chapter 5: Optional Equipment

    5 Optional Equipment 5.1 Options and Attachments 5.1.1 Additional Skid Shoes In addition to the standard skid shoes, two additional skid shoes may be added for extra control of cutting height and protection of cutting components. MD #B4594 Figure 5.1: Skid Shoe 5.1.2 Gauge Roller Kit The gauge roller kit replaces the outer skid shoes with rollers.

  • Page 208: Replacement Reel Bat Kit

    OPTIONAL EQUIPMENT 5.1.3 Replacement Reel Bat Kit This kit consists of one complete bat assembly for ease of replacement. Separate kits are available for different header widths: • 4.3 m (14 ft.): MD #B4716 • 4.9 m (16 ft.): MD #B4717 •...

  • Page 209: Tall Crop Divider Kit

    OPTIONAL EQUIPMENT 5.1.5 Tall Crop Divider Kit Tall crop dividers attach to the ends of the header for clean crop dividing and reel entry in tall crops. The kit includes left and right dividers, lean bar extensions and attachment hardware. MD #B4690 Figure 5.5: Tall Crop Divider (Left Side) 214804...

  • Page 211: Chapter 6: Unloading And Assembly

    6 Unloading and Assembly Header-specific instructional manuals for unloading, assembly and set-up procedures are included with your shipment. Header Description Used on Instruction Part Number A40D, A40DX Self-Propelled Windrower MD #214805 214804 Revision A...

  • Page 213: Chapter 7: Troubleshooting

    7 Troubleshooting 7.1 Header Performance Symptom Problem Solution Section Reduce reel speed 3.6.3 Adjusting Reel Carryover of crop on reel Reel speed too fast (sprocket size). Speed, page 61 3.6.2 Adjusting Reduce auger speed Material build-up on Auger speed too fast Auger Speed, page (sprocket size).
  • Page 214 TROUBLESHOOTING Symptom Problem Solution Section Lower cutting height with 3.6.8 Setting Cutting Long stubble in down crop Cutting height too high skid shoes. Height, page 71 3.10 Selecting Long stubble in down crop Ground speed too fast Slow down. Ground Speed, page 93 Header angle too flat for 3.6.7 Adjusting...
  • Page 215 TROUBLESHOOTING Symptom Problem Solution Section 4.7.7 Guards, page Conditioner plugging; knife 3.10 Selecting plugging; uneven Ground speed too fast Slow down. Ground Speed, formation and bunching of page 93 windrow Conditioner plugging; knife 3.6.12 Adjusting plugging; uneven Roll gap too large for Decrease roll gap.
  • Page 216 TROUBLESHOOTING Symptom Problem Solution Section Conditioner plugging; knife 3.10 Selecting Reel not feeding properly plugging; uneven Decrease ground speed. Ground Speed, in heavy crops formation and bunching of page 93 windrow Conditioner plugging; knife Bent or misaligned guards Align guards for proper plugging;...
  • Page 217 TROUBLESHOOTING Symptom Problem Solution Section Header angle too steep, 3.6.9 Checking/ Reel causes seed loss Flatten header angle, and check Adjusting Float – M causing tines to contact (e.g. grass seed) header float. ground Series, page 72 Lower reel speed, move reel 3.6.3 Adjusting Reel rearward, as close as possible Reel causes seed loss...

  • Page 218: Mechanical

    TROUBLESHOOTING 7.2 Mechanical Symptom Problem Solution Section 3.6.11 Setting Feed Auger and/or conditioner Feed pan doesn't allow Pan and Rock Drop Lower rock-drop tines. rolls damaged by stones stones to fall through. Tine Position, page 3.10 Selecting Excessive breakage of Ground speed too high in Reduce ground speed.
  • Page 219 TROUBLESHOOTING Symptom Problem Solution Section Header turns while 4.6.1 Servicing unloaded but slows or Low reservoir oil level Add oil to reservoir. Header Hydraulics, stops when starting to cut page 116 Header turns while 3.10 Selecting Reduce ground speed until oil unloaded but slows or Cold oil in system Ground Speed,...
  • Page 220 TROUBLESHOOTING Symptom Problem Solution Section 4.16 Maintaining the Electrical Lights malfunctioning Burned out bulb Replace bulb. System, page 191 — Lights malfunctioning Poor connection Check connector at windrower. 214804 Revision A...

  • Page 221: Chapter 8: Reference

    8 Reference 8.1 Recommended Torques 8.1.1 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 222 REFERENCE Table 8.2 SAE Grade 5 Bolt and Grade F Distorted Thread Nut Torque (lbf·ft) Torque (Nm) Nominal (*lbf·in) Size (A) Min. Max. Min. Max. 1/4-20 5/16-18 16.7 18.5 *149 *164 3/8-16 7/16-14 1/2-13 9/16-12 Figure 8.2: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...

  • Page 223: Metric Bolt Specifications

    REFERENCE Table 8.4 SAE Grade 8 Bolt and Grade 8 Free Spinning Nut Torque (lbf·ft) Torque (Nm) Nominal (*lbf·in) Size (A) Min. Max. Min. Max. 1/4-20 16.8 18.6 *150 *165 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 Figure 8.4: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...
  • Page 224 REFERENCE Table 8.6 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (lbf·ft) Torque (Nm) Nominal (*lbf·in) 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 Figure 8.6: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...

  • Page 225: Metric Bolt Specifications Bolting Into Cast Aluminum

    REFERENCE Table 8.8 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (lbf·ft) Torque (Nm) Nominal (*lbf·in) 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 Figure 8.8: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5...

  • Page 226: Flare-Type Hydraulic Fittings

    REFERENCE 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. 3.

  • Page 227: O-Ring Boss Hydraulic Fittings - Adjustable

    REFERENCE 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 228 REFERENCE Table 8.11 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 229: O-Ring Boss Hydraulic Fittings - Non-Adjustable

    REFERENCE 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. Install fitting (C) into port until fitting is hand-tight. 5.

  • Page 230: O-Ring Face Seal Hydraulic Fittings

    REFERENCE 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 8.14: Hydraulic Fitting 2. Apply hydraulic system oil to O-ring (B). 3. Align tube or hose assembly so that flat face of sleeve (A) or (C) comes in full contact with O-ring (B).

  • Page 231: Tapered Pipe Thread Fittings

    REFERENCE Table 8.13 O-Ring Face Seal (ORFS) Hydraulic Fittings (continued) Torque Value SAE Dash Size Thread Size (in.) Tube O.D. (in.) lbf·ft – – Note 1 7/16 150–165 111–122 1 11/16 1 1/4 205–226 151–167 1–2 1 1/2 315–347 232–256 2 1/2 510–561 376–414...

  • Page 232: Conversion Chart

    REFERENCE 8.2 Conversion Chart Table 8.15 Conversion Chart Quantity SI Units (Metric) Factor US Customary Units (Standard) Unit Name Abbreviation Unit Name Abbreviation acre acres Area hectare x 2.4710 = US gallons per minute gpm Flow liters per minute L/min x 0.2642 = Force Newton...

  • Page 233: Index

    M100 or M105..........31 adjusting conditioner roll tension .....78 M150, M155, or M155E4......36 roll alignment M200............40 checking/adjusting........183 detaching A40D from windrower .....55 roll timing modifications needed to attach header ....31 checking/adjusting........185 A40DX SP windrower header forming shield, See forming shields attaching to M1 Series windrower ....25...
  • Page 234 ........73 removing ............189 removing and restoring float.......74 setting cutting height .........71 header operation gearboxes header float A40D conditioner drive gearbox float operating guidelines........73 installing ............. 180 headers removing............. 178 header specifications.........21 A40DX conditioner drive gearbox hex keys installing .............
  • Page 235 – DK header ....137 M100/M105 SP windrowers removing spare knife from storage ....120 attaching A40D header ........31 replacing knife section........117 M150, M155, and M155E4 SP windrowers knife drive attaching A40D header ........36 windrower header ........
  • Page 236 ....75 adjusting ............61 float reel tines and tine bar bearings M Series ............72 A40D SP windrower header M1 Series ..........72 replacing – disc #2 ........157 forming shield position ........79 replacing opposite cam – section Y ....159 ground speed ..........93...
  • Page 237 ...............97 fluids and lubricants ........225 windrower headers header .............21 attaching torque specifications ........207 A40D to M Series SP windrower .....31 storage .............. 106 A40DX to M1 Series windrower ......25 stripper bars detaching description............164 A40D from M Series SP windrower ....55 installing front extensions ........
  • Page 238 INDEX for M100, M105, M205 only ......50 troubleshooting mechanical issues ....204 troubleshooting performance issues ....199 unplugging conditioner and knife ......86 windrow forming rods ........92 windrows driving on windrows...........98 windrow characteristics ........98 wobble boxes, See knife drive boxes...

  • Page 239: Recommended Fluids And Lubricants

    Recommended Fluids and Lubricants Your machine can operate at top efficiency ONLY if clean lubricants are used. • Use clean containers to handle all lubricants. • Store in an area protected from dust, moisture, and other contaminants. Lubricant Specification Description Capacities High temperature extreme pressure (EP2) performance...
  • Page 240 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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