MacDon A40-D, Operator'S Manual

Page 1: ...A40D and A40DX Self Propelled Windrower Auger Header Operator s Manual 214804 Revision A Original Instruction The harvesting specialists...

Page 2: ...MacDon A40D Self Propelled Windrower Auger Header Published November 2018...

Page 3: ...EC Declaration of Conformity Figure 1 EC Declaration of Conformity Page 1 214804 i Revision A...

Page 4: ...Figure 2 EC Declaration of Conformity Page 2 214804 ii Revision A...

Page 5: ...e the Table of Contents and the Index to guide you to specific topics Study the Table of Contents to familiarize yourself with how the information is organized If you follow the instructions provided...

Page 6: ...ersion can be downloaded from our website www macdon com or from our Dealer only site https portal macdon com login required NOTE A Russian translation of this manual can be ordered from MacDon downlo...

Page 7: ...wer Header page 8 Figure 1 17 Right Side of Header Updated graphic 1 7 Safety Sign Locations Self Propelled Windrower Header page 8 Figure 1 18 Decals on Right Side of Header Updated note Introduction...

Page 8: ...on Record the model number serial number and model year of the header in the spaces below The header serial number plate is located on the top of the left end frame A Header Model Number ____________...

Page 9: ...A40DX Header to M1 Series Windrowers 25 3 2 Detaching A40DX Header from M1 Series Windrower 29 3 3 Attaching A40D Headers to M Series SP Windrowers 31 3 3 1 Attaching A40D to M100 or M105 31 3 3 2 At...

Page 10: ...eflector Fluffer Shield 80 3 7 Recommended Operating Settings 82 3 8 Unplugging Conditioner and Knife 86 3 9 Grass Seed Special 88 3 9 1 Stub Guards and Hold Downs 88 3 9 2 Special Auger Design for Gr...

Page 11: ...igning Guard 123 Replacing Pointed Guards and Hold Downs 124 Replacing Pointed Center Guard on Double Knife Header 126 Replacing Center Stub Guard on Double Knife Header 128 4 7 8 Hold Downs 130 Adjus...

Page 12: ...4 13 Conditioner 167 4 13 1 Changing Gearbox Oil 167 4 13 2 Removing Forming Shield 169 4 13 3 Disassembling Forming Shield 170 4 13 4 Assembling Forming Shield 172 4 13 5 Installing Forming Shield 17...

Page 13: ...t Torque Specifications 207 Metric Bolt Specifications 209 Metric Bolt Specifications Bolting into Cast Aluminum 211 Flare Type Hydraulic Fittings 212 O Ring Boss Hydraulic Fittings Adjustable 213 O R...

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Page 15: ...es important safety messages in this manual and on safety signs on the machine This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Carefully read and follow the safety message accompanyin...

Page 16: ...l 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 practice...

Page 17: ...or goggles Heavy gloves Wet weather gear Respirator or filter mask Figure 1 3 Safety Equipment Be aware that exposure to loud noises can cause hearing impairment or loss Wear suitable hearing protecti...

Page 18: ...ne function and or safety It may also shorten machine s life To avoid bodily injury or death from unexpected startup of machine ALWAYS stop the engine and remove the key from the ignition before leavi...

Page 19: ...machine Make sure all components are tight and that steel lines hoses and couplings are in good condition before applying pressure to hydraulic systems Keep hands feet clothing and hair away from all...

Page 20: ...pressure Makeshift repairs will fail suddenly and create hazardous and unsafe conditions Figure 1 12 Hydraulic Pressure Hazard Wear proper hand and eye protection when searching for high pressure hydr...

Page 21: ...air part displays the current safety sign Replacement safety signs are available from your MacDon Dealer Parts Department 1 6 1 Installing Safety Decals 1 Clean and dry installation area 2 Decide on e...

Page 22: ...gn Locations Self Propelled Windrower Header Figure 1 15 Left Side of Header A MD 174632 B MD 184422 C MD 166452 D MD 174436 E MD 171288 F MD 184372 G MD 194464 H MD 194521 J MD 36651 Figure 1 16 Deca...

Page 23: ...214804 9 Revision A Figure 1 17 Right Side of Header A MD 184422 B MD 170638 C MD 166452 Figure 1 18 Decals on Right Side of Header SAFETY...

Page 24: ...Dealer Do NOT allow untrained persons to operate the machine Review safety instructions with all Operators every year Ensure that all safety signs are installed and legible Make certain everyone is cl...

Page 25: ...azard WARNING Do not go near leaks High pressure oil easily punctures skin causing serious injury gangrene or death If injured seek emergency medical help Immediate surgery is required to remove oil D...

Page 26: ...hydraulic lock out valves before going under unit Figure 1 25 MD 171281 MD 171281 Hot fluid under pressure CAUTION Coolant is under pressure and may be hot Never remove radiator cap when engine is ho...

Page 27: ...otating reel stand clear of header while machine is running Figure 1 29 MD 184372 MD 184372 General hazard pertaining to machine operation and servicing CAUTION To avoid injury or death from improper...

Page 28: ...n the raised position Use slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited by law Figure 1 30 MD 184422 MD 184422 Chain drive hand and arm entangleme...

Page 29: ...year Ensure that all safety signs are installed and legible Make certain everyone is clear of machine before starting engine and during operation Keep riders off the machine Keep all shields in place...

Page 30: ...er use Review the manual and all safety related items with all Operators annually Be alert for other Operators not using recommended procedures or not following safety precautions Correct these mistak...

Page 31: ...n front of the windrower will usually swerve towards the ditch When working on inclines travel uphill or downhill when possible Be sure to keep windrower transmission in gear when travelling downhill...

Page 32: ......

Page 33: ...FFFT Flats from finger tight Finger tight Finger tight is a reference position where sealing surfaces or components are making contact with each other and fitting has been tightened to a point where...

Page 34: ...elled SP Windrower Self propelled machine consisting of a power unit with a header SKD Single knife drive Soft joint A joint made with use of a fastener where joining materials are compressible or exp...

Page 35: ...tching pulleys No load 1400 1950 Knife speed strokes per minute Switching pulleys Load 1400 1950 Double heat treated forged pointed guards GSS headers fitted with stub guards Standard Bolted over serr...

Page 36: ...in Single piece tine bar with replaceable polyethylene bearings N A Sectioned tine bar with regreasable ball bearings Standard Drive Hydraulic motor 14 2 cu in 232 cc rev to enclosed gearbox Standard...

Page 37: ...d Structure Two amber transport lights Standard Header width Nominal cut width plus 480 mm 18 7 8 in Header attachment Windrower Spare knife storage Lean bar Tool and parts storage compartment N A Hea...

Page 38: ......

Page 39: ...Auger Header to an M1 Series Windrower and for modifications to the windrower hydraulic connections if required IMPORTANT If attempting to attach an A40D Header to an M1170 or M1240 Windrower the M1...

Page 40: ...70 M1240 Disc Header Configured 3 If attaching to a disc ready windrower ensure knife drive hose A is connected to coupler B NOTE Hose A provides power to run the knife conditioner Figure 3 4 M1170 St...

Page 41: ...to receptacle Align pins in coupler with slots in handle and push handle F toward windrower so that coupler is locked onto receptacle and button E snaps out Figure 3 6 Windrower Electrical Connector 9...

Page 42: ...214804 28 Revision A Figure 3 7 Electrical Connection 10 Remove cover from receptacle A on windrower and connect electrical harness B from header OPERATION...

Page 43: ...Upper harness connection also needs to be disconnected if reel speed kit option is connected Figure 3 9 Multicouplers 2 Push button E on front multicoupler and pull handle F away from windrower 3 Remo...

Page 44: ...nd remove header hose bundle C from the windrower Figure 3 11 Detached Header Hydraulics Bundle 9 Keeping hose bundle A in hose guide B store hose bundle on top of header walkway C away from the windr...

Page 45: ...NOTE Header reel motor hose routing must be properly configured before attaching the header to a windrower Hose routing on the header is factory configured for M150 M155 M155E4 and M200 Self Propelle...

Page 46: ...C Figure 3 15 Hose and Electrical Bundle 4 3 m and 4 9 m 14 ft and 16 ft Header Shown 5 5 m 18 ft Header Similar 4 Move hose electrical bundle A to header 5 Route bundle A from windrower through suppo...

Page 47: ...D Knife and Conditioner Pressure 10 Push hose connectors onto mating receptacles as shown until collars on receptacles snap into lock position NOTE Hoses attached to connectors not shown in illustrati...

Page 48: ...ration 13 If valve blocks are NOT configured as shown A install required fittings as described in the unloading and assembly instructions that were supplied with your A40D Auger Header Figure 3 20 Aug...

Page 49: ...ck hose routing at the reel motor NOTE 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 Figur...

Page 50: ...nd speed lever GSL to Park center steering wheel to lock shut off engine and remove key Figure 3 24 Header Drive Hoses M150 M155 and M155E4 self propelled windrowers are factory equipped with four hea...

Page 51: ...r 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 t...

Page 52: ...d 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 31 M150 M155 M155E4 with Reve...

Page 53: ...n 5 5 m 18 ft Header Similar 14 Locate the auger pressure A and auger reel return B hoses 15 Proceed to 3 3 5 Configuring Reverser Valve Jumper Hose for A40D page 49 Figure 3 34 M150 M155 M155E4 with...

Page 54: ...taching A40D to M200 CAUTION To prevent accidental movement of windrower return ground speed lever GSL to Park center steering wheel to lock shut off engine and remove key Figure 3 36 Drive Hoses The...

Page 55: ...eader by installing kit MD B4651 The kit includes an additional hose A hardware and installation instructions Figure 3 38 Driveline Shield 1 Disengage rubber latch A and open driveline shield B Figure...

Page 56: ...ctor 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 couplers Clean if necessary Figure 3 41 A4...

Page 57: ...e Bundle 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 Figur...

Page 58: ...pressure A and auger reel return B hoses Figure 3 47 M200 with Reverser Valve 15 Push auger pressure A and auger reel return B hose couplers onto mating receptacles on valve block until collar on rec...

Page 59: ...r Drive Basic Kit and Completion Kit Installed The M205 Windrower must be equipped with an auger drive basic kit and a completion kit as shown at right If necessary order and install the following kit...

Page 60: ...C 4 Move hose electrical bundle C to header Figure 3 52 Hose and Electrical Bundle 4 3 m and 4 9 m 14 ft and 16 ft Header Shown 5 5 m 18 ft Header Similar 5 Route bundle A from windrower through suppo...

Page 61: ...in D Knife and Conditioner Pressure 10 Push hose connectors onto mating receptacles as shown until collars on receptacles snap into lock position NOTE Hoses attached to connectors not shown in illustr...

Page 62: ...ure and Auger Reel Return Hose Couplers 13 Push auger reel pressure A and auger reel return B hose couplers onto mating receptacles on valve block until collar on receptacle snaps into lock position F...

Page 63: ...A jumper hose on this valve block has a specific routing for each model of header NOTE If a reverser valve block A has been installed the jumper hose B must be routed for the correct header model Do N...

Page 64: ...mper hose C to port C2 fitting A on header drive valve block B 6 Install previously removed cap onto 90 degree fitting in port R4 on reverser valve block D 7 Move left windrower platform back to norma...

Page 65: ...l latch at location B to stay open Figure 3 63 Driveline Shield 2 Disengage rubber latch A and open driveline shield B Figure 3 64 Auger and Reel Pressure Coupler and Hose 4 3 m and 4 9 m 14 ft and 16...

Page 66: ...at locations shown in illustration Figure 3 67 Adjusted Configuration M100 M105 and M205 6 Reconnect hoses as follows a Reroute hose E behind hose A and F to hose C and connect tee B to lower port fi...

Page 67: ...ness routing Figure 3 68 Adjusted Configuration M100 M105 and M205 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 lea...

Page 68: ...n A Figure 3 70 Auger and Reel Pressure Coupler and Hose 5 5 m 18 ft Header Shown Figure 3 71 Driveline Shield 9 Close driveline shield B and engage rubber latch A 10 Close driveshield before engaging...

Page 69: ...windrower return ground speed lever GSL to Park center steering wheel to lock shut off engine and remove key Figure 3 72 M100 and M105 1 Move left cab forward platform to rear of windrower 2 Disconnec...

Page 70: ...214804 56 Revision A Figure 3 74 M150 without Reverser Valve M155 and M155E4 Similar Figure 3 75 M200 with Reverser Valve Figure 3 76 M200 without Reverser Valve OPERATION...

Page 71: ...Figure 3 79 Standard Header A Reel Auger Pressure B Knife and Conditioner Return C Case Drain D Knife and Conditioner Pressure 5 Install caps on connectors and hose ends if equipped 6 At the header di...

Page 72: ...and position on windrower left side with hose ends in support B and under lever C 9 Rotate lever C clockwise and push to engage bracket 10 Position electrical harness through support B and attach cap...

Page 73: ...214804 59 Revision A 3 5 Header Lift Cylinder Lock Out Valves Refer to your windrower operator s manual for information about the lift cylinder lock out valves OPERATION...

Page 74: ...eed 3 6 3 Adjusting Reel Speed page 61 Auger position 3 6 4 Setting Auger Position page 61 Reel position 3 6 5 Setting Reel Position page 64 Tine aggressiveness adjustment 3 6 6 Setting Tine Aggressiv...

Page 75: ...Reel Speed An A40 auger header features a hydraulic direct drive reel with operating speed ranges of 50 to 85 rpm for M100 M105 M200 M205 as well as M1170 and M1240 models with standard reel configur...

Page 76: ...n The auger should clear the stripper bars on the auger pan by approximately 1 4 mm 1 32 5 32 in Shimming the stripper bars may be required Refer to 4 12 Stripper Bar page 164 Adjusting Auger Fore Aft...

Page 77: ...lever GSL to Park center steering wheel to lock shut off engine and remove key Figure 3 86 A40D Left Side 1 Shut off engine and remove key 2 Open left endshield 3 Loosen four nuts A 4 Loosen jam nuts...

Page 78: ...lugs knife Back and down close to guards Short crop Back Thick stemmed or heavy standing Up and forward To make adjustments to reel position refer to the following sections Adjusting Reel Fore Aft Pos...

Page 79: ...juster bolt B and turn bolt B to adjust reel fore aft position 5 Tighten jam nut 6 Tighten nuts A Figure 3 90 Auger Header Right Side 7 Open right endshield 8 Loosen four nuts A 9 Loosen jam nut on ad...

Page 80: ...r GSL to Park center steering wheel to lock shut off engine and remove key Figure 3 91 Auger Header Left Side 1 Shut off engine and remove key 2 Open left endshield 3 Loosen four nuts A Figure 3 92 Au...

Page 81: ...am nuts on adjuster bolts A and turn bolts A to adjust reel vertical position NOTE The factory setting at forward adjuster bolt should be 12 mm 15 32 in lower than at rear adjuster bolt If tine aggres...

Page 82: ...heck that the reel rotates freely NOTE Manually rotate reel and ensure that tines do not contact header pan otherwise damage to pan will result If necessary grind off excessive length from tine if tin...

Page 83: ...rances to knife sections and auger pan are adequate for working conditions 2 Check that reel rotates freely NOTE If there are a few reel tines that are touching the pan while the rest are at the corre...

Page 84: ...re 3 100 Auger Header Right Side 5 Tighten nuts A and jam nuts on bolts 6 Check that chain and or belt have NOT become over tight Adjust to recommended tension if required 7 Check reel tine to header...

Page 85: ...oe or gauge roller 3 Raise or lower skid shoe or gauge roller to desired position 4 Replace pins A Figure 3 103 Gauge Roller 5 Check that skid shoes or gauge rollers are adjusted to the same position...

Page 86: ...the header fully with the lift cylinders fully retracted 4 Set left and right float fine adjustments to mid range position 5 0 on the cab display module Refer to your windrower operator s manual for d...

Page 87: ...nition key 5 Grasp one end of the header and lift Lifting force should be 335 380 N 75 85 lbf and should be the same at both ends 6 Restart the engine and adjust float as required Refer to Setting the...

Page 88: ...now set NOTE Float adjustments of 1 0 out of 10 change the header weight at the cutterbar by approximately 91 kg 200 lb Adjust float in increments of 0 05 to optimize field performance 7 Use soft key...

Page 89: ...an and rock drop tines Lowering the feed pan helps prevent plugging in heavy crop Raising the feed pan helps to form an even windrow in light crop WARNING To avoid bodily injury or death from fall of...

Page 90: ...in CAUTION To prevent accidental movement of windrower return ground speed lever GSL to Park center steering wheel to lock shut off engine and remove key Figure 3 112 Roll Gap Adjustment Gauge 1 Loos...

Page 91: ...olls at access port C IMPORTANT Roll timing and alignment are critical when the roll gap is decreased because Conditioning is affected The bars may contact each other 7 Check roll timing and alignment...

Page 92: ...ring for each end of the roll Figure 3 114 Conditioner Roll Tension Springs Table 3 2 Conditioner Roll Tension Factory Settings Left spring A 81 91 mm 3 3 16 3 9 16 in Right spring B 41 51 mm 1 5 8 2...

Page 93: ...uld be made based on the following factors Weather conditions rain sun humidity wind Type and yield of crop Drying time available Method of processing green feed bales silage A wider windrow will gene...

Page 94: ...3 117 Forming Shield Adjustment Nut 2 If forming shield attachment is too tight or too loose tighten or loosen nut A as required Positioning Rear Deflector Fluffer Shield The rear deflector A slows t...

Page 95: ...ctor A by pushing down on one side of the deflector and then on the other side Locking handles B are located at either end of deflector and may be loosened slightly 3 For heavier crops raise the defle...

Page 96: ...214804 82 Revision A 3 7 Recommended Operating Settings These settings are intended as a starting point Operators should fine tune to crop and field conditions Refer to Table 3 3 page 83 OPERATION...

Page 97: ...hallow 1600 1800 65 70 Low Light Upper slot 10 3 8 Alfalfa Lodged Smooth 0 Steep 1600 1800 73 77 High Heavy Variable Refer to above Alfalfa Lodged Rocky 0 Shallow 1600 1800 73 77 High Light Normal Var...

Page 98: ...eep 1700 1850 70 75 Normal High Heavy Variable Refer to above Sudan Tall Crop Lodged Rocky 152 6 Shallow 1700 1850 70 75 Normal High Light Normal Variable Refer to above Triticale winter forage 10 Smo...

Page 99: ...0 1950 73 77 High Light Lower slot 10 3 8 Wild Grass Hay 2 3 Smooth 0 Steep 1850 1950 70 75 Normal Normal Center slot 6 1 4 Wild Grass Hay 2 3 Rocky 0 Shallow 1850 1950 70 75 Normal Light Center slot...

Page 100: ...TION 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 Stop forward movement of windrow...

Page 101: ...eshaft A to turn rolls forward until plug clears 9 Return wrench to storage location and secure in place with pin WARNING Return unplug wrench to storage location and close left side driveshield befor...

Page 102: ...e 88 3 9 2 Special Auger Design for Grass Seed Special page 89 3 9 3 Seven Bat Reel page 89 3 9 4 Auger Pan Extensions page 90 3 9 5 Windrow Forming Rods page 92 3 9 1 Stub Guards and Hold Downs Figur...

Page 103: ...he center beaters and beater supports have been removed to reduce auger wrapping Figure 3 122 Grass Seed Auger 3 9 3 Seven Bat Reel Figure 3 123 Grass Seed Reel A seventh bat is added to the reel body...

Page 104: ...l the pan extensions do the following Figure 3 124 Shipping Configuration 1 Remove deflectors A from their shipping positions on the header and unwrap Figure 3 125 Pan Extension Wide Setting 2 Remove...

Page 105: ...installing the pan extension on the opposite side of the header To adjust a pan extension s width do the following Figure 3 127 Left Side Pan Extension 1 Remove nut and bolt A 2 Loosen nut B but do N...

Page 106: ...ded to assist in forming the narrow windrows preferred for this application Bend rods to modify the windrow shape Use forming rods in conjunction with auger pan extensions to achieve the width and sha...

Page 107: ...ory Choose a ground speed that allows the knife to cut the crop smoothly and evenly The chart below indicates the relationship between ground speed and area cut for three header sizes For example at a...

Page 108: ...reel entry in tall crops They can be easily adjusted to suit the crop or removed when not required 3 11 1 Adjusting Tall Crop Dividers Figure 3 131 Tall Crop Divider 1 Loosen U bolt A 2 Remove bolts...

Page 109: ...Figure 3 132 Tall Crop Divider 1 Remove U bolt A and bolts B and remove divider Repeat for other divider 2 Remove bolts attaching lean bar to header Figure 3 133 Lean Bar 3 Remove bolts A attaching ex...

Page 110: ...214804 96 Revision A Figure 3 134 Lean Bar 4 Reposition lean bar on header at desired height and install existing carriage bolts A two per side Tighten bolts OPERATION...

Page 111: ...ng Use a moisture tester or estimate level If ground is wet due to irrigation wait until soil moisture drops below 45 If ground is wet due to frequent rains cut hay when weather allows and let the for...

Page 112: ...n drying time by a full day If practical set forming shields to produce a narrower windrow that the machine can straddle NOTE Driving on the windrow in high yield crops may be unavoidable if a full wi...

Page 113: ...service manual that is available from your Dealer A parts catalog is provided with your shipment 4 1 Preparing for Servicing CAUTION To avoid personal injury before servicing header or opening drive...

Page 114: ...shield This procedure is for opening and closing the driveshield over the conditioner drivelines Opening driveshield Figure 4 1 Driveline Shield Figure 4 2 Driveline Shield Open 1 Disengage rubber lat...

Page 115: ...214804 101 Revision A Closing driveshield Figure 4 3 Driveline Shield 1 Lower shield B 2 Engage rubber latch A MAINTENANCE AND SERVICING...

Page 116: ...driver or equivalent into opening A at base of endshield and push to release latch 2 Pull bottom and lift endshield until shield support B engages bolt Check that support B is engaged before releasing...

Page 117: ...fied in chart on the inside back cover of this manual Log hours of operation use the maintenance record and keep copies of your maintenance records Refer to 4 4 1 Maintenance Schedule Record page 104...

Page 118: ...Lubricant level End of Season Refer to 4 4 4 Storage page 106 10 Hours or Daily Hydraulic Hoses and Lines2 S Sections guards And hold downs2 Knife hold downs2 Knife assembly2 Knife drive box bolt tor...

Page 119: ...CAUTION Review the operator s manual to refresh your memory on safety and operating recommendations Review all safety signs and other decals on the header and note hazard areas Be sure all shields an...

Page 120: ...e block up the header to take weight off tires 5 Repaint all worn or chipped painted surfaces to prevent rust 6 Loosen drive belts 7 Lubricate header thoroughly leaving excess grease on fittings to ke...

Page 121: ...rease interval B in hours of operation Use the recommended lubricants specified in this manual at the inside back cover Figure 4 5 Grease Interval Decal 1 Wipe grease fitting with a clean cloth before...

Page 122: ...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 greas...

Page 123: ...D Knifehead Bearing 1 Place 25 Hours 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 b...

Page 124: ...0DX Header Left Side A Tine Bar Bearing 4 Places Each Tine Bar 50 Hours B Knifehead Bearing 1 Place 25 Hours C Gauge Roller Bearings 2 Places Both Sides if Installed 50 Hours D Knife Drive Bearing 1 P...

Page 125: ...TE High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base Figure 4 8 Hay Conditioner A Roll Pivot 1 Place Both Sides B Roll Shaft Bearings 2 Place...

Page 126: ...ife pressing on guards do NOT over grease If more than 6 to 8 pumps of grease gun are required to fill the cavity replace the seal in the knifehead Figure 4 9 Drivelines A Driveline Shafts 2 Places 50...

Page 127: ...214804 113 Revision A MAINTENANCE AND SERVICING...

Page 128: ...re lubrication Refer to the inside back cover of this manual for proper oil Figure 4 10 Knife and Gearbox Oil A Oil Knife Daily Except in Sandy Soil SAE 30 C Knife Drive Box 2 Places 3 B Check Roll Ge...

Page 129: ...The locking cam is only on one side of the bearing 3 Install but do NOT tighten flangette bolts E 4 When the shaft is correctly located lock the lock collar with a punch NOTE The collar should be lock...

Page 130: ...ure before disconnecting hydraulic lines Tighten all connections before applying pressure Keep hands and body away from pin holes and nozzles which eject fluids under high pressure If ANY fluid is inj...

Page 131: ...section can be replaced without removing the knife from the cutterbar WARNING To avoid bodily injury or death from unexpected start up or fall of raised machine always stop engine remove key and enga...

Page 132: ...hisel in slot C to release the load on the knifehead pin 7 Use a screwdriver or chisel to pry the pin upwards in the pin groove until the pin is clear of the knifehead 8 Push the knife assembly inboar...

Page 133: ...ation E is 0 25 mm 0 01 in Figure 4 18 Knifehead 7 Install grease fitting A into the knifehead pin and turn the grease fitting for easy access IMPORTANT Grease knifehead just enough to start a slight...

Page 134: ...bearing into the knifehead until the top of the bearing is flush with the step in the knifehead 3 Install seal B into knifehead with the lip facing outwards IMPORTANT To prevent premature knifehead or...

Page 135: ...are suitable for most standing crops and cutting conditions Stub guards improve cutting performance in tough stringy grass type crops and crops that need to be cut close to the ground Guards are also...

Page 136: ...18346 G Stub Drive End No Ledger MD 118347 H Stub Center MD 124775 CAUTION To avoid bodily injury or death from unexpected startup of machine always stop engine and remove key from ignition before lea...

Page 137: ...d Adjustment 2 To adjust guard tips downward position tool as shown at right and push down Figure 4 26 Guard Tip Upward Adjustment 3 To adjust guard tips upward position tool as shown at right and pul...

Page 138: ...knife pointed center guard and hold down in this section Figure 4 27 Pointed Guards 1 Stroke the knife so that knife sections are spaced midway between the guards 2 Remove two nuts A and carriage bol...

Page 139: ...h guard C adjuster bar D and hold down E to the cutterbar 2 Remove guard C hold down E and adjuster bar D 3 Position new guard C on cutterbar and install carriage bolts B 4 Install adjuster bar D and...

Page 140: ...a double knife header IMPORTANT Replace adjacent guards when replacing center guard Figure 4 32 Center Guard Double Knife IMPORTANT Ensure center guard A has offset B cutting surface IMPORTANT Ledger...

Page 141: ...ar E 4 Position new guard C on cutterbar and install two 7 16 x 2 3 4 in carriage bolts B 5 Position adjuster bar E and hold down D on cutterbar and install nuts A 6 Torque nuts to 68 92 Nm 50 68 lbf...

Page 142: ...ANT Replace adjacent guards when replacing center guard Figure 4 37 Center Guard Double Knife IMPORTANT Ensure center guard A has offset cutting surface B IMPORTANT Ledger surfaces of center and adjac...

Page 143: ...b Guard Adjustment NOTE Top guide C which is an inverted stub guard must accommodate the two overlapping knives at center guard location on double knife header Ensure replacement is correct part IMPOR...

Page 144: ...knife overlap Standard Used at all other locations Figure 4 42 Hold Downs A Pointed Standard MD 118162 B Pointed Center Double Knife MD 124344 C Stub Center Double Knife MD 118346 D Stub Standard MD 0...

Page 145: ...insufficient clearance Insufficient clearance will also result in overheating of the knife and guards Adjusting Knife Hold Down Stub Guard Double Knife Header Figure 4 44 Stub Guard Double Knife 1 Tor...

Page 146: ...es with clamping bolts The oil level in the knife drive box A is checked with a dipstick that is incorporated into the breather B Mounting Bolts CAUTION To avoid bodily injury or death from unexpected...

Page 147: ...Timing Belt Tension on Right Side page 145 Figure 4 48 Knifehead 2 Stroke knife to its outer limit 3 Clean area around knifehead 4 Remove grease fitting A from knifehead pin B 5 Remove nut and bolt C...

Page 148: ...de L9 bolts and flat washers 2 Apply medium strength threadlocker Loctite 243 or equivalent in two bands B around shaft as shown with one band at end of shaft and one band approximately mid way Figure...

Page 149: ...ifehead pin This will allow any trapped air to escape and knifehead pin will seat correctly 10 Tap underside of the knifehead until the pin is flush with the upper face of the pitman arm C 11 Carefull...

Page 150: ...rive Box 1 Remove any rust or paint from inner spline For replacement parts remove oil grease with degreasing agent 2 Apply medium strength threadlocker Loctite 243 or equivalent in two bands around s...

Page 151: ...box drain to collect oil Figure 4 58 Knife Drive Box Breather 2 Engage safety props 3 Remove breather dipstick A and drain plug B and allow oil to drain 4 Replace drain plug and add oil to required l...

Page 152: ...rclockwise until the right side knife is at the center of the inboard stroke NOTE Secure knives to prevent movement when installing the belts 4 Install the right side knife drive box drive belt and te...

Page 153: ...and must begin moving at exactly the same time Figure 4 64 Knife Timing 7 If timing is correct skip the remaining steps 8 If timing is off loosen right side timing belt sufficiently to allow skipping...

Page 154: ...ove key 2 Open left endshield 3 Apply a force of 35 50 N 8 12 lbf on each belt at midspan D Belt should deflect 4 mm 3 16 in If necessary adjust as follows a Loosen three nuts A and jam nut on adjuste...

Page 155: ...ys B and C IMPORTANT To prolong belt and drive life do NOT over tighten belts 2 Turn adjuster bolt D to move pulley B until a force of 35 50 N 8 12 lbf applied at midspan to each belt deflects each be...

Page 156: ...hours of operation Removing Timing Belt from Left Side To remove the knife drive timing belt from the left side of an auger header follow these steps Figure 4 69 Gearbox Locking Bolts 1 Turn off engi...

Page 157: ...e box pulley Rotate the pulley with the belt in the notch until it is free for removal Figure 4 72 Auger Hoses NOTE Mark the ports and hoses and place port caps or plastic bags with tie wraps to preve...

Page 158: ...x pulley B 3 Route knife drive belt A onto knife drive pulley C 4 Turn adjuster bolt D to move pulley C until a force of 22 30 N 5 6 5 lbf deflects belt 14 mm 9 16 in at knife drive belt midspan A IMP...

Page 159: ...e always stop engine and remove key from ignition before leaving operator s seat for any reason Figure 4 77 Right Side Timing Belt 1 Turn off engine and remove key 2 Open right endshield 3 Apply a for...

Page 160: ...operator s seat for any reason Figure 4 78 Right Inboard Cover 1 Remove bolt A and remove cover B in right endsheet Figure 4 79 Right Timing Belt 2 Open right endshield 3 Loosen three nuts A and jam n...

Page 161: ...of endsheet through opening A Figure 4 81 Right Timing Belt 2 Position belt C onto knife drive box pulley E and knife drive pulley D as shown IMPORTANT To prolong belt and drive life do NOT over tight...

Page 162: ...in period 5 hours 4 8 2 Header Reel Drive The reel drive gearbox is a sealed factory assembled unit on an A40D and A40DX header The reel drive gearbox requires no scheduled maintenance but if service...

Page 163: ...lacing Tine and Bearing Opposite Cam Section Y page 159 4 9 5 Replacing Tine Tine Bar Extension Section Z page 161 IMPORTANT Keep reel tines in good condition Straighten or replace as required 4 9 1 R...

Page 164: ...eepers B and shoulder bolts C that connect cam arm D and end tines E to tine bar IMPORTANT Tine attachment hardware and configuration may vary between Tine Bar Type A and Tine Bar Type B Identify loca...

Page 165: ...off tine bar d Install replacement tine on tine bar and secure with bolt A and keeper B Install nut with flat side against tine bar e Slide remaining tines onto tine bar and attach to tine bar Do NOT...

Page 166: ...figuration to include both Type A Tine Bar and Type B Tine Bar configurations a 5 16 x 2 1 2 in carriage bolt A b Spacer B c Lock nut C d 5 16 x 2 in hex head bolt D Figure 4 92 Type B Tine Bar A Carr...

Page 167: ...Type B Identify locations so that tine hardware will be reinstalled at same locations Both Tine Bar Type A and Tine Bar Type B configurations are required to stagger tines on the reel bat and ensure...

Page 168: ...ines as required to facilitate replacement of damaged or worn tine c Slide tines off tine bar d Install replacement tine on tine bar and secure with bolt A and keeper B Install nut with flat side agai...

Page 169: ...ine bars Figure 4 101 Tine Bar Type B 13 Remove flangette mounting bolts A at reel disc 2 14 Remove shoulder bolts B and keeper C from tine bar 15 Separate left tine bar D with bearing from center tin...

Page 170: ...ent of damaged or worn tine c Slide tines off tine bar d Install replacement tine on tine bar and secure with bolt A and keeper B Install nut with flat side against tine bar e Slide remaining tines on...

Page 171: ...mounting bolts A at reel discs 3 and 4 Figure 4 108 Disc 3 A Flangette Mounting Bolts B Shoulder Bolts C Keeper X Section X Y Section Y 2 Remove shoulder bolts B and keeper C connecting tine bar sect...

Page 172: ...l nut with tapered side against tine bar Do NOT install bolts in end tines at this time Figure 4 110 Disc 3 A Flangette Mounting Bolts B Shoulder Bolts C Keeper X Section X Y Section Y 6 Assemble tine...

Page 173: ...4 A Shoulder bolts B Keeper C Flangette Mounting Bolts Y Section Y Z Section Z 1 Remove shoulder bolts A and keeper B connecting tine bar sections Z and Y at reel disc 4 2 Remove flangette mounting bo...

Page 174: ...secure with bolts A and keepers B Install nut with tapered side against tine bar Do NOT install bolts in end tines at this time 6 Install tine bar extension Z including bearing to section Y at reel di...

Page 175: ...center section Z Z as follows Figure 4 117 Disc 4 A Bolt B Keepers Z Section Z 1 Remove bolt A and keepers B on tine to be replaced and slide tines off tine bar Figure 4 118 End View of Tine Bar 2 Ins...

Page 176: ...void personal injury before servicing header or opening drive covers follow procedures in 4 1 Preparing for Servicing page 99 and 1 Safety page 1 1 Heat the deformed area with a heat gun until the pol...

Page 177: ...missing or damaged To replace a rubber finger follow these steps Figure 4 119 Auger Finger 1 Remove nut and bolt A and then remove finger B 2 Position new finger in holder and then install bolt and nu...

Page 178: ...cause plugging across the auger due to restricted flow at the stripper bars To address this problem remove the lower stripper bar A and if necessary the center stripper bar B at each end of the header...

Page 179: ...Retighten bolts to specified torque 4 12 3 Installing Front Stripper Bar Extensions Extensions for the front stripper bar are provided for installation if required for certain crop conditions especia...

Page 180: ...s D Forward 4 Position extension A at inboard end of front stripper bars and mark locations of the two holes onto the pan 5 Drill two 8 mm 5 16 in holes at these locations 6 Install extension A with c...

Page 181: ...machine always stop engine and remove key from ignition before leaving operator s seat for any reason NOTE Change conditioner drive gearbox lubricant after the first 50 hours of operation and every 1...

Page 182: ...e 4 127 Check Plug 4 Place a suitable container under gearbox drain to collect oil 5 Remove breather A and check plug B Figure 4 128 Gearbox Drain 6 Remove drain plug A and allow oil to drain Replace...

Page 183: ...ended lubricant 8 Oil is at required level when it runs out of check plug B 4 13 2 Removing Forming Shield Figure 4 131 Forming Shield Straps 1 Turn off engine and remove key 2 Remove hairpins B and w...

Page 184: ...ground Replace clevis pins in forming shield 6 Slide forming shield out from under windrower or drive windrower away from forming shield 4 13 3 Disassembling Forming Shield To disassemble the forming...

Page 185: ...ssemble nut A from bolt B and lift deflector C and washer D off forming shield Repeat for other deflector Figure 4 135 Cover 4 Disassemble locking handles A and remove bolts 5 Disassemble fluffer shie...

Page 186: ...ling Forming Shield To assemble the forming shield follow these steps Figure 4 137 Cover 1 Attach deflector fins B to forming shield cover with bolts A Figure 4 138 Cover 2 Attach fluffer shield B to...

Page 187: ...ure 4 139 Forming Shield 4 Attach deflectors C and washers D to forming shield cover with nuts A and bolts B Figure 4 140 Forming Shield 5 Attach adjuster rods B to side deflectors C with lynch pin A...

Page 188: ...for procedure NOTE Do NOT install the two triangular shaped plates from the forming shield kit Triangular plates are used with rotary headers Figure 4 142 Windrower Leg 2 Install bolt A with spacer B...

Page 189: ...d under Windrower 4 Position forming shield A under windrower frame Figure 4 145 Forming Shield Attached to Windrower Legs 5 Position forming shield onto bolts A in windrower legs and secure with clev...

Page 190: ...ing for a wide windrow Refer to 3 6 14 Positioning the Forming Shields page 79 8 Adjust fluffer shield C to middle position Loosen handles B if required Refer to Positioning Rear Deflector Fluffer Shi...

Page 191: ...lways stop engine and remove key from ignition before leaving operator s seat for any reason Install hydraulic motor onto the gearbox as follows Figure 4 149 Motor Single Knife 1 Turn off engine and r...

Page 192: ...ing channel B to frame Figure 4 151 Header Drive 3 Remove two hex bolts A and one carriage bolt B securing channel C to endsheet and remove channel C Figure 4 152 Gearbox Motor 4 Remove two bolts A se...

Page 193: ...ure 4 154 Knife Drive Belts 9 Remove knife drive V belts A Refer to Removing Double V Belts from Left Side page 140 10 Remove the three bolts B from the tapered bushing D 11 Install two bolts B in the...

Page 194: ...ulley B onto shaft Figure 4 158 Gearbox Pulley 4 Place tapered bushing A onto shaft align with key B in shaft and push bushing A into place 5 Align slot in pulley C with key D in tapered bushing and s...

Page 195: ...rt on the inside back cover of this manual Figure 4 161 Upper and Lower Drivelines 11 Align keyway in upper driveline yoke B with key in gearbox shaft and attach yoke B to shaft 12 Install two hex hea...

Page 196: ...to 4 13 11 Checking Adjusting Roll Timing page 185 Figure 4 163 Conditioner Drive 17 Position channel B against endsheet as shown picking up the three holes in endsheet 18 Install two carriage bolts a...

Page 197: ...t rests on the ground CAUTION To avoid bodily injury or death from unexpected startup of machine always stop engine and remove key from ignition before leaving operator s seat for any reason 2 Open co...

Page 198: ...in align rolls as follows a Remove nuts and bolts A and remove shims B The shims can be lifted off the pivot rod b Move upper roll until dimension X at both ends looking through port as shown in Step...

Page 199: ...nditioner driveshield at left end of conditioner 2 Loosen bolt A and rotate cover B to expose access port at each end of conditioner Figure 4 171 Roll Timing 3 Examine roll spacing X at each end of th...

Page 200: ...s of yoke plate on lower driveline b Turn rolls to achieve best timing c When roll timing is satisfactory tighten bolts A to secure the position 5 Recheck distance between the bars at both ends Refer...

Page 201: ...follow these steps Figure 4 174 Skid Shoe 1 Raise header and engage safety props 2 Turn off engine and remove key 3 Remove bolts and clips A from forward edge of skid shoe NOTE Use a socket and ratch...

Page 202: ...on frame and secure with clevis pin B Figure 4 177 Skid Shoe 9 Reinstall clips A with bolts and nuts removed at Step 3 page 187 to secure skid shoe to cutterbar NOTE Use a socket and ratchet wrench to...

Page 203: ...n off engine and remove key Figure 4 178 Gauge Roller 3 Remove bolts and clips A from forward edge of gauge roller assembly NOTE Use a socket and ratchet wrench to access the nuts 4 Remove hairpins on...

Page 204: ...ure roller assembly to cutterbar NOTE Use a socket and ratchet wrench to access the nuts 4 Tighten nuts Figure 4 181 Support Bracket 5 Remove pins A and adjust rollers to desired height Reinstall the...

Page 205: ...nt wires from dragging or rubbing Keep lights clean and replace defective bulbs To replace light bulbs follow these steps Figure 4 182 A40D Hazard Light 1 Using a Phillips screwdriver remove screws A...

Page 206: ......

Page 207: ...ddition to the standard skid shoes two additional skid shoes may be added for extra control of cutting height and protection of cutting components MD B4594 5 1 2 Gauge Roller Kit Figure 5 2 Gauge Roll...

Page 208: ...4 9 m 16 ft MD B4717 5 5 m 18 ft MD B4718 5 1 4 Stub Guard Conversion Kit Figure 5 4 Stub Guards Stub guards complete with top guides and adjuster plates are designed to cut tough crops Separate kits...

Page 209: ...ure 5 5 Tall Crop Divider Left Side Tall crop dividers attach to the ends of the header for clean crop dividing and reel entry in tall crops The kit includes left and right dividers lean bar extension...

Page 210: ......

Page 211: ...ding and Assembly Header specific instructional manuals for unloading assembly and set up procedures are included with your shipment Header Description Used on Instruction Part Number A40D A40DX Self...

Page 212: ......

Page 213: ...ecking Adjusting Roll Timing page 185 Slow crop drying Rolls not crimping crop sufficiently Decrease roll gap 3 6 12 Adjusting Conditioner Roll Gap page 76 Slow crop drying Crop is spread too narrow A...

Page 214: ...tting of crop Bent or misaligned guards causing poor shearing action Align guards for proper shearing action Aligning Guard page 123 Ragged or uneven cutting of crop Bent knife causing binding Straigh...

Page 215: ...age 71 Consider use of stub guards 4 7 7 Guards page 121 Conditioner plugging knife plugging uneven formation and bunching of windrow Header float too heavy Adjust to lighter float setting 3 6 9 Check...

Page 216: ...n page 61 Conditioner plugging knife plugging uneven formation and bunching of windrow Roll gap too large Adjust roll gap 3 6 12 Adjusting Conditioner Roll Gap page 76 Conditioner plugging knife plugg...

Page 217: ...auger and downward as close as possible to knife and pan 3 6 3 Adjusting Reel Speed page 61 3 6 5 Setting Reel Position page 64 Auger plugging in heavy grass seed Poor crop flow across auger Remove lo...

Page 218: ...ump and gear drive at PTO 2 2 Product Specifications page 21 Excessive breakage of knife sections or guards Guards knife and hold downs misaligned Straighten guards align hold downs 4 7 7 Guards page...

Page 219: ...n needle bearing in knifehead Replace 4 7 4 Removing Knifehead Bearing page 119 Knocking in knife drive Worn knifehead pin Replace 4 7 3 Installing Knife page 118 Knocking in knife drive Incorrect end...

Page 220: ...n A Symptom Problem Solution Section Lights malfunctioning Burned out bulb Replace bulb 4 16 Maintaining the Electrical System page 191 Lights malfunctioning Poor connection Check connector at windrow...

Page 221: ...e torque applied to regular nuts by f 0 65 Self tapping screws Standard torque is to be used NOT to be used on critical or structurally important joints SAE Bolt Torque Specifications Torque values sh...

Page 222: ...2 105 116 77 86 5 8 11 144 160 107 118 3 4 10 259 286 192 212 7 8 9 413 456 306 338 1 8 619 684 459 507 Figure 8 3 Bolt Grades A Nominal Size B SAE 8 C SAE 5 D SAE 2 Table 8 3 SAE Grade 8 Bolt and Gra...

Page 223: ...7 5 8 11 299 330 221 345 3 4 10 531 587 393 435 7 8 9 855 945 633 700 1 8 1165 1288 863 954 Metric Bolt Specifications Figure 8 5 Bolt Grades Table 8 5 Metric Class 8 8 Bolts and Class 9 Free Spinning...

Page 224: ...65 72 48 53 14 2 0 104 115 77 85 16 2 0 161 178 119 132 20 2 5 314 347 233 257 24 3 0 543 600 402 444 Figure 8 7 Bolt Grades Table 8 7 Metric Class 10 9 Bolts and Class 10 Free Spinning Nut Nominal S...

Page 225: ...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 Metric Bolt Specifications Bolting into C...

Page 226: ...ith other wrench to torque shown 5 Assess final condition of connection Table 8 10 Flare Type Hydraulic Tube Fittings SAE Dash Size Thread Size in Torque Value5 Flats from Finger Tight FFFT Nm lbf ft...

Page 227: ...r as possible 3 Check that O ring A is NOTon threads and adjust if necessary 4 Apply hydraulic system oil to O ring A Figure 8 12 Hydraulic Fitting 5 Install fitting B into port until backup washer D...

Page 228: ...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 1 5 16 12 176 193 130 1...

Page 229: ...page 215 6 Check final condition of fitting Table 8 12 O Ring Boss ORB Hydraulic Fittings Non Adjustable SAE Dash Size Thread Size in Torque Value7 Nm lbf ft lbf in 2 5 16 24 6 7 53 62 3 3 8 24 12 13...

Page 230: ...ttings according to values in Table 8 13 page 216 NOTE If applicable hold hex on fitting body E to prevent rotation of fitting body and hose when tightening fitting nut D 6 Use three wrenches when ass...

Page 231: ...d connector typically 45 degree or 90 degree is aligned to receive incoming tube or hose assembly Always finish alignment of fitting in tightening direction Never back off loosen pipe threaded connect...

Page 232: ...ressure megapascal MPa x 145 038 pounds per square inch psi Pressure bar Non SI bar x 14 5038 pounds per square inch psi Torque Newton meter Nm x 0 7376 pound feet or foot pounds lbf ft Torque Newton...

Page 233: ...l position 63 auger speeds adjusting 61 B bearings 115 belts See knife drive belts knife drive belt 140 removing left side 142 bolts definition 19 break in inspections 105 C center links 19 definition...

Page 234: ...ions 90 adjusting extensions 90 seven bat reel standard 89 special auger design 89 stub guards and hold downs 88 windrow forming rods 92 ground speed 93 guards aligning guard 123 description 121 grass...

Page 235: ...ling timing belt 144 removing double V belts 140 right side adjusting timing belt tension 145 installing timing belt 147 removing timing belt 146 knife drive boxes 132 changing oil 137 installing knif...

Page 236: ...ponsibilities 16 P pointed guards See guards power take off PTO PTO speed vi preseason checks 105 pulleys installing 136 removing 136 R raking 98 reel and reel drives replacement reel bat kit 194 seve...

Page 237: ...ting dividers 94 removing dividers 95 tall crop divider kit 195 tedding 98 TFFT definition 19 topography 97 torque definition 19 torque angles definition 19 torque specifications 207 flare type hydrau...

Page 238: ...leshooting mechanical issues 204 troubleshooting performance issues 199 unplugging conditioner and knife 86 windrow forming rods 92 windrows driving on windrows 98 windrow characteristics 98 wobble bo...

Page 239: ...enum disulphide NLGI Grade 2 Lithium base As required unless otherwise specified Grease SAE Multi Purpose High temperature extreme pressure EP performance with 10 max molybdenum disulphide NLGI Grade...

Page 240: ...16 891 7313 f 816 891 7323 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Centre t 7 495 775 6971 f 7 495 967 7600 MacDon Australia Pty Ltd...