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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.

Table 2.1 Lifting Vehicle

Minimum Capacity

1

3630 kg (8000 lb)

Minimum Fork Length

1981 mm (78 in.)

IMPORTANT:

Forklifts are normally rated for a load located 610 mm (24 in.) ahead of back end of the forks. To obtain the forklift
capacity at 1220 mm (48 in.), check with your forklift distributor.

WARNING

Be sure forks are secure before moving away from load. Stand clear when lifting.

2.1.1

Unloading the Header from a Truck Flatbed

IMPORTANT:

Do

NOT

unload using lean bar for lifting. Chain hook slots in lean bar are only for laying the machine over into

working position after it is on the ground.

NOTE:

Take care not to bend parts on backtube.

1.

At 1220 mm (48 in.) from back end of forks.

147913

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Revision A

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Summary of Contents for A40-D

Page 1: ...The harvesting specialists A40 D Self Propelled Windrower Auger Header Unloading and Assembly Instructions 147913 Revision A 2017 Model Year Original Instruction ...

Page 2: ...A40 D Self Propelled Windrower Auger Header Published May 2016 ...

Page 3: ...to guide you to specific topics Follow the procedures provided in this manual in the order given CAREFULLY READ THE INFORMATION PROVIDED IN THIS MANUAL BEFORE ATTEMPTING TO UNLOAD ASSEMBLE OR USE THE MACHINE NOTE Keep your MacDon publications up to date The most current version can be downloaded from our website www macdon com or from our Dealer only site https portal macdon com login required 147...

Page 4: ...or changes from the previous version of this document Summary of Change Location Included note to lower header to the ground when checking roll gearbox lubricant level 4 6 Knife and Gearbox Oil page 76 and 5 6 Checking Conditioner Rolls page 83 147913 ii Revision A ...

Page 5: ... 47 3 13 2 Modifying Hydraulics M150 M155 M155E4 49 3 13 3 Modifying Hydraulics M200 with Reverser Valve 51 3 13 4 Modifying Hydraulics M200 without Reverser Valve 52 3 13 5 Modifying Hydraulics M205 54 3 14 Routing Reverser Valve Jumper Hose 55 3 15 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 201...

Page 6: ...3 6 Reference 95 6 1 Recommended Torques 95 6 1 1 Torque Specifications 95 SAE Bolt Torque Specifications 95 Metric Bolt Specifications 97 Metric Bolt Specifications Bolting into Cast Aluminum 100 Flare Type Hydraulic Fittings 100 O Ring Boss ORB Hydraulic Fittings Adjustable 102 O Ring Boss ORB Hydraulic Fittings Non Adjustable 104 O Ring Face Seal ORFS Hydraulic Fittings 105 Tapered Pipe Thread ...

Page 7: ...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 It may also be used to alert against unsafe practices CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It may be used to alert against u...

Page 8: ...ter mask Figure 1 1 Safety Equipment Be aware that exposure to loud noises can cause hearing impairment or loss Wear suitable hearing protection devices such as ear muffs or ear plugs to help protect against objectionable or loud noises Figure 1 2 Safety Equipment Provide a first aid kit for use in case of emergencies Keep a fire extinguisher on the machine Be sure the fire extinguisher is properl...

Page 9: ...rten the machine s life To avoid bodily injury or death from unexpected startup of machine always shut down the engine and remove the key from ignition before leaving operator s seat for any reason Figure 1 5 Safety around Equipment Keep the service area clean and dry Wet or oily floors are slippery Wet spots can be dangerous when working with electrical equipment Be sure all electrical outlets an...

Page 10: ...ce safety signs that are missing or become illegible If original parts on which a safety sign was installed are replaced be sure the repair part also bears the current safety sign Safety signs are available from MacDon Parts Figure 1 7 Operator s Manual Decal 147913 4 Revision A ...

Page 11: ...0 kg 8000 lb Minimum Fork Length 1981 mm 78 in IMPORTANT Forklifts are normally rated for a load located 610 mm 24 in ahead of back end of the forks To obtain the forklift capacity at 1220 mm 48 in check with your forklift distributor WARNING Be sure forks are secure before moving away from load Stand clear when lifting 2 1 1 Unloading the Header from a Truck Flatbed IMPORTANT Do NOT unload using ...

Page 12: ...ching the unit 3 Raise header off deck IMPORTANT If load is two wide take care not to contact the other machine Figure 2 1 Forks in Position 4 Back up until unit clears trailer and slowly lower to 150 mm 6 in from ground 5 Take to storage or setup area 6 Set header down securely on level ground 7 Repeat for other header if required 8 Check for shipping damage and missing parts Figure 2 2 Topside o...

Page 13: ...o 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 Remove four bolts A and remove shipping stand B Discard stand and hardware Figure 3 1 Underside Shipping Stand 147913 7 Revision A ...

Page 14: ...gure 3 2 Skid Shoe Bundle 4 Position skid shoe below cutterbar and insert tabs on skid shoe into slots A in frame Secure with clevis pin B Figure 3 3 Skid Shoe Hardware 5 Attach clips A with bolts and nuts removed earlier in this procedure to secure skid shoe to cutterbar NOTE Use a socket and ratchet wrench to access the nuts 6 Tighten nuts 7 Remove clevis pin B and adjust skid shoe to desired he...

Page 15: ...sembly sequence but it may be easier prior to laying the header down 1 Unpack gauge roller bundle 2 Remove two locking pins A from each assembly 3 Remove nuts bolts and clips B from assembly Figure 3 5 Gauge Roller in Shipping Configuration 4 Insert tabs on roller assembly into slots A on cutterbar at outboard mounting locations on frame Figure 3 6 Gauge Roller Mounting Location 147913 9 Revision ...

Page 16: ...Use a socket and ratchet wrench to access the nuts Figure 3 7 Gauge Roller 8 Remove locking pin A and adjust rollers to desired height Reinstall both locking pins A 9 Ensure that nut B on each pin registers in adjacent hole in support bracket 10 Secure pins with hairpins C 11 Repeat previous steps for opposite side Set both gauge rollers to the same position Figure 3 8 Gauge Roller and Locking Pin...

Page 17: ...hooks to lean bar at slots as shown IMPORTANT See table below for minimum chain specifications Also chain length must be sufficient to provide a minimum 1 2 m 4 ft vertical chain height Table 3 1 Chain Specifications Chain Type Overhead lifting quality 1 2 in Minimum Working Load 2270 kg 5000 lb CAUTION Stand clear when lowering as machine may swing NOTE Do NOT lift at lean bar when unloading from...

Page 18: ... 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 12 Revision A ...

Page 19: ... clevis pin A in header stand at right side of header 9 Hold stand B and remove clevis pin A Figure 3 13 Header Stand in Shipping Position 10 Invert stand A and reinstall on header leg in upper hole location with clevis pin B Secure clevis pin B with lynch pin NOTE In soft conditions use a wooden block under the stand 11 Lower header onto stand A Figure 3 14 Header Stand 147913 13 Revision A ...

Page 20: ... 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 Remove four bolts A and remove angle B Discard angle and hardware Figure 3 16 Shipping Stands 147913 14 Revision A ...

Page 21: ...es A to each end of lean bar B with four 1 2 x 1 0 in hex bolts C and nuts provided 4 Reinstall lean bar on header with existing hardware Tighten bolts Figure 3 18 Extension Angles Attached to Ends of Lean Bar 5 Position left hand divider C at left hand side of lean bar and attach with U bolt A two 3 8 in nuts and two 1 2 x 1 0 in hex bolts B and nuts provided The divider may be positioned as show...

Page 22: ...n 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 Refer to 3 6 Installing Tall Crop Divider Kit page 15 Figure 3 20 Lean Bar 147913 16 Revision A ...

Page 23: ...idest delivery Adjust as follows 1 Remove two bolts A and loosen bolt B Figure 3 21 Pan Extension Wide Setting 2 Slide pan extensions C and swath forming rods inboard to desired position and align holes 3 Reinstall two bolts A Tighten bolts A and B 4 Repeat for opposite pan extension Figure 3 22 Pan Extension Narrow Setting 147913 17 Revision A ...

Page 24: ...sition yet allows the light to pivot out of the way of obstructions NOTE Do NOT overtighten mounting hardware 3 Ensure base of light housings and bolted connections on light supports provide proper electrical grounding 4 Amber reflector C should face direction of travel If required remove bolts D flip reflector assembly and reinstall bolts Figure 3 23 Amber Hazard Light 147913 18 Revision A ...

Page 25: ... bracket B using bolt C washer D and nut E 4 Repeat for the other side Figure 3 25 Rubber Strap 5 Lay cover A upside down on a flat surface 6 Install the center deflectors B using three bolts C on each side NOTE Orient deflectors B so that narrow end D is toward the front of the cover A and deep end E is toward the rear as shown in Figure 3 26 Center Deflectors page 19 Figure 3 26 Center Deflector...

Page 26: ...A enough to hold deflectors C in position but still allow deflectors to move 9 Tighten jam nut E against cover while holding bolt B Figure 3 27 Side Deflectors 10 Remove lynch pin A from adjuster rod B and locate rod in hole in side deflector C Secure with lynch pin A 11 Repeat for other deflector Figure 3 28 Adjuster Rod 147913 20 Revision A ...

Page 27: ...ASSEMBLING THE MACHINE 12 Invert forming shield to installation position as shown Figure 3 29 Forming Shield in Installation Position 147913 21 Revision A ...

Page 28: ...manual for procedure NOTE Do NOT install the two triangular shaped plates Triangular plates used with rotary headers Figure 3 30 Triangular Plate 2 Install bolt A with spacer B and nut on each leg in the upper hole Hardware is supplied with forming shield kit Figure 3 31 Windrower Leg 3 Remove two clevis pins A from forward end of forming shield Figure 3 32 Forming Shield 147913 22 Revision A ...

Page 29: ...eld 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 23 Revision A ...

Page 30: ...lectors to desired width by positioning adjuster bars A Use the same hole location on both sides Position deflectors at the narrowest setting for a narrow windrow silage for example Position deflectors at the widest setting for a wide windrow NOTE Refer to the operator s manual or quick card for additional information on adjusting the forming shield 8 Adjust fluffer shield C to middle position Loo...

Page 31: ...r header reel damage and improper operation Refer to 3 14 Routing Reverser Valve Jumper Hose page 55 and if necessary to instruction MD 169213 Reverser Kit Installation Instructions available from our Dealer only site https portal macdon com login required NOTE Header reel motor hose routing must be properly configured before attaching the header to a windrower The header is factory configured for...

Page 32: ...e Bundle 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 Push connector onto receptacle and turn collar on connector to lock it in place 8 Attach cover to mating cover on windrower wiring harness 9 Remove caps from hydraulic c...

Page 33: ...acles snap into lock position Figure 3 41 Early Build 2015 2014 and Earlier 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 3 42 2015 Grass Seed Header Hose Connectors A Reel and Auger Pressure B Knife and Conditioner Return C Case Drain D Knife and Conditioner Pressure 147913 27 Revision...

Page 34: ...ain 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 44 Auger Return and Reel Pressure Hose Bundle 13 If valve blocks are NOT configured as shown A refer to 3 13 1 Modifying Hydraulics M100 M105 page 47 Figure 3 45 Valve Block Configuration 147913 28 Rev...

Page 35: ...er left driveshield and check hose routing at the reel motor 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 The hose routing depends on which windrower model the header is being attached to ...

Page 36: ...se Routing Early Build 2015 2014 and Earlier A40 D page 67 Figure 3 49 Modified Routing M100 M105 and M205 Later Build 2015 shown 3 12 2 Attaching to M150 M155 or M155E4 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 and M155E4 self propelled windrowers are factory equipped with fo...

Page 37: ...e Bundle 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 Push connector onto receptacle and turn collar on connector to lock it in place 8 Attach cover to mating cover on windrower wiring harness 9 Remove caps from hydraulic c...

Page 38: ... snap into lock position Figure 3 54 Early Build 2015 2014 and Earlier Standard Header 14 Ft and 16 Ft Header Shown 18 Ft Similar A Reel and Auger Pressure B Knife and Conditioner Return C Case Drain D Knife and Conditioner Pressure Figure 3 55 2015 Grass Seed Header Hose Connectors A Reel and Auger Pressure B Knife and Conditioner Return C Case Drain D Knife and Conditioner Pressure 147913 32 Rev...

Page 39: ... 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 57 Auger Return and Reel Pressure Hose Bundle 13 If valve blocks are NOT configured as shown at right refer to 3 13 2 Modifying Hydraulics M150 M155 M155E4 page 49 Figure 3 58 M150 M155 M155E4 with Reverser Valve ...

Page 40: ...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 16 Proceed to 3 14 Routing Reverser Valve Jumper Hose page 55 Figure 3 61 M150 M155 M155E4 with Reverser Valve 147913 34 Revision A ...

Page 41: ...hing to M200 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 The M200 Windrower requires four drive hoses A to run an A40 D Auger Header Figure 3 63 Drive Hoses 147913 35 Revision A ...

Page 42: ...al hose A hardware and installation instructions Figure 3 64 Kit MD B4651 1 Disengage rubber latch A and open driveline shield B Figure 3 65 Driveline Shield 2 Remove 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 66 Support Bracket and Hose Bundle 147913 36 Revisio...

Page 43: ...s 9 Remove caps from hydraulic couplers Clean if necessary Figure 3 67 Hose and Electrical Bundle 14 Ft and 16 Ft Header Shown 18 Ft Similar NOTE At location C later build 2015 units 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 68 Early Build 2015 2014 and Earlier...

Page 44: ...e 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 38 Revision A ...

Page 45: ...r 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 12 Secure with three straps D and lower lever B Figure 3 72 Auger Return and Reel Pressure Hose Bundle 147913 39 Revision A ...

Page 46: ... 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 Locate the auger pressure A and auger reel return B hoses Figure 3 75 Auger Pressure and Auger Reel Return Hose Couplers 14 Ft and 16 Ft Header Shown 18 Ft Similar 147913 40 Revision A ...

Page 47: ... into lock position 16 Proceed to 3 14 Routing Reverser Valve Jumper Hose page 55 Figure 3 76 M200 with Reverser Valve Figure 3 77 M200 without Reverser Valve 3 12 4 Attaching to M205 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 147913 41 Revision A ...

Page 48: ...the kits Kit Description MacDon Part Number Base kit MD B5491 Reverser kit2 MD B5492 Coupler MD B5497 Figure 3 78 Auger Drive Basic Kit and Completion Kit Installed 1 Disengage rubber latch A and open driveline shield 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 a...

Page 49: ...nto receptacle and turn collar on connector to lock it in place 8 Attach cover to mating cover on windrower wiring harness 9 Remove caps from hydraulic couplers Clean if necessary Figure 3 81 Hose and Electrical Bundle 14 ft and 16 Ft Header Shown 18 Ft Similar NOTE At location C later build 2015 units will have a tee going to case drain on square reel motor only 10 Push hose connectors onto matin...

Page 50: ...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 D Case Drain 147913 44 Revision A ...

Page 51: ...n B hose couplers onto mating receptacles on valve block until collar on receptacle snaps into lock position Figure 3 86 Auger Reel Pressure and Auger Reel Return Hose Couplers 14 Check hose routing at the reel motor A The hose routing depends on which windrower model the header is being attached to The header is factory configured for M150 M155 M155E4 and M200 Windrowers NOTE Reel drive motor may...

Page 52: ...based on the year of manufacture Later build 2015 3 16 Hydraulic Drive Hose Routing Later Build 2015 A40 D Units Only page 62 Early build 2015 2014 and earlier 3 17 Hydraulic Drive Hose Routing Early Build 2015 2014 and Earlier A40 D page 67 Figure 3 88 Modified Routing M100 M105 and M205 147913 46 Revision A ...

Page 53: ...Hydraulics M100 M105 1 Open left hand maintenance platform on windrower 2 At valve A on the valve block remove cap B from port R1 fitting and plug C from DWA tee fitting Ports might NOT be identified NOTE Check valve D is required when attaching an A40 D Auger Header to an M100 or M105 Windrowers All M105 Windrowers made in 2012 and forward come factory installed with check valve D If required che...

Page 54: ...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 If O ring is missing reuse O ring from discarded adapter fitting in Step 4 page 48 Figure 3 92 Valve Block Configured for Auger Header 6 Remove and discard cap C and adapter fitting B from the small coupler assembly A Figure 3 93 Small Coupler Assembly 147913 48 Revision A ...

Page 55: ...ure 3 94 Valve Block Configured for Auger Header 3 13 2 Modifying Hydraulics M150 M155 M155E4 1 Open left hand maintenance platform on windrower 2 Remove the plugs from ports R2 on valve blocks A and B Ports may NOT be identified Figure 3 95 Valve Blocks with Reverser Valve in Factory Configuration Figure 3 96 Valve Blocks without Reverser Valve in Factory Configuration 147913 49 Revision A ...

Page 56: ...stall smaller coupler assembly C in port R2 on valve block A and the larger coupler assembly D in port R2 on valve block B 5 Proceed to 3 14 Routing Reverser Valve Jumper Hose page 55 Figure 3 98 Valve Blocks with Reverser Valve Configured for Auger Header Figure 3 99 Valve Blocks without Reverser Valve Configured for Auger Header 147913 50 Revision A ...

Page 57: ...on MD 169213 Reverser Kit Installation Instructions for proper plumbing articles for each header type 1 Open left hand maintenance platform on windrower 2 Remove the plugs from ports R2 on valve blocks A and B Figure 3 100 Valve Blocks with Reverser Valve in Factory Configuration 3 Remove female coupler assemblies C and D from hoses in bundle E from header and remove caps NOTE To avoid contact wit...

Page 58: ...th R1 hose E 5 Proceed to 3 14 Routing Reverser Valve Jumper Hose page 55 Figure 3 102 Valve Blocks with Reverser Valve Configured for Auger Header 3 13 4 Modifying Hydraulics M200 without Reverser Valve 1 Open left hand maintenance platform on windrower 2 Remove the plug from port R2 on valve block A and the cap from fitting in port R2 on valve block B Ports may NOT be identified Figure 3 103 Val...

Page 59: ...pler Assembly 5 Install larger coupler H onto fitting at port R2 on valve block B 6 Remove cap from smaller coupler assembly C and install assembly in port R2 on valve A IMPORTANT Make sure O ring is on JIC threads in port R1 to ensure a proper seal with the coupler H If O ring is missing reuse O ring from discarded adapter fitting in Step 4 page 53 Figure 3 106 Valve Blocks without Reverser Valve...

Page 60: ...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 shown at right 2 Proceed to 3 15 Attaching Hydraulics page 56 Figure 3 107 Auger Header Hydraulics 147913 54 Revision A ...

Page 61: ...and change as required 3 Route jumper hose B from C2 conveyor circuit C to CR on reverser block A as shown NOTE For draper headers CR is routed to port R4 as shown in image to the right on reverser block Reroute jumper hose B when switching between draper and auger headers This prevents draper header reel damage and improper operation which occurs if reel runs backwards Figure 3 108 Hose B Positio...

Page 62: ...veline shield B Figure 3 110 Driveline Shield 2 Remove cap A from electrical connector and remove connector from support bracket 3 Disengage and rotate lever B counterclockwise to the fully up position to release hose bundle C Figure 3 111 Windrower Hoses and Harness in Storage Position 4 Move hose bundle A to header 5 Rotate lever B clockwise and engage in bracket to store Figure 3 112 Windrower ...

Page 63: ...rs Clean if necessary Figure 3 113 Windrower Hoses and Harness Connected to Header 14 Ft and 16 Ft Header Shown 18 Ft Similar 11 Connect the four hoses from windrower to mating receptacles on header Ensure collar snaps into lock position Figure 3 114 Hose Connections on Standard Header 14 Ft and 16 Ft Header Shown A Reel Auger Pressure B Knife and Conditioner Return C Case Drain D Knife and Condit...

Page 64: ...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 C Knife Pressure Female Fitting at Header D Case Drain 147913 58 Revision A ...

Page 65: ...lt C and locking nut Install bolt from under bracket 15 Repeat Step 13 page 59 through Step 14 page 59 at the two other brackets on hose support Figure 3 118 Adjustable Straps 16 Route reel auger return and auger pressure hose bundle A from header to windrower and position bundle above existing hose support C as shown 17 Secure with three straps D and lower lever B Figure 3 119 Reel Auger Return a...

Page 66: ...lve 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 Figure 3 122 M150 M155 M155E4 without Reverser Valve A Auger Pressure B Reel Auger Return 147913 60 Revision A ...

Page 67: ...re 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 61 Revision A ...

Page 68: ...M105 and M205 Windrowers proceed as follows IMPORTANT If you have a 2015 A40 D SP windrower header confirm whether you have an early build or a later build 2015 unit If the reel motor is round B then it is an earlier build 2015 model Refer to 3 17 Hydraulic Drive Hose Routing Early Build 2015 2014 and Earlier A40 D page 67 If the reel motor is square A then use the following procedure Figure 3 126...

Page 69: ...hield 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 14 Ft and 16 Ft Header Shown Figure 3 130 Auger and Reel Pressure Coupler and Hose 18 Ft Header Shown 147913 63 Revision A ...

Page 70: ...d F and connect hose C to tee B Tighten hose C c Loosen 45 degree fittings at both ports This allows room for wrenches when tightening tee B to lower port d Connect hose A to upper port fitting as shown and check orientation of 45 degree fitting NOTE Ensure that hose A is routed in front of hose C and E e Confirm orientation of upper port 45 degree fitting back off tee B and tighten upper port fit...

Page 71: ... hose bundle E and knife drive timing belt F Figure 3 133 Adjusted Configuration M100 M105 and M205 8 Rotate coupler B and hose C downward as shown until slack has been sufficiently reduced Tighten bulkhead nut A Figure 3 134 Auger and Reel Pressure Coupler and Hose 14 Ft and 16 Ft Header Shown Figure 3 135 Auger and Reel Pressure Coupler and Hose 18 Ft Header Shown 147913 65 Revision A ...

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 66 Revision A ...

Page 73: ...tor is square A then it is a later build 2015 model Refer to 3 16 Hydraulic Drive Hose Routing Later Build 2015 A40 D Units Only page 62 If the reel motor is round B then use the following procedure Figure 3 137 Auger Drive Motor 1 Press screwdriver against latch in opening A and lift to open header left hand driveshield Shield will latch at B to stay open 2 Check hose routing at the reel motor Th...

Page 74: ...otor upper port c Disconnect tee C from reel motor lower port 4 Reconnect hoses as follows a Relocate tee C to reel motor upper port b Connect hose B to tee C c Connect hose A to reel motor lower port Figure 3 139 Early Build 2015 2014 and Earlier Factory Configuration M150 M155 and M200 Figure 3 140 Adjusted Configuration M100 M105 and M205 5 Close driveline shield before engaging header Figure 3...

Page 75: ...ck port and install plug B in forward port at knife drive boxes Figure 3 142 Top View of Knife Drive Box 2 With top of knife drive box horizontal check oil level It should be between the lower hole A and the end of the dipstick 3 If required add SAE 85W 140 lubricant Figure 3 143 Side View of Knife Drive Box and Close up of Dipstick 147913 69 Revision A ...

Page 76: ......

Page 77: ...h a clean cloth before greasing to avoid injecting dirt and grit 2 Inject grease through fitting with grease gun until grease overflows fitting except where noted 3 Leave excess grease on fitting to keep out dirt 4 Replace any loose or broken fittings immediately 5 If fitting will not take grease remove and clean thoroughly Also clean lubricant passageway Replace fitting if necessary Figure 4 1 Gr...

Page 78: ... 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 2 Header LH Side A Tine Bar Bearing 4 Places Each Tine Bar B Knife Drive Bearing 1 Place C Gauge Roller Bearing 2 Places Both Sides if Installed D Knifehead Bearing 1 Place 147913 72 Revision A ...

Page 79: ...hium 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 3 Header RH Side A Knife Drive Bearing 1 Place B Reel Shaft Bearing 1 Place C Auger Shaft Bearing 1 Place D Knifehead Bearing 1 Place 147913 73 Revision A ...

Page 80: ...oner 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 74 Revision A ...

Page 81: ... 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 147913 75 Revision A ...

Page 82: ...earbox 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 147913 76 Revision A ...

Page 83: ...s for detailed instructions as indicated on the checklist 2 The completed checklist should be retained either by the Operator or the Dealer 5 1 Checking Drive Belts and Chains 1 Open shield on header right hand side 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 h...

Page 84: ... 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 Shimming the stripper bars may be required Figure 5 4 End View Diagram Showing Auger and Stripper Bars 147913 78 Revision A ...

Page 85: ...ine clearances to knife sections and auger pan are adequate for working conditions 2 Check that reel rotates freely IMPORTANT If there are a few reel tine fingers that are touching the pan while the rest are at the correct height trim the longer tines to match the rest Be sure to adjust both sides of the reel Ensure that tines do NOT contact the plastic header pan Figure 5 5 Reel Tine to Header Pa...

Page 86: ...w these steps 1 Check float by grasping the lean bar and lifting Lifting force should be 335 380 N 75 85 lbf and should be approximately the same at both ends 2 If necessary perform the following steps to adjust the float a Raise header fully shut down engine and remove key b Turn drawbolt A clockwise to increase float makes header lighter or counterclockwise to decrease float makes header heavier...

Page 87: ...ures 3 Raise header fully and hold momentarily to allow lift cylinders to rephase 4 Stop engine and remove key 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 5 Place float pins A in locked out position CAUTION Check to be sure all bystanders have cleared the area Figure 5 7 Flo...

Page 88: ...her and bolt A that attach shims B to link at the header high end 12 Remove one or both shims B and reinstall the hardware A 13 Start engine and raise header slightly Check level of header 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 NOTE Float does NOT require adjustment a...

Page 89: ...t gap by loosening nut A and turning adjuster B Retighten nut A NOTE When adjusting roll gap be sure that the decal reading is the same on both sides of the conditioner roll to achieve consistent intermesh across the rolls Figure 5 12 Roll Gap Adjustment Hardware 4 Loosen bolt A and rotate cover B to expose access port C 5 Check roll timing by examining distance X at each end of the rolls C Each s...

Page 90: ...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 Figure 5 14 Roll Timing Adjustment Hardware 9 Reposition cover A and tighten bolt B Figure 5 15 Access Port Covered 147913 84 Revision A ...

Page 91: ... 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 3 Replace check plug A Figure 5 16 Check Plug 147913 85 Revision A ...

Page 92: ... 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 Check that pins A are installed in the same position in all skid shoes gauge rollers Figure 5 17 Skid Shoe Figure 5 18 Gauge Roller 147913 86 Revision A ...

Page 93: ...unted 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 Figure 5 19 Hazard Light 147913 87 Revision A ...

Page 94: ...ly for five minutes watching and listening FROM THE WINDROWER SEAT for binding interfering parts or unusual noises 2 Run the machine for 15 minutes at maximum engine operating rpm and perform the run up check as listed on the Predelivery Checklist yellow sheet attached to this manual Predelivery Checklist page 111 to ensure machine is field ready 3 Check knife speed in the windrower cab display mo...

Page 95: ... the first time knife speed should be set to the MAXIMUM setting Table 5 1 A40 D Auger Header Knife Speed Header Description Knife Speed Minimum Maximum Type Size rpm3 spm4 rpm5 spm6 Auger A40 D All 700 1400 975 1950 Setting Knife Speed With Expansion Module MD B4666 1 Press SELECTOR button B on the ground speed lever GSL until the CDM A displays the knife speed in SPM strokes per minute This indi...

Page 96: ...pose the screw Figure 5 22 Knife Drive Pump 7 Loosen jam nut A 8 Turn adjuster screw B clockwise screw in to decrease knife speed and counterclockwise screw out to increase the knife speed NOTE One turn of the adjuster screw B will change the knife speed by approximately 116 strokes per minute spm or the knife drive box pulley speed by 58 revolutions per minute rpm 9 Once adjustment has been made ...

Page 97: ... box pulley speed with a handheld tachometer 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 89 4 If required adjust knife speed Refer to Step 4 page 90 Figure 5 24 Knife Drive Box on Header 147913 91 Revision A ...

Page 98: ...nt check gap between knifehead A and pitman arm B A business card should slide easily through the gap If not adjust gap by loosening bolt and tapping knifehead A with a hammer Retighten bolt Figure 5 25 Knifehead and Pitman Arm 4 Adjust guard alignment as necessary using guard straightening tool MD 140135 Adjust guard tips upwards by positioning tool as shown and pulling up Figure 5 26 Guard Tips ...

Page 99: ...case C Figure 5 28 Manual Case 2 A Series manuals are shipped with shipping documents and auger header unloading and assembly instructions Be sure to place the following manuals in the manual case A Series Auger Header Quick Card A Series Operator s Manual A Series Parts Catalog 3 Replace cable tie on manual case and close endshield Figure 5 29 Manuals 147913 93 Revision A ...

Page 100: ......

Page 101: ... their identifying head markings SAE Bolt Torque Specifications Torque values shown in the following tables are valid for non greased or non oiled threads and heads therefore do NOT grease or oil bolts or cap screws unless otherwise specified in this manual Table 6 1 SAE Grade 5 Bolt and Grade 5 Free Spinning Nut Torque N m Torque ft lbf in lbf Nominal Size A Min Max Min Max 1 4 20 11 9 13 2 106 1...

Page 102: ...456 306 338 1 8 619 684 459 507 Figure 6 2 Bolt Grades A Nominal Size B SAE 8 C SAE 5 D SAE 2 Table 6 3 SAE Grade 8 Bolt and Grade G Distorted Thread Nut Torque N m Torque ft lbf in lbf Nominal Size A Min Max Min Max 1 4 20 16 8 18 6 150 165 5 16 18 24 26 18 19 3 8 16 42 46 31 34 7 16 14 67 74 50 55 1 2 13 102 113 76 84 9 16 12 148 163 109 121 5 8 11 204 225 151 167 3 4 10 362 400 268 296 7 8 9 58...

Page 103: ... 1165 1288 863 954 Figure 6 4 Bolt Grades A Nominal Size B SAE 8 C SAE 5 D SAE 2 Metric Bolt Specifications Table 6 5 Metric Class 8 8 Bolts and Class 9 Free Spinning Nut Torque N m Torque ft lbf in lbf Nominal Size A Min Max Min Max 3 0 5 1 4 1 6 13 14 3 5 0 6 2 2 2 5 20 22 4 0 7 3 3 3 7 29 32 5 0 8 6 7 7 4 59 66 6 1 0 11 4 12 6 101 112 8 1 25 28 30 20 23 10 1 5 55 60 40 45 12 1 75 95 105 70 78 1...

Page 104: ...16 2 0 161 178 119 132 20 2 5 314 347 233 257 24 3 0 543 600 402 444 Figure 6 6 Bolt Grades Table 6 7 Metric Class 10 9 Bolts and Class 10 Free Spinning Nut Torque N m Torque ft lbf in lbf Nominal Size A Min Max Min Max 3 0 5 1 8 2 18 19 3 5 0 6 2 8 3 1 27 30 4 0 7 4 2 4 6 41 45 5 0 8 8 4 9 3 82 91 6 1 0 14 3 15 8 140 154 8 1 25 38 42 28 31 10 1 5 75 83 56 62 12 1 75 132 145 97 108 14 2 0 210 232 ...

Page 105: ...Size A Min Max Min Max 3 0 5 1 3 1 5 12 13 3 5 0 6 2 1 2 3 19 21 4 0 7 3 1 3 4 28 31 5 0 8 6 3 7 56 62 6 1 0 10 7 11 8 95 105 8 1 25 26 29 19 21 10 1 5 51 57 38 42 12 1 75 90 99 66 73 14 2 0 143 158 106 117 16 2 0 222 246 165 182 20 2 5 434 480 322 356 24 3 0 750 829 556 614 Figure 6 8 Bolt Grades 147913 99 Revision A ...

Page 106: ...ects 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 the flared surfaces 3 Torque the fitting nut E to the specified number of flats from finger tight FFFT or to a given torque value in Table 6 10 Flare Type Hydraulic Tube Fittings page 101 4 Use two wrenches to prevent fitting D from rotating Place one wr...

Page 107: ... 20 19 21 14 15 2 2 6 9 16 18 30 33 22 24 2 1 1 2 8 3 4 16 57 63 42 46 2 1 1 2 10 7 8 14 81 89 60 66 1 1 2 1 1 2 12 1 1 16 12 113 124 83 91 1 1 2 1 1 4 14 1 3 16 12 136 149 100 110 1 1 2 1 1 4 16 1 5 16 12 160 176 118 130 1 1 2 1 20 1 5 8 12 228 250 168 184 1 1 24 1 7 8 12 264 291 195 215 1 1 32 2 1 2 12 359 395 265 291 1 1 40 3 12 1 1 7 Torque values shown are based on lubricated connections as i...

Page 108: ...e threads and adjust if necessary 4 Apply hydraulic system oil to the O ring A Figure 6 11 Hydraulic Fitting 5 Install fitting B into port until back up washer D and O ring A contact the part face E 6 Position angle fittings by unscrewing no more than one turn 7 Turn lock nut C down to washer D and tighten to torque shown Use two wrenches one on fitting B and the other on lock nut C 8 Check the fi...

Page 109: ...4 7 16 20 19 21 14 15 5 1 2 20 21 33 15 24 6 9 16 18 26 29 19 21 8 3 4 16 46 50 34 37 10 7 8 14 75 82 55 60 12 1 1 16 12 120 132 88 97 14 1 3 8 12 153 168 113 124 16 1 5 16 12 176 193 130 142 20 1 5 8 12 221 243 163 179 24 1 7 8 12 270 298 199 220 32 2 1 2 12 332 365 245 269 8 Torque values shown are based on lubricated connections as in reassembly 147913 103 Revision A ...

Page 110: ...heck the final condition of the fitting Figure 6 13 Hydraulic Fitting Table 6 12 O Ring Boss ORB Hydraulic Fittings Non Adjustable Torque Value9 SAE Dash Size Thread Size in N m ft lbf in lbf 2 5 16 24 6 7 53 62 3 3 8 24 12 13 106 115 4 7 16 20 19 21 14 15 5 1 2 20 21 33 15 24 6 9 16 18 26 29 19 21 8 3 4 16 46 50 34 37 10 7 8 14 75 82 55 60 12 1 1 16 12 120 132 88 97 14 1 3 8 12 153 168 113 124 16...

Page 111: ...omes in full contact with O ring B 4 Thread tube or hose nut D until hand tight The nut should turn freely until it is bottomed out 5 Torque fittings according to the values in Table 6 13 O Ring Face Seal ORFS Hydraulic Fittings page 106 NOTE If applicable hold the hex on the fitting body E to prevent rotation of fitting body and hose when tightening the fitting nut D 6 Use three wrenches when ass...

Page 112: ... 3 8 40 44 29 32 8 13 16 1 2 55 61 41 45 10 1 5 8 80 88 59 65 12 1 3 16 3 4 115 127 85 94 14 Note11 7 8 16 1 7 16 1 150 165 111 122 20 1 11 16 1 1 4 205 226 151 167 24 1 2 1 1 2 315 347 232 256 32 2 1 2 2 510 561 376 414 10 Torque values and angles shown are based on lubricated connection as in reassembly 11 O ring face seal type end not defined for this tube size 147913 106 Revision A ...

Page 113: ...ignment of fitting in the tightening direction Never back off loosen pipe threaded connectors to achieve alignment 5 Clean all residue and any excess thread conditioner with the appropriate cleaner 6 Assess the final condition of the fitting Pay special attention to the possibility of cracks to the port opening 7 Mark the final position of the fitting If a fitting leaks disassemble the fitting and...

Page 114: ...egapascals MPa x 00689 Pressure bar Non SI bar 14 5038 pounds per square inch psi Newton meters N m x 1 3558 pound feet or foot pounds ft lbf Torque Newton meters N m x 0 1129 pound inches or inch pounds in lbf Temperature Celsius C F 32 x 0 56 degrees Fahrenheit F meters per minute m min x 0 3048 feet per minute ft min meters per second m s x 0 3048 feet per second ft s Velocity kilometers per ho...

Page 115: ...t is a reference position where sealing surfaces or components are making contact with each other and the fitting has been tightened to a point where the fitting is no longer loose FFFT Flats from finger tight GSL Ground speed lever GSS Grass Seed Special GVW Gross vehicle weight Hard joint A joint made with the use of a fastener where the joining materials are highly incompressible Header A machi...

Page 116: ...gle knife drive Soft joint A joint made with the use of a fastener where the joining materials are compressible or experience relaxation over a period of time spm Strokes per minute Timed knife drive Synchronized motion applied at the cutterbar to two separately driven knives from a single hydraulic motor Tension Axial load placed on a bolt or screw usually measured in Newtons N or pounds lb TFFT ...

Page 117: ... Checking Auger Stripper Bar Clearance page 78 If mechanical link set header angle to middle of adjustment range for first use Check that header is level 5 5 Checking Header Levelling page 81 Check header float 335 380 N 75 85 lbf 5 4 Checking Adjusting Float page 80 Check lean bar is adjusted at a setting appropriate for first crop 3 7 Adjusting Lean Bar page 16 Check skid shoes are evenly adjust...

Page 118: ...d signal lights are functional 5 9 Checking Lights page 87 Check header ID on windrower CDM POST RUN UP CHECKS STOP ENGINE Check for hydraulic leaks Check belt and chain drives for idler alignment and heated bearings 5 1 Checking Drive Belts and Chains page 77 Check knife sections for discoloration caused by misalignment of components 5 12 Adjusting Knife page 92 Check manuals in the right hand he...

Page 119: ......

Page 120: ...204 885 5590 f 204 832 7749 MacDon Inc 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 03 9432 9972 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Centre t...

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