MacDon A40-D Assembly Instructions Manual
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MacDon A40-D Assembly Instructions Manual

MacDon A40-D Assembly Instructions Manual

Self-propelled windrower auger header
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A40-D
Self-Propelled Windrower Auger
Header
Unloading and Assembly Instructions
147913 Revision A
2017 Model Year
Original Instruction
The harvesting specialists.

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Summary of Contents for MacDon A40-D

  • Page 1 A40-D Self-Propelled Windrower Auger Header Unloading and Assembly Instructions 147913 Revision A 2017 Model Year Original Instruction The harvesting specialists.
  • Page 2 A40-D Self-Propelled Windrower Auger Header Published May, 2016...
  • 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 List of Revisions The following list provides an account of major changes from the previous version of this document. Location Summary of Change Included note to lower header to the ground when 4.6 Knife and Gearbox Oil, page 76 5.6 Checking checking roll gearbox lubricant level.

  • Page 5: Table Of Contents

    Attaching Hydraulics ........................56 3.16 Hydraulic Drive Hose Routing (Later-Build 2015 A40-D Units Only)........... 62 3.17 Hydraulic Drive Hose Routing (Early-Build 2015, 2014 and Earlier A40-D)......... 67 3.18 Repositioning Knife Drive Box Breather................... 69 Lubricating the Machine........................71 Greasing Procedure........................71 Lubrication Points: Left Side of Header ...................
  • Page 6 TABLE OF CONTENTS Checking Lights ..........................87 5.10 Running Up Header ........................88 5.11 Checking Knife Speed........................89 5.11.1 Setting Knife Speed on an M100 or M105 ................89 Setting Knife Speed (With Expansion Module MD #B4666) ..........89 Setting Knife Speed (Without Expansion Module MD #B4666) ........... 91 5.12 Adjusting Knife ..........................

  • Page 7: 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 8: 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 9 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 10: Safety Signs

    • If original parts on which a safety sign was installed are replaced, be sure the repair part also bears the current safety sign. • Safety signs are available from MacDon Parts. Figure 1.7: Operator’s Manual Decal 147913 Revision A...

  • Page 11: Unloading The Machine

    2 Unloading the Machine Follow each procedure in this chapter in order. 2.1 Unloading the Header CAUTION To avoid injury to bystanders from being struck by machinery, do NOT allow anyone to stand in unloading area. CAUTION Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment may result in chain breakage, vehicle tipping, or machine damage.
  • Page 12 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 13: Assembling The Machine

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

  • Page 14: Installing Skid Shoes

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

  • Page 15: Installing Gauge Rollers

    ASSEMBLING THE MACHINE 3.3 Installing Gauge Rollers If kit is NOT supplied, proceed to 3.4 Lowering the Header, page 11. Otherwise, proceed as follows. NOTE: This kit may be installed later in the header assembly sequence, but it may be easier prior to laying the header down.
  • Page 16 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 17: Lowering The Header

    ASSEMBLING THE MACHINE 3.4 Lowering the Header To lower the header to the ground, follow these steps: 1. Attach either a spreader bar or chain to forks. CAUTION Ensure spreader bar or chain is secured to the forks so that it cannot slide off the forks or towards the mast as the header is lowered to the ground.
  • Page 18 ASSEMBLING THE MACHINE Figure 3.10: Header with Crane A - 1.2 m (48 in.) 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 3.11: Header on Blocks 147913 Revision A...
  • Page 19 ASSEMBLING THE MACHINE 7. Attach chain to center-link anchor (A) on frame tube and raise rear of header approximately 305 mm (12 in.) off ground. Figure 3.12: Center-Link Anchor 8. Remove lynch pin from clevis pin (A) in header stand at right side of header.

  • Page 20: Removing Shipping Stands

    ASSEMBLING THE MACHINE 3.5 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 3.15: Shipping Stands 4.

  • Page 21: Installing Tall Crop Divider Kit

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

  • Page 22: Adjusting Lean Bar

    ASSEMBLING THE MACHINE 3.7 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 23: Adjusting Pan Extensions: Grass Seed Special

    ASSEMBLING THE MACHINE 3.8 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 3.21: Pan Extension – Wide Setting 2.

  • Page 24: Adjusting Transport Lights

    ASSEMBLING THE MACHINE 3.9 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 25: Assembling Forming Shield

    ASSEMBLING THE MACHINE 3.10 Assembling Forming Shield 1. Unpack and remove shipping material. 2. Remove bolts (B) from side deflectors (C). Figure 3.24: 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 26 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 27 ASSEMBLING THE MACHINE 12. Invert forming shield to installation position as shown. Figure 3.29: Forming Shield in Installation Position 147913 Revision A...

  • Page 28: Installing Forming Shield - Sp Windrower Headers

    ASSEMBLING THE MACHINE 3.11 Installing Forming Shield – SP Windrower Headers 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. Triangular plates used with rotary headers.
  • Page 29 ASSEMBLING THE MACHINE 4. Position forming shield (A) under windrower frame. Figure 3.33: Forming Shield Under Windrower 5. Position forming shield onto bolts (A) in windrower legs and secure with clevis pins (B) and lynch pin. Figure 3.34: Forming Shield Attached to Windrower Legs 147913 Revision A...
  • Page 30 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 3.35: Forming Shield Attached to Windrower Frame 7.

  • Page 31: Attaching A40-D Header To Sp Windrower

    For M150, M155, M155E4, and M200 Windrowers with Reverser kit MD #B4656 installed, hose plumbing to the reverser valve must be changed if switching between a D-Series Draper Header with a conditioner and an A40-D Auger Header to prevent draper header reel damage and improper operation. Refer to 3.14 Routing Reverser...
  • Page 32 ASSEMBLING THE MACHINE 1. Disengage rubber latch (A) and open driveline shield (B). Figure 3.38: 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 3.39: Support Bracket and Hose Bundle 4.
  • Page 33 ASSEMBLING THE MACHINE NOTE: At location (C), later-built 2015 will have a “tee” going to case drain on square reel motor only. 10. Push hose connectors onto mating receptacles as shown until collars on receptacles snap into lock position. Figure 3.41: Early-Build 2015, 2014 and Earlier Standard Header –...
  • Page 34 ASSEMBLING THE MACHINE Figure 3.43: 2014 and Earlier 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.
  • Page 35 NOTE: Reel drive motor may not be exactly as shown. Later-build 2015 A40-D units have a square reel motor; Early-build 2015 A40-D (and 2014 and earlier units) have a round reel motor. The image at the right shows a square reel motor and so is a later-build model.

  • Page 36: Attaching To M150, M155, Or M155E4

    M105 Windrowers, refer to the section based on the year of manufacture: • Later-build 2015: 3.16 Hydraulic Drive Hose Routing (Later-Build 2015 A40-D Units Only), page • Early-build 2015, 2014 and earlier: 3.17 Hydraulic Drive Hose Routing (Early-Build 2015, 2014 and Earlier A40-D), page 67 Figure 3.49: Modified Routing M100, M105, and...
  • Page 37 ASSEMBLING THE MACHINE 1. Disengage rubber latch (A) and open driveline shield (B). Figure 3.51: 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 3.52: Support Bracket and Hose Bundle 4.
  • Page 38 ASSEMBLING THE MACHINE NOTE: At location (C), later-built 2015 will have a “tee” going to case drain on square reel motor only. 10. Push hose connectors onto mating receptacles as shown until collars on receptacles snap into lock position. Figure 3.54: Early-Build 2015, 2014 and Earlier Standard Header –...
  • Page 39 ASSEMBLING THE MACHINE Figure 3.56: 2014 and Earlier 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.
  • Page 40 ASSEMBLING THE MACHINE Figure 3.59: M150/M155/M155E4 without Reverser Valve 14. Locate the auger pressure (A) and auger/reel return (B) hoses. Figure 3.60: Auger Pressure and Auger/Reel Return Hose Couplers – 14-Ft. and 16-Ft. Header Shown (18-Ft. Similar) 15. 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 41: Attaching To M200

    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. The M200 Windrower requires four drive hoses (A) to run an A40-D Auger Header. Figure 3.63: Drive Hoses 147913...
  • Page 42 ASSEMBLING THE MACHINE 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 (A), hardware, and installation instructions.
  • Page 43 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 44 ASSEMBLING THE MACHINE Figure 3.69: 2015 Grass Seed Header Hose Connectors A - Reel and Auger Pressure B - Knife and Conditioner Return C - Case Drain D - Knife and Conditioner Pressure Figure 3.70: 2015 Grass Seed Header Hose Connectors Side View 147913 Revision A...
  • Page 45 ASSEMBLING THE MACHINE Figure 3.71: 2014 and Earlier 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.
  • Page 46 ASSEMBLING THE MACHINE 13. If valve blocks are NOT configured as shown at right, refer to relevant section for your windrower: • 3.13.3 Modifying Hydraulics – M200 with Reverser Valve, page 51 • 3.13.4 Modifying Hydraulics – M200 without Reverser Valve, page 52 Figure 3.73: M200 with Reverser Valve Figure 3.74: M200 without Reverser Valve 14.

  • Page 47: Attaching To M205

    ASSEMBLING THE MACHINE 15. 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. 16. Proceed to 3.14 Routing Reverser Valve Jumper Hose, page Figure 3.76: M200 with Reverser Valve Figure 3.77: M200 without Reverser Valve 3.12.4 Attaching to M205 CAUTION...
  • Page 48 (B). Figure 3.79: Driveline Shield 2. Reverser kit is optional and not required, although most A40-D Headers have a Reverser kit (MD #B5492) ordered for the windrower. Check with your Dealer, and install prior to hook-up if required. 147913...
  • Page 49 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 3.80: Support Bracket and Hose Bundle 5.
  • Page 50 ASSEMBLING THE MACHINE Figure 3.83: 2015 Grass Seed Header Hose Connectors A - Reel and Auger Pressure B - Knife and Conditioner Return C - Case Drain D - Knife and Conditioner Pressure Figure 3.84: 2014 and Earlier 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)
  • Page 51 ASSEMBLING THE MACHINE 11. Route auger return and reel pressure hose bundle (A) from header to windrower, and position bundle above existing hose support (C) as shown. 12. Secure with three straps (D), and lower lever (B). Figure 3.85: Auger Return and Reel Pressure Hose Bundle 13.
  • Page 52 Windrowers, refer to the section based on the year of manufacture: • Later-build 2015: 3.16 Hydraulic Drive Hose Routing (Later-Build 2015 A40-D Units Only), page • Early-build 2015, 2014 and earlier: 3.17 Hydraulic Drive Hose Routing (Early-Build 2015, 2014 and Earlier A40-D), page Figure 3.88: Modified Routing M100, M105,...

  • Page 53: Modifying Hydraulics

    ASSEMBLING THE MACHINE 3.13 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: • 3.13.1 Modifying Hydraulics – M100, M105, page 47 •...
  • Page 54 ASSEMBLING THE MACHINE 4. Remove and discard cap (C) and adapter fitting (B) with O-ring from the large coupler (A). Figure 3.91: 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 to ensure a proper seal with the coupler (A).

  • Page 55: Modifying Hydraulics - M150, M155, M155E4

    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 3.94: Valve Block Configured for Auger Header 3.13.2 Modifying Hydraulics –...
  • Page 56 ASSEMBLING THE MACHINE 3. Remove female coupler assemblies (A) and (B) from hoses in bundle (C) from header and remove caps. Figure 3.97: Header Hose Bundle 4. Install smaller coupler assembly (C) in port R2 on valve block (A) and the larger coupler assembly (D) in port R2 on valve block (B).

  • Page 57: Modifying Hydraulics - M200 With 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 (Reverser Kit Installation Instructions) for proper plumbing articles for each header type.

  • Page 58: Modifying Hydraulics - M200 Without Reverser Valve

    ASSEMBLING THE MACHINE 4. Install smaller coupler assembly (C) in port R2 on valve block (A) and the larger coupler assembly (D) in port R2 on valve block (B). NOTE: Position of adjacent hoses may require slight adjustment to allow access for new hoses. Align larger coupler assembly (D) with R1 hose (E).
  • Page 59 ASSEMBLING THE MACHINE 3. Remove female coupler assemblies (C) and (D) from hoses in bundle (E) from header. Figure 3.104: Header Hose Bundle (E) 4. Remove and discard the cap (F) and adapter fitting (G) with O-ring from the large coupler (H). Figure 3.105: Large Coupler Assembly 5.

  • Page 60: Modifying Hydraulics - 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 61: Routing Reverser Valve Jumper Hose

    This prevents draper header reel damage and improper operation, which occurs if reel runs backwards. Figure 3.108: Hose (B) Position (A40-D on M200 Shown – M150, M155, and M155E4 Similar) NOTE: Jumper hose re-routing is unnecessary if hay conditioner is not installed on draper header.

  • Page 62: Attaching Hydraulics

    ASSEMBLING THE MACHINE 3.15 Attaching Hydraulics 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. Disengage rubber latch (A), and open driveline shield (B).
  • Page 63 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 64 ASSEMBLING THE MACHINE Figure 3.116: Hose Connections on Standard Header – 18-Ft. Header Shown A - Reel/Auger Pressure B - Knife and Conditioner Return C - Case Drain D - Knife and Conditioner Pressure Figure 3.117: Hose Connections on Grass Seed Header A - Knife Return (Male Fitting at Header) (Not Visible) B - Auger/Reel Pressure...
  • Page 65 ASSEMBLING THE MACHINE 12. If not already installed, retrieve package of three adjustable straps shipped with the header. 13. Position adjustable 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 66 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 3.120: M100/M105 A - Reel/Auger Return B - Auger/Reel Pressure Figure 3.121: M150/M155/M155E4 with Reverser Valve A - Auger Pressure B - Reel/Auger Return...
  • Page 67 ASSEMBLING THE MACHINE Figure 3.123: M200 with Reverser Valve A - Auger Pressure B - Reel/Auger Return Figure 3.124: M200 without Reverser Valve A - Auger Pressure B - Reel/Auger Return Figure 3.125: M205 A - Reel/Auger Return B - Auger/Reel Pressure 147913 Revision A...

  • Page 68: Hydraulic Drive Hose Routing (Later-Build 2015 A40-D Units Only)

    3.16 Hydraulic Drive Hose Routing (Later-Build 2015 A40-D Units Only) The A40-D Auger Header hydraulic drive hose routing depends on the windrower model to which the header is being attached. The header is factory-configured for M150, M155, M155E4, and M200 SP Windrowers as shown in Figure 3.131:...
  • Page 69 ASSEMBLING THE MACHINE 2. Disengage rubber latch (A), and open driveline shield (B). Figure 3.128: Driveline Shield 3. Loosen bulkhead nut (A) on auger and reel pressure coupler (B). This allows auger and reel pressure hose (C) to rotate freely. Figure 3.129: Auger and Reel Pressure Coupler and Hose –...
  • Page 70 ASSEMBLING THE MACHINE 4. Disconnect hoses as follows: a. Disconnect hose (A) from tee (B). b. Disconnect tee (B) from reel motor upper port. c. Disconnect hose (C) from reel motor lower port. 5. Cut cable ties (D) at locations shown in illustration. Figure 3.131: Factory Configuration (M150, M155, M155E4, and M200) 6.
  • Page 71 ASSEMBLING THE MACHINE 7. Secure electrical harness (B), motor case drain hose (C), and hose (D) together with cable ties (A), as shown. IMPORTANT: Ensure there is at least 25 mm (1 in.) clearance between hose bundle (E) and knife drive timing belt (F).
  • Page 72 ASSEMBLING THE MACHINE 9. Close driveline shield (B) and engage rubber latch (A). 10. Close driveshield before engaging header. Figure 3.136: Driveline Shield 147913 Revision A...

  • Page 73: Hydraulic Drive Hose Routing (Early-Build 2015, 2014 And Earlier A40-D)

    3.17 Hydraulic Drive Hose Routing (Early-Build 2015, 2014 and Earlier A40-D) The A40-D Auger Header drive hose routing depends on the windrower model to which the header is being attached. Early build A40-D Headers are for use on M100, M105 and M205 Windrowers Only.
  • Page 74 ASSEMBLING THE MACHINE To route hoses on early-build 2015, 2014 and earlier A40-D Headers for use on M100, M105, and M205 Windrowers, proceed as follows. 3. Disconnect hoses as follows: a. Disconnect hose (A) from tee (C). b. Disconnect hose (B) from reel motor upper port.

  • Page 75: Repositioning Knife Drive Box Breather

    ASSEMBLING THE MACHINE 3.18 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 3.142: Top View of Knife Drive Box 2.

  • Page 77: Lubricating The Machine

    4 Lubricating the Machine 4.1 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 78: Lubrication Points: Left Side Of Header

    LUBRICATING THE MACHINE 4.2 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 79: Lubrication Points: Right Side Of Header

    LUBRICATING THE MACHINE 4.3 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 80: Lubrication Points: Hay Conditioner

    LUBRICATING THE MACHINE 4.4 Lubrication Points: Hay Conditioner NOTE: High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base. Figure 4.4: Hay Conditioner A - Roll Pivot (1 Place - Both Sides) B - Roll Shaft Bearings (2 Places) C - Roll Shaft Bearings (2 Places) 147913 Revision A...

  • Page 81: Lubrication Points: Drivelines

    LUBRICATING THE MACHINE 4.5 Lubrication Points: Drivelines NOTE: High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base. Figure 4.5: Drivelines A - Driveline Shafts (2 Places) NOTE: 10% moly grease is recommended for driveline shaft slip joints ONLY. B - Cross Shafts (2 Places) C - Driveline Universals (2 Places) D - Driveline Universals (2 Places)

  • Page 82: Knife And Gearbox Oil

    LUBRICATING THE MACHINE 4.6 Knife and Gearbox Oil Figure 4.6: Knife and Gearbox Oil A - Oil Knife Daily Except in Sandy Soil (SAE 30) C - Knife Drive Box (2 Places) (Check Oil Level with Knife Drive Box Horizontal) B - Check Roll Gearbox (1 Place) (Lower Header to the Ground).

  • Page 83: Performing Predelivery Checks

    2. Check knife drive timing belt (A). It should deflect 14 mm (0.55 in.) when a load of 22–30 N (5–6.5 lbf) is applied at mid-span. Figure 5.1: A40-D Header RH Side 3. Open shield on header left-hand side. 4. Check knife drive timing belt (A). It should deflect 14 mm (0.55 in.) when a load of 22–30 N (5–6.5 lbf)

  • Page 84: Checking Auger Stripper Bar Clearance

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

  • Page 85: Checking Reel Tine To Header Pan Clearance

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

  • Page 86: Checking/Adjusting Float

    PERFORMING PREDELIVERY CHECKS 5.4 Checking/Adjusting Float The windrower float springs are NOT used to level the header. 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. To adjust the float, follow these steps: 1.

  • Page 87: Checking Header Levelling

    PERFORMING PREDELIVERY CHECKS 5.5 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 88 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 5.11: Shims NOTE: Float does NOT require adjustment after levelling header.

  • Page 89: Checking Conditioner Rolls

    PERFORMING PREDELIVERY CHECKS 5.6 Checking Conditioner Rolls 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. Lower header fully, stop engine, and remove key. 2.
  • Page 90 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 91: Checking Conditioner Gearbox Oil Level

    PERFORMING PREDELIVERY CHECKS 5.7 Checking Conditioner Gearbox Oil Level 1. Lower header fully, stop engine, and remove key. NOTE: Check that gearbox is level with ground. 2. Remove check plug (A) and ensure that oil runs out. If oil does not run, fill conditioner gearbox using SAE 85W-140.

  • Page 92: Checking Skid Shoes/Gauge Rollers

    PERFORMING PREDELIVERY CHECKS 5.8 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 93: Checking Lights

    PERFORMING PREDELIVERY CHECKS 5.9 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 94: Running Up Header

    PERFORMING PREDELIVERY CHECKS 5.10 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 95: Checking Knife Speed

    PERFORMING PREDELIVERY CHECKS 5.11 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, M155E4, M200, or M205 Windrower.
  • Page 96 PERFORMING PREDELIVERY CHECKS 4. If required, adjust knife speed as follows: 5. Shut down engine, and open engine hood. 6. Locate the knife drive pump (A) and knife speed adjuster screw (B) under the right (cab-forward) side of the windrower. NOTE: The knife speed adjuster screw may have a plastic cap (B) covering it.

  • Page 97: 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 5.1 A40-D Auger Header Knife Speed, page 4. If required, adjust knife speed. Refer to Step 4., page Figure 5.24: Knife Drive Box on Header...

  • Page 98: Adjusting Knife

    PERFORMING PREDELIVERY CHECKS 5.12 Adjusting Knife WARNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine. 1. Stop engine and remove the key. 2. Check guards for signs of heating during run-up due to insufficient clearance between guard and knife.

  • Page 99: Checking Manuals

    PERFORMING PREDELIVERY CHECKS 5.13 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 5.28: Manual Case 2. A-Series manuals shipped with shipping documents and auger header unloading and assembly instructions.

  • Page 101: Reference

    6 Reference 6.1 Recommended Torques 6.1.1 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 102 REFERENCE Table 6.2 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 16.7 18.5 *149 *164 3/8-16 7/16-14 1/2-13 9/16-12 Figure 6.2: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...

  • Page 103: Metric Bolt Specifications

    REFERENCE Table 6.4 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 16.8 18.6 *150 *165 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 Figure 6.4: Bolt Grades 5/8-11 A - Nominal Size B - SAE-8 C - SAE-5...
  • Page 104 REFERENCE Table 6.6 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 18.8 20.8 *167 *185 Figure 6.6: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0...
  • Page 105 REFERENCE Table 6.8 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 10.7 11.8 *105 8-1.25 Figure 6.8: Bolt Grades 10-1.5 12-1.75 14-2.0 16-2.0 20-2.5...

  • Page 106: Metric Bolt Specifications Bolting Into Cast Aluminum

    REFERENCE Metric Bolt Specifications Bolting into Cast Aluminum Table 6.9 Metric Bolt Bolting into Cast Aluminum Bolt Torque Nominal 10.9 Size (A) (Cast Aluminum) (Cast Aluminum) N·m ft·lbf N·m ft·lbf – – – – – – – Figure 6.9: Bolt Grades –...
  • Page 107 REFERENCE Table 6.10 Flare-Type Hydraulic Tube Fittings Torque Value Flats from Finger Tight (FFFT) SAE Dash Size Thread Size (in.) Swivel Nut or N·m ft·lbf Tube Hose — — 5/16–24 4–5 3–4 — — 3/8–24 7–8 5–6 7/16–20 18–19 13–14 2-1/2 1/2–20 19–21...

  • Page 108: O-Ring Boss (Orb) Hydraulic Fittings (Adjustable)

    REFERENCE 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 loose and is pushed toward the lock nut (C) as far as possible.
  • Page 109 REFERENCE Table 6.11 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) Torque Value SAE Dash Size Thread Size (in.) N·m ft·lbf (*in·lbf) 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 110: O-Ring Boss (Orb) Hydraulic Fittings (Non-Adjustable)

    REFERENCE 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 111: O-Ring Face Seal (Orfs) Hydraulic Fittings

    REFERENCE 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 6.14: Hydraulic Fitting 2. Apply hydraulic system oil to the O-ring (B). 3.
  • Page 112 REFERENCE Table 6.13 O-Ring Face Seal (ORFS) Hydraulic Fittings Torque Value SAE Dash Size Thread Size (in.) Tube O.D. (in.) N·m ft·lbf Note 3/16 – – 9/16 25–28 18–21 Note – – 5/16 11/16 40–44 29–32 13/16 55–61 41–45 80–88 59–65 1-3/16 115–127...

  • Page 113: Tapered Pipe Thread Fittings

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

  • Page 114: Conversion Chart

    REFERENCE 6.2 Conversion Chart Table 6.15 Conversion Chart SI Units (Metric) Inch-Pound Units Quantity Factor Unit Name Abbreviation Unit Name Abbreviation Area hectares x 0.4047 = acres acres US gallons Flow liters per minute L/min x 3.7854 = per minute Force Newtons x 4.4482 =...

  • Page 115: Definitions

    6.3 Definitions The following terms and acronyms may be used in this manual. Term Definition A-Series header MacDon auger header 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 116 REFERENCE Term Definition N-DETENT The slot opposite the NEUTRAL position on operator’s console 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 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...

  • Page 117: 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 118 PREDELIVERY CHECKLIST RUN-UP PROCEDURE 5.10 Running Up Header, page 88 Check hydraulic hose and wiring harness routing for — clearance when raising or lowering header and when retracting or extending center-link. Check knife speed. 5.11 Checking Knife Speed, page 89 Check that amber flasher and signal lights are 5.9 Checking Lights, page 87 functional.
  • Page 120 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.

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