MacDon A40-D Assembly Instructions Manual
  1. Manuals
  2. Brands
  3. MacDon Manuals
  4. Farm Equipment
  5. A40-D
  6. Assembly instructions manual
MacDon A40-D Assembly Instructions Manual

MacDon A40-D Assembly Instructions Manual

Self-propelled windrower auger header
Hide thumbs Also See for A40-D:
Table of Contents

Advertisement

Quick Links

Download this manual
A40-D
Self-Propelled Windrower Auger
Header
Unloading and Assembly Instructions
169957 Revision A
Original Instruction
The harvesting specialists.

Advertisement

Table of Contents
loading

Related Manuals for MacDon A40-D

Summary of Contents for MacDon A40-D

  • Page 1 A40-D Self-Propelled Windrower Auger Header Unloading and Assembly Instructions 169957 Revision A Original Instruction The harvesting specialists.
  • Page 2 A40-D Self-Propelled Windrower Auger Header Published October, 2014...
  • Page 3 Introduction This instructional manual describes the unloading, setup, and predelivery requirements for the MacDon A40-D Self-Propelled Windrower Auger Header, including a Grass Seed version. Use the Table of Contents to guide you to specific topics. Follow the procedures provided in this manual in the order given.
  • Page 4 6.16 Hose Routing, page 73 Added note regarding check valve MD #167344 when attaching an A40-D Auger Header to an M100 or M105 6.13.1 Modifying Hydraulics on an M100 or M105, Self-Propelled Windrower. page 58 Removed reference to Routing Reverser Valve Jumper Hose when modifying M100 or M105 hydraulics.
  • Page 5 Summary of Change Location Added Checking Knife Speed sections to Predelivery 8.10 Checking Knife Speed, page 96 Checks. Updated illustration to show new manuals case. Removed manual part numbers and revised 8.12 Checking Manuals, page 100 instructions to have A-Series manuals placed in the manual case.

  • Page 7: Table Of Contents

    Installing Forming Shield ........................ 38 6.12 Attaching an A-Series Header to an SP Windrower ................41 6.12.1 Attaching A40-D Header to M100 or M105 ................41 6.12.2 Attaching A40-D Header to M150 or M155 ................46 6.12.3 Attaching A40-D Header to M200 .................... 50 6.12.4...
  • Page 8 TABLE OF CONTENTS Lubrication Points: Drivelines ......................83 Oiling ............................84 Performing Predelivery Checks......................85 Checking Drive Belts and Chains ....................85 Checking Auger Stripper Bar Clearance ..................86 Checking Reel Tine to Header Pan Clearance ................. 87 Checking Header Float ........................88 Checking Header Levelling......................

  • Page 9: Safety

    1 Safety 1.1 Signal Words Three signal words, “DANGER”, “WARNING”, and “CAUTION”, are used to alert you to hazardous situations. The appropriate signal word for each situation has been selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. WARNING Indicates a potentially hazardous situation that, if not avoided, could 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 the protective clothing and personal safety devices that COULD be necessary for the 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 the shaft and can telescope freely. •...

  • Page 12: Safety Signs

    SAFETY 1.3 Safety Signs • Keep safety signs clean and legible at all times. • Replace safety signs that missing become illegible. • If original parts on which a safety sign was installed are replaced, be sure the repair part also bears the current safety sign.

  • Page 13: Recommended Torques

    2 Recommended Torques 2.1 Torque Specifications The following tables provide the correct torque values for various bolts, cap screws, and hydraulic fittings. • Tighten all bolts to the torque values specified in the charts (unless otherwise noted throughout this manual). •...
  • Page 14 RECOMMENDED TORQUES Table 2.2 SAE Grade 5 Bolt and Grade F Distorted Thread Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) Size (A) Min. Max. Min. Max. 1/4-20 5/16-18 *149 *164 16.7 18.5 3/8-16 7/16-14 1/2-13 9/16-12 Figure 2.2: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8...

  • Page 15: Metric Bolt Specifications

    RECOMMENDED TORQUES Table 2.4 SAE Grade 8 Bolt and Grade 8 Free Spinning Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) Size (A) Min. Max. Min. Max. 1/4-20 *150 *165 16.8 18.6 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 Figure 2.4: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8...
  • Page 16 RECOMMENDED TORQUES Table 2.6 Metric Class 8.8 Bolts and Class 9 Distorted Thread Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) 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 *167 *185 18.8 20.8 Figure 2.6: Bolt Grades 10-1.5 12-1.75 14-2.0...
  • Page 17 RECOMMENDED TORQUES Table 2.8 Metric Class 10.9 Bolts and Class 10 Distorted Thread Nut Torque (ft·lbf) Torque (N·m) Nominal (*in·lbf) Size (A) Min. Max. Min. Max. 3-0.5 3.5-0.6 4-0.7 5-0.8 6-1.0 *105 10.7 11.8 8-1.25 Figure 2.8: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...

  • Page 18: Metric Bolt Specifications Bolting Into Cast Aluminum

    RECOMMENDED TORQUES 2.1.3 Metric Bolt Specifications Bolting into Cast Aluminum Table 2.9 Metric Bolt Bolting into Cast Aluminum Bolt Torque Nominal 10.9 Size (A) (Cast Aluminum) (Cast Aluminum) N·m N·m ft·lbf ft·lbf – – – – – – – Figure 2.9: Bolt Grades –...
  • Page 19 RECOMMENDED TORQUES Table 2.10 Flare-Type Hydraulic Tube Fittings Flats from Finger Nut Size Torque Value Tube Size Thread Tight (FFFT) SAE No. Across Flats O.D.(in.) Size (in.) (in.) ft·lbf N·m Flats Turns 3/16 7/16 7/16 9/16 5/16 9/16 11/16 1-1/16 1-1/4 1-3/8 1-3/8...

  • Page 20: O-Ring Boss (Orb) Hydraulic Fittings (Adjustable)

    RECOMMENDED TORQUES 2.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) 1. Inspect O-ring (A) and seat (B) for dirt or obvious defects. 2. Back off the lock nut (C) as far as possible. Ensure that washer (D) is not loose and is pushed toward the lock nut (C) as far as possible.
  • Page 21 RECOMMENDED TORQUES Table 2.11 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) Torque Value SAE Dash Size Thread Size (in.) ft·lbf (*in·lbf) N·m 3/8-24 *106–115 12–13 7/16–20 14–15 19–21 1/2–20 15–24 21–33 9/16–18 19–21 26–29 3/4–16 34–37 46–50 7/8–14 55–60 75–82 1-1/16-12 88–97 120–132 1-3/8-12...

  • Page 22: O-Ring Boss (Orb) Hydraulic Fittings (Non-Adjustable)

    RECOMMENDED TORQUES 2.1.6 O-Ring Boss (ORB) 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 the threads and adjust if necessary. 3. Apply hydraulic system oil to the O-ring. 4.

  • Page 23: O-Ring Face Seal (Orfs) Hydraulic Fittings

    RECOMMENDED TORQUES 2.1.7 O-Ring Face Seal (ORFS) Hydraulic Fittings 1. Check components to ensure that the sealing surfaces and fitting threads are free of burrs, nicks, scratches, or any foreign material. Figure 2.14: Hydraulic Fitting 2. Apply hydraulic system oil to the O-ring (B). 3.
  • Page 24 RECOMMENDED TORQUES Table 2.13 O-Ring Face Seal (ORFS) Hydraulic Fittings Torque Value Thread SAE Dash ft·lbf Size Size (in.) N·m (*in·lbf) Note – – 9/16–18 18–21 25–28 – – Note 11/16-16 29–32 40–44 13/16-16 41–45 55–61 1–14 59–65 80–88 1-3/16-12 85–94 115–127 Note...

  • Page 25: Conversion Chart

    3 Conversion Chart Table 3.1 Conversion Chart Inch-Pound Units SI Units (Metric) Quantity Factor Unit Name Abbreviation Unit Name Abbreviation Area Acres acres x 0.4047 = Hectares US Gallons Flow x 3.7854 = Liters per Minute L/min per Minute Force Pounds Force x 4.4482 = Newtons...

  • Page 27: Definitions

    4 Definitions The following terms and acronyms may be used in this manual. Term Definition A-Series header MacDon auger header American Petroleum Institute Articulated Power Turn ASTM American Society of Testing and Materials Bolt A headed and externally threaded fastener that is designed to be paired with a nut...
  • Page 28 DEFINITIONS Term Definition O-ring boss: a style of fitting commonly used in port opening on manifolds, pumps and motors O-ring face seal: a style of fitting commonly used for connecting hoses and tubes. ORFS This style of fitting is also commonly called ORS, which stands for O-ring seal Power Take-Off RoHS (Reduction of A directive by the European Union to restrict the use of certain hazardous...

  • Page 29: Unloading The Machine

    5 Unloading the Machine Follow each procedure in this chapter in order. 5.1 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, or machine damage.
  • Page 30 UNLOADING THE MACHINE To unload the header, follow these steps: 1. Remove hauler’s tie-down straps and chains. 2. Approach header from either its underside or topside and slide forks (A) in underneath lifting framework as far as possible. NOTE: When possible, approach from the underside to minimize potential for scratching the unit.

  • Page 31: Assembling The Machine

    6 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. 6.1 Removing Underside Shipping Stand CAUTION Keep feet clear when removing final bolts. 1.

  • Page 32: Installing Skid Shoes

    ASSEMBLING THE MACHINE 6.2 Installing Skid Shoes If kit is NOT supplied, proceed to 6.3 Installing Gauge Rollers, page 25. 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.

  • Page 33: Installing Gauge Rollers

    ASSEMBLING THE MACHINE 6.3 Installing Gauge Rollers If kit is NOT supplied, proceed to 6.4 Lowering the Header, page 27. 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.
  • Page 34 ASSEMBLING THE MACHINE 5. Secure to support bracket with locking pin (B) at lowest position. 6. Attach clips (A) with bolts and nuts removed earlier in this procedure to secure roller assembly to cutterbar. 7. Tighten nuts. NOTE: Use a socket and ratchet wrench to access the nuts.

  • Page 35: Lowering The Header

    ASSEMBLING THE MACHINE 6.4 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 36 ASSEMBLING THE MACHINE Figure 6.10: Header with Crane A - 48 in. (1.2 m) Minimum 5. Back up SLOWLY, while simultaneously lowering machine, so that cutterbar skid shoes rest on blocks (A). 6. Remove chain hooks from lean bar. Figure 6.11: Header on Blocks 169957 Revision A...
  • Page 37 ASSEMBLING THE MACHINE 7. Attach chain to center-link anchor (A) on frame tube and raise rear of header approximately 12 in. (305 mm) off ground. Figure 6.12: Center-Link Anchor 8. Remove lynch pin from clevis pin (A) in header stand at right side of header.

  • Page 38: Removing Shipping Stands

    ASSEMBLING THE MACHINE 6.5 Removing Shipping Stands To remove shipping stands, follow these steps: 1. Remove two bolts (A) from shipping stand (B). 2. Remove hairpin from pin (C). 3. Hold shipping stand (B), remove pin (C), and remove stand. Discard stand and hardware. Figure 6.15: Shipping Stands 4.

  • Page 39: Installing Tall Crop Divider Kit

    ASSEMBLING THE MACHINE 6.6 Installing Tall Crop Divider Kit If kit is NOT supplied, proceed to 6.7 Adjusting Lean Bar, page 32. Otherwise, proceed as follows: 1. Unpack kit and disassemble hardware from divider. 2. Remove hardware on both sides of lean bar and remove lean bar from header.

  • Page 40: Adjusting Lean Bar

    ASSEMBLING THE MACHINE 6.7 Adjusting Lean Bar The lean bar is fully retracted for shipping. Adjust as follows: 1. Remove hardware (A) on both sides and install lean bar in field position.Check that field position is suitable for the crop (normally 2/3 of crop height). NOTE: If optional tall crop divider kit is supplied, it can be installed prior to reinstalling the lean bar.

  • Page 41: Adjusting Pan Extensions: Grass Seed Special

    ASSEMBLING THE MACHINE 6.8 Adjusting Pan Extensions: Grass Seed Special The grass seed header auger pan extensions are factory-installed for the widest delivery. Adjust as follows: 1. Remove two bolts (A) and loosen bolt (B). Figure 6.21: Pan Extension – Wide Setting 2.

  • Page 42: Adjusting Transport Lights

    ASSEMBLING THE MACHINE 6.9 Adjusting Transport Lights 1. Position amber light supports (A) perpendicular to 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. NOTE: Do NOT overtighten mounting hardware.

  • Page 43: Assembling Forming Shield

    ASSEMBLING THE MACHINE 6.10 Assembling Forming Shield 1. Unpack and remove shipping material. 2. Remove bolts (B) from side deflectors (C). Figure 6.24: Forming Shield in Shipping Configuration 3. Install rubber strap (A) to the side bracket (B) using bolt (C), washer (D), and nut (E). 4.
  • Page 44 ASSEMBLING THE MACHINE 7. Assemble side deflectors (C) to cover with bolts (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 45 ASSEMBLING THE MACHINE 12. Invert forming shield to installation position as shown. Figure 6.29: Forming Shield in Installation Position 169957 Revision A...

  • Page 46: Installing Forming Shield

    ASSEMBLING THE MACHINE 6.11 Installing Forming Shield 1. Remove header from the windrower (if attached) for ease of installing the forming shield. Refer to windrower operator’s manual for procedure. NOTE: Do NOT install the two triangular shaped plates. Figure 6.30: Triangular Plate 2.
  • Page 47 ASSEMBLING THE MACHINE 4. Position forming shield (A) under windrower frame. Figure 6.33: Forming Shield Under Windrower 5. Position forming shield onto bolts (A) in windrower legs and secure with clevis pins (B) and lynch pin. Figure 6.34: Forming Shield Attached to Windrower Legs 169957 Revision A...
  • Page 48 ASSEMBLING THE MACHINE 6. Lift aft end of the forming shield and attach straps (B) to pins (A) on windrower frame. Install washer and hairpin to secure strap. Use the middle hole and adjust height to suit the crop. Figure 6.35: Forming Shield Attached to Windrower Frame 7.

  • Page 49: Attaching An A-Series Header To An Sp Windrower

    For M150, M155, M155 E4, and M200 Windrowers with Reverser kit MD #B4656 installed, hose plumbing to the reverser valve must be changed to suit the header type if switching between draper header and A40-D Auger Header to prevent draper header reel damage and improper operation. Refer to instruction MD #169213 for proper plumbing articles for each header type.
  • Page 50 ASSEMBLING THE MACHINE 1. Disengage rubber latch (A) and open driveline shield (B). Figure 6.38: Driveline Shield 2. Remove the cap (A) from electrical connector and remove connector from support bracket. 3. Disengage and rotate lever (B) counterclockwise to fully up position to release the hose bundle (C). Figure 6.39: Support Bracket and Hose Bundle 4.
  • Page 51 ASSEMBLING THE MACHINE 10. Push hose connectors onto mating receptacles as shown until collars on receptacles snap into lock position. Figure 6.41: Standard Header – 14 Ft. and 16 Ft. Header Shown (18 Ft. Similar) A - Reel Pressure B - Knife and Conditioner Return C - Case Drain D - Knife and Conditioner Pressure Figure 6.42: Grass Seed Header...
  • Page 52 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 6.43: Auger Return and Reel Pressure Hose Bundle 13.
  • Page 53 ASSEMBLING THE MACHINE Figure 6.46: Auger/Reel Pressure and Auger/Reel Return Valve Block Receptacles 15. Open header left-hand driveshield and check hose routing at the reel motor. The hose routing depends on which windrower model the header is being attached to. The header is factory-configured for M150, M155, and M200 Windrowers.

  • Page 54: Attaching A40-D Header To M150 Or M155

    ASSEMBLING THE MACHINE 6.12.2 Attaching A40-D Header to M150 or M155 CAUTION To prevent accidental movement of windrower, return ground speed lever (GSL) to N-DETENT, center steering wheel to lock, shut off engine, and remove key. M150 M155 Self-Propelled Windrowers factory-equipped with four header drive hoses on the left-hand side.
  • Page 55 ASSEMBLING THE MACHINE 4. Move hose/electrical bundle (A) to header. 5. Route bundle (A) from windrower through support (B) and access hole (C) in header frame alongside existing hose bundle (D) from header. 6. Remove cover on header electrical receptacle (E). 7.
  • Page 56 ASSEMBLING THE MACHINE Figure 6.54: Grass Seed Header A - Knife Return (Male Fitting at Header) (Hidden in this Image) B - Auger and Reel Pressure C - Knife Pressure (Female Fitting at Header) D - Case Drain 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 57 ASSEMBLING THE MACHINE 13. If valve blocks are NOT configured as shown at right, refer to 6.13.2 Modifying Hydraulics on an M150 or M155, page Figure 6.56: M150/M155 with Reverser Valve Figure 6.57: M150/M155 without Reverser Valve 14. Push auger pressure (A) and auger/reel return (B) hose couplers onto mating receptacles on valve block until collar on receptacle snaps into lock position.

  • Page 58: Attaching A40-D Header To M200

    Figure 6.59: Drive Hoses If only three drive hoses are present, before following the procedure below, configure the M200 to run an A40-D Auger Header by installing kit MD #B4651. The kit includes an additional hose, hardware, and installation instructions.
  • Page 59 ASSEMBLING THE MACHINE 2. Remove the cap (A) from electrical connector and remove connector from support bracket. 3. Disengage and rotate lever (B) counterclockwise to fully up position to release the hose bundle (C). Figure 6.62: Support Bracket and Hose Bundle 4.
  • Page 60 ASSEMBLING THE MACHINE Figure 6.65: Grass Seed Header A - Knife Return (Male Fitting at Header) (Hidden in this Image) B - Auger and Reel Pressure C - Knife Pressure (Female Fitting at Header) D - Case Drain (2015 &up would have a Tee at D) 11.
  • Page 61 ASSEMBLING THE MACHINE 13. If valve blocks are NOT configured as shown, refer to the relevant section for your windrower: • 6.13.3 Modifying Hydraulics on an M200 with a Reverser Valve, page 62 • 6.13.4 Modifying Hydraulics on an M200 without a Reverser Valve, page 63 Figure 6.67: M200 with Reverser Valve Figure 6.68: M200 without Reverser Valve...

  • Page 62: Attaching A40-D Header To M205

    1. Disengage rubber latch (A) and open driveline shield (B). Figure 6.71: Driveline Shield Reverser kit is optional and not required, although most A40-D headers have a reverser kit (B5492) ordered for the windrower. Check with the sales department and install prior to hook-up if required. 169957...
  • Page 63 ASSEMBLING THE MACHINE 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). 4. Move hose/electrical bundle (C) to header. Figure 6.72: Support Bracket and Hose Bundle 5.
  • Page 64 ASSEMBLING THE MACHINE Figure 6.75: Grass Seed Header A - Knife Return (Male Fitting at Header) (Hidden in this Image) B - Auger and Reel Pressure C - Knife Pressure (Female Fitting at Header) D - Case Drain 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 65 ASSEMBLING THE MACHINE 14. Check hose routing at the reel motor. The hose routing depends on which windrower model the header is being attached to. The header is factory-configured for M150, M155, and M200 Windrowers. Figure 6.78: Factory Configuration (M150, M155, and M200) 15.

  • Page 66: Modifying Hydraulics

    ASSEMBLING THE MACHINE 6.13 Modifying Hydraulics The windrower hydraulics must be modified to work correctly with an A40-D Auger Header. Follow the instructions in the relevant section for your windrower model: • 6.13.1 Modifying Hydraulics on an M100 or M105, page 58 •...
  • Page 67 ASSEMBLING THE MACHINE 4. Remove and discard cap (C) and adapter fitting (B) with O-ring from the large coupler (A). Figure 6.82: Large Coupler Assembly 5. Install large coupler (A) onto fitting at port ‘R1’ on valve block (B). IMPORTANT: Make sure O-ring is on JIC threads in port ‘R1’...

  • Page 68: Modifying Hydraulics On An M150 Or M155

    ASSEMBLING THE MACHINE 7. Install the small coupler subassembly (A) onto the tee (B) on valve block (C). NOTE: Position of adjacent hoses may require slight adjustment to allow access for new hoses. Figure 6.85: Valve Block Configured for Auger Header 6.13.2 Modifying Hydraulics on an M150 or M155 1.
  • Page 69 ASSEMBLING THE MACHINE 3. Remove female coupler assemblies (A) and (B) from hoses in bundle (C) from header and remove caps. Figure 6.88: Header Hose Bundle 4. Install smaller coupler assembly (C) in ‘R2’ port in valve block (A) and the larger coupler assembly (D) in ‘R2’ port in valve block (B).

  • Page 70: Modifying Hydraulics On An M200 With A Reverser Valve

    For windrowers with Reverser kit MD #B4656, hose plumbing to reverser valve must be changed to suit the header type if switching between A40-D Auger Header and draper header to prevent draper header reel damage and improper operation. See instruction MD #169213 for proper plumbing articles for each header type.

  • Page 71: Modifying Hydraulics On An M200 Without A Reverser Valve

    ASSEMBLING THE MACHINE 4. Install smaller coupler assembly (C) in ‘R2’ port in valve block (A) and the larger coupler assembly (D) in ‘R2’ port in valve block (B). NOTE: Position of adjacent hoses may require slight adjustment to allow access for new hoses. 5.
  • Page 72 ASSEMBLING THE MACHINE 3. Remove female coupler assemblies (C) and (D) from hoses in bundle (E) from header. Figure 6.95: Header Hose Bundle (E) 4. Remove and discard the cap (F) and adapter fitting (G) with O-ring from the large coupler (H). Figure 6.96: Large Coupler Assembly 5.

  • Page 73: Modifying Hydraulics On An M205

    The M205 hydraulics need to be modified to accept an A-Series Auger Header. Kits MD #B5491, MD #B5492, and MD #B5497 should have been supplied with your header. If required, the aforementioned kits can be ordered from your MacDon Dealer. 1. Install kits in accordance with the instructions that were supplied with the kits to achieve the configuration...

  • Page 74: Routing Reverser Valve Jumper Hose

    (B) must be routed according to header being operated to prevent draper header reel damage and improper operation. Figure 6.99: Hose (B) Position (A40-D on M200 Shown – M150 and M155 Similar) 169957 Revision A...

  • Page 75: Attaching Hydraulics

    ASSEMBLING THE MACHINE 6.15 Attaching Hydraulics CAUTION Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine. 1. Disengage rubber latch (A) and open driveline shield (B).
  • Page 76 ASSEMBLING THE MACHINE 6. Route hoses (A) from windrower through support (B) and access hole (C) in header frame alongside hose bundle (D). Hose bundle (D) will be attached later in the procedure. 7. Remove cover on header electrical receptacle (E). 8.
  • Page 77 ASSEMBLING THE MACHINE Figure 6.106: Hose Connections on Standard Header – 18 Ft. Header Shown A - Reel and Auger Pressure B - Knife and Conditioner Return C - Case Drain D - Knife and Conditioner Pressure Figure 6.107: Hose Connections on Grass Seed Header A - Knife Return (Male Fitting at Header) (Not Visible) B - Auger and Reel Pressure...
  • Page 78 ASSEMBLING THE MACHINE 12. If not already installed, retrieve package of three adjustable straps shipped with the header. 13. Position adjustable strap strap (A) through slot and under bracket (B) on hose support. 14. Attach strap to bracket with 1/2 in. carriage bolt (C) and locking nut.
  • Page 79 ASSEMBLING THE MACHINE 18. Connect auger/reel pressure and reel/auger return hoses from header to receptacles on windrower valve block. Refer to the relevant illustration for your equipment. Figure 6.110: M100/M105 A - Reel/Auger Return B - Auger/Reel Pressure Figure 6.111: M150/M155 with Reverser Valve A - Auger Pressure B - Reel/Auger Return Figure 6.112: M150/M155 without Reverser Valve...
  • Page 80 ASSEMBLING THE MACHINE Figure 6.113: M200 with Reverser Valve A - Auger Pressure B - Reel/Auger Return Figure 6.114: M200 without Reverser Valve A - Auger Pressure B - Reel/Auger Return Figure 6.115: M205 A - Reel/Auger Return B - Auger/Reel Pressure 169957 Revision A...

  • Page 81: Hose Routing

    ASSEMBLING THE MACHINE 6.16 Hose Routing The A40-D Auger Header drive hose routing depends on the windrower model to which the header is being attached. The header is factory-configured for M150, M155, and M200 Windrowers as shown in Figure 6.120: Factory Configuration (M150, M155, and M200), page...
  • Page 82 ASSEMBLING THE MACHINE 3. Loosen bulkhead nut (A) on auger and reel pressure coupler (B).This allows auger and reel pressure hose (C) to rotate freely. Figure 6.118: Auger and Reel Pressure Coupler and Hose – 14 Ft. and 16 Ft. Header Shown Figure 6.119: Auger and Reel Pressure Coupler and Hose –...
  • Page 83 ASSEMBLING THE MACHINE 4. Disconnect hoses as follows: a. Disconnect hose (A) at tee (B). b. Disconnect tee (B) at reel motor upper port. c. Disconnect hose (C) at reel motor lower port. 5. Cut cable ties (D) at locations shown in illustration. 6.
  • Page 84 ASSEMBLING THE MACHINE 8. Rotate coupler (B) and hose (C) downward as shown until slack has been sufficiently reduced. Tighten bulkhead nut (A). Figure 6.123: Auger and Reel Pressure Coupler and Hose – 14 Ft. and 16 Ft. Header Shown Figure 6.124: Auger and Reel Pressure Coupler and Hose –...

  • Page 85: Repositioning Knife Drive Box Breather

    ASSEMBLING THE MACHINE 6.17 Repositioning Knife Drive Box Breather There is one knife drive box at each end of the header. 1. Move breather/dipstick (A) to back port and install plug (B) in forward port at knife drive boxes. Figure 6.126: Top View of Knife Drive Box 2.

  • Page 87: Lubricating The Machine

    7 Lubricating the Machine 7.1 Greasing Procedure 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. Wipe grease fitting with a clean cloth before greasing to avoid injecting dirt and grit.

  • Page 88: Lubrication Points: Left Side Of Header

    LUBRICATING THE MACHINE 7.2 Lubrication Points: Left Side of 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.

  • Page 89: Lubrication Points: Right Side Of Header

    LUBRICATING THE MACHINE 7.3 Lubrication Points: Right Side of 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.

  • Page 90: Lubrication Points: Hay Conditioner

    LUBRICATING THE MACHINE 7.4 Lubrication Points: Hay Conditioner 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.

  • Page 91: Lubrication Points: Drivelines

    LUBRICATING THE MACHINE 7.5 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 7.5: Drivelines A - Driveline Shafts (2 Places) NOTE: 10% moly grease is recommended for driveline shaft slip joints ONLY.

  • Page 92: Oiling

    LUBRICATING THE MACHINE 7.6 Oiling NOTE: When oiling chains, apply oil to upper edge of lower spans. Figure 7.6: Oiling (SAE 30 Oil) A - Oil Knife Daily Except in Sandy Soil C - Knife Drive Box (2 Places) (Check Oil Level with Knife Drive Box Horizontal) B - Check Roll Gearbox (1 Place) 169957 Revision A...

  • Page 93: Performing Predelivery Checks

    2. Check knife drive timing belt (A). It should deflect 0.55 in. (14 mm) when a load of 5–6.5 lbf (22–30 N) is applied at mid-span. Figure 8.1: A40-D Header RH Side 3. Open shield on header left-hand side. 4. Check knife drive timing belt (A). It should deflect 0.55 in.

  • Page 94: Checking Auger Stripper Bar Clearance

    PERFORMING PREDELIVERY CHECKS 8.2 Checking Auger Stripper Bar Clearance 1. Check for signs of auger flighting (A) rubbing stripper bars (B) after run-up. Figure 8.3: 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 1/32–5/32 in.

  • Page 95: Checking Reel Tine To Header Pan Clearance

    PERFORMING PREDELIVERY CHECKS 8.3 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 96: Checking Header Float

    PERFORMING PREDELIVERY CHECKS 8.4 Checking Header Float The windrower float springs are NOT used to level the header. To adjust the float, follow these steps: 1. Check float by grasping the lean bar and lifting. Lifting force should be 75–85 lbf (335–380 N) and should be approximately the same at both ends.

  • Page 97: Checking Header Levelling

    PERFORMING PREDELIVERY CHECKS 8.5 Checking Header Levelling 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, perform the following checks prior to adjusting the levelling linkages. The float springs are NOT used to level the header.
  • Page 98 14. 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. Figure 8.11: Shims NOTE: Float does NOT require adjustment after levelling header.

  • Page 99: Checking Conditioner Rolls

    PERFORMING PREDELIVERY CHECKS 8.6 Checking Conditioner Rolls CAUTION Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine. 1. Lower header fully, stop engine, and remove key. 2.
  • Page 100 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 101: Checking Skid Shoes/Gauge Rollers

    PERFORMING PREDELIVERY CHECKS 8.7 Checking Skid Shoes/Gauge Rollers 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. Raise header and engage safety props. 2.

  • Page 102: Checking Lights

    PERFORMING PREDELIVERY CHECKS 8.8 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 upright position, yet will permit the light to pivot out of the way of obstructions.

  • Page 103: Running Up Header

    PERFORMING PREDELIVERY CHECKS 8.9 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 104: Checking Knife Speed

    PERFORMING PREDELIVERY CHECKS 8.10 Checking Knife Speed Refer to the following sections to check header knife speed when attaching an A40-D Auger Header to an M100 or M105 Windrower. Refer to windrower operator’s manual to check header knife speed in windrower cab display module (CDM) when attaching an A40-D Auger Header to an M150, M155, M155 E4, M200, or M205 Windrower.
  • Page 105 Setting Knife Speed (Without Expansion Module MD #B4666), page 8. Compare reading to Table 8.1 A40-D Auger Header Knife Speed, page Figure 8.21: Operator Console 9. If required, adjust knife speed as follows: 10. Shut down engine, and open engine hood.

  • Page 106: Setting Knife Speed (Without Expansion Module Md #B4666)

    2. Multiply the rpm reading by two to obtain the knife speed in strokes per minute. 3. Compare reading to Table 8.1 A40-D Auger Header Knife Speed, page 4. If required, adjust knife speed. Refer to Step 9., page Figure 8.24: Knife Drive Box on Header...

  • Page 107: Adjusting Knife

    PERFORMING PREDELIVERY CHECKS 8.11 Adjusting Knife 1. Check guards for signs of heating during run-up due to insufficient clearance between guard and knife. 2. If heating is evident, check gap between knifehead (A) and pitman arm (B). A business card should slide easily through the gap.

  • Page 108: Checking Manuals

    PERFORMING PREDELIVERY CHECKS 8.12 Checking Manuals The manual case is located inside the right-hand endshield. 1. Open the right endshield (A) and remove cable tie (B) on manual case (C). Figure 8.28: Manual Case 2. A-Series manuals shipped with shipping documents and auger header unloading and assembly instructions.

  • Page 109: Predelivery Checklist

    CAUTION Carefully follow the instructions given. Be alert for safety-related messages that bring your attention to hazards and unsafe practices. Header Serial Number: Table 1 A40-D Predelivery Checklist  Item Reference Check for shipping damage or missing parts. Be sure —...
  • Page 110 PREDELIVERY CHECKLIST  Item Reference Check knife speed. 8.10 Checking Knife Speed, page 96 Check that amber flasher and signal lights are 8.8 Checking Lights, page 94 functional. — Check header ID on windrower CDM. POST RUN-UP CHECKS. STOP ENGINE. —...
  • Page 112 10708 N. Pomona Avenue Kansas City, Missouri United States 64153-1924 t. (816) 891-7313 f. (816) 891-7323 MacDon Australia Pty. Ltd. A.C.N. 079 393 721 P.O. Box 243, Suite 3, 143 Main Street Greensborough, Victoria, Australia 3088 t. 03 9432 9982 f.

Table of Contents