MacDon A40-D User manual

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

A40-D Self-Propelled Windrower Auger Header
Published May, 2016

Introduction
This instructional manual describes the unloading, setup, and predelivery requirements for the MacDon A40-D
Self-Propelled Windrower Auger Header, including a Grass Seed version.
Use the Table of Contents to guide you to specifictopics.
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)orfromourDealer-onlysite(https://portal.macdon.com)(login required).
147913 iRevision A

List of Revisions
The following list provides an account of major 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

TABLE OF CONTENTS
Introduction...................................................................................................................................... i
List of Revisions ...............................................................................................................................ii
1 Safety.................................................................................................................................................... 1
1.1 Signal Words................................................................................................................................... 1
1.2 General Safety ................................................................................................................................ 2
1.3 Safety Signs.................................................................................................................................... 4
2 Unloading the Machine.......................................................................................................................... 5
2.1 Unloading the Header...................................................................................................................... 5
2.1.1 Unloading the Header from a Truck Flatbed............................................................................... 5
3 Assembling the Machine....................................................................................................................... 7
3.1 Removing Underside Shipping Stand................................................................................................ 7
3.2 Installing Skid Shoes........................................................................................................................ 8
3.3 Installing Gauge Rollers ................................................................................................................... 9
3.4 Lowering the Header.......................................................................................................................11
3.5 Removing Shipping Stands ............................................................................................................ 14
3.6 Installing Tall Crop Divider Kit ......................................................................................................... 15
3.7 Adjusting Lean Bar ........................................................................................................................ 16
3.8 Adjusting Pan Extensions: Grass Seed Special............................................................................... 17
3.9 Adjusting Transport Lights.............................................................................................................. 18
3.10 Assembling Forming Shield............................................................................................................ 19
3.11 Installing Forming Shield – SP Windrower Headers.......................................................................... 22
3.12 Attaching A40-D Header to SP Windrower....................................................................................... 25
3.12.1 Attaching to M100 or M105.....................................................................................................25
3.12.2 Attaching to M150, M155, or M155E4...................................................................................... 30
3.12.3 Attaching to M200.................................................................................................................. 35
3.12.4 Attaching to M205.................................................................................................................. 41
3.13 Modifying Hydraulics...................................................................................................................... 47
3.13.1 Modifying Hydraulics – M100, M105........................................................................................ 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, 2014 and Earlier A40-D)......................................... 67
3.18 Repositioning Knife Drive Box Breather........................................................................................... 69
4 Lubricating the Machine...................................................................................................................... 71
4.1 Greasing Procedure....................................................................................................................... 71
4.2 Lubrication Points: Left Side of Header...........................................................................................72
4.3 Lubrication Points: Right Side of Header......................................................................................... 73
4.4 Lubrication Points: Hay Conditioner................................................................................................ 74
4.5 Lubrication Points: Drivelines ......................................................................................................... 75
4.6 Knife and Gearbox Oil.................................................................................................................... 76
5 Performing Predelivery Checks........................................................................................................... 77
5.1 Checking Drive Belts and Chains.................................................................................................... 77
5.2 Checking Auger Stripper Bar Clearance.......................................................................................... 78
5.3 Checking Reel Tine to Header Pan Clearance................................................................................. 79
5.4 Checking/Adjusting Float................................................................................................................ 80
5.5 Checking Header Levelling............................................................................................................. 81
5.6 Checking Conditioner Rolls ............................................................................................................ 83
5.7 Checking Conditioner Gearbox Oil Level......................................................................................... 85
5.8 Checking Skid Shoes/Gauge Rollers...............................................................................................86
147913 iiiRevision A

TABLE OF CONTENTS
5.9 Checking Lights............................................................................................................................. 87
5.10 Running Up Header....................................................................................................................... 88
5.11 Checking Knife Speed.................................................................................................................... 89
5.11.1 Setting Knife Speed on an M100 or M105................................................................................ 89
Setting Knife Speed (With Expansion Module MD #B4666) ............................................... 89
Setting Knife Speed (Without Expansion Module MD #B4666)........................................... 91
5.12 Adjusting Knife .............................................................................................................................. 92
5.13 Checking Manuals......................................................................................................................... 93
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 Fittings..........................................................................................107
6.2 Conversion Chart..........................................................................................................................108
6.3 Definitions....................................................................................................................................109
Predelivery Checklist ....................................................................................................................111
147913 iv Revision A

1Safety
1.1 Signal Words
Three signal words, DANGER,WARNING,andCAUTION, are used to alert you to hazardous situations. The
appropriate signal word for each situation has been selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicatesapo
tentially hazardous situation that, if not avoided, could result in death or serious injury. It
mayalsobeuse
d 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 unsafe practices.
147913 1Revision A

SAFETY
1.2 General Safety
CAUTION
The following are general farm safety precautions
that should be part of your operating procedure for
all types of machinery.
Protect yourself.
• When assembling, operating, and servicing machinery,
wear all the protective clothing and personal safety
devices that could be necessary for the job at hand.
Don’t take chances. You may need the following:
• Hard hat
• Protective footwear with slip resistant soles
• Protective glasses or goggles
• Heavy gloves
• Wet weather gear
• Respirator or filter 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
•Provideafirst aid kit for use in case of emergencies.
•Keepafire extinguisher on the machine. Be sure the
fire extinguisher is properly maintained. Be familiar with
its proper use.
• Keep young children away from the machinery at
all times.
• Be aware that accidents often happen when the
Operator is tired or in a hurry. Take the time to
consider the safest way. Never ignore the warning
signs of fatigue.
Figure 1.3: Safety Equipment
147913 2Revision A

SAFETY
•Wearclose-fitting clothing and cover long hair. Never
wear dangling items such as scarves or bracelets.
• Keep all shields in place. Never alter or remove safety
equipment. Make sure driveline guards can rotate
independently of the shaft and can telescope freely.
• Use only service and repair parts made or approved by
the equipment manufacturer. Substituted parts may not
meet strength, design, or safety requirements.
Figure 1.4: Safety around Equipment
• Keep hands, feet, clothing, and hair away from moving
parts. Never attempt to clear obstructions or objects
from a machine while the engine is running.
•DoNOT modify the machine. Non-authorized
modifications may impair machine function and/or
safety. It may also shorten 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
and tools are properly grounded.
• Keep work area well lit.
• Keep machinery clean. Straw and chaff on a hot
engine is a fire hazard. Do NOT allow oil or grease to
accumulate on service platforms, ladders, or controls.
Clean machines before storage.
• Never use gasoline, naphtha, or any volatile material
for cleaning purposes. These materials may be toxic
and/or flammable.
• When storing machinery, cover sharp or extending
components to prevent injury from accidental contact. Figure 1.6: Safety around Equipment
147913 3Revision A

SAFETY
1.3 Safety Signs
• Keep safety signs clean and legible at all times.
• Replace 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 4Revision A

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 Capacity13630 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 5Revision A

UNLOADING THE MACHINE
To unload the header, follow these steps:
1. Remove hauler’s tie-down straps and chains.
2. Approach header from either its underside or topside
and slide forks (A) in underneath lifting framework as
far as possible.
NOTE:
When possible, approach from the underside to
minimize potential for scratching the unit.
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
150mm (6in.)fromground.
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 of Header in Shipping
Configuration
Figure 2.3: Underside of Header in Shipping
Configuration
147913 6Revision A

3 Assembling the Machine
Once all unloading procedures have been completed, it is time to set up the machine. Follow each procedure in this
chapter in order.
3.1 Removing Underside Shipping Stand
CAUTION
Keep feet clear when removing final bolts.
1. Remove four bolts (A) and remove shipping stand (B).
Discard stand and hardware.
Figure 3.1: Underside Shipping Stand
147913 7Revision A

ASSEMBLING THE MACHINE
3.2 Installing Skid Shoes
If kit is NOT supplied, proceed to 3.3 Installing Gauge Rollers, page 9. Otherwise, proceed as follows:
NOTE:
This kit may be installed later in the header assembly sequence, but it may be easier prior to laying the
header down.
1. Unpack skid shoe bundle.
2. Remove two clevis pins (A) from each skid shoe.
3. Remove nuts, bolts, and clips (B) from skid shoe.
Figure 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:
Useasocketandratchetwrenchtoaccess
the nuts.
6. Tighten nuts.
7. Remove clevis pin (B) and adjust skid shoe to desired
height. Reinstall two clevis pins (B) and secure with
lynch pins.
8. Repeat previous steps for opposite side. Set both skid
shoes to the same position. Figure 3.4: Skid Shoe Installed
147913 8Revision A

ASSEMBLING THE MACHINE
3.3 Installing Gauge Rollers
If kit is NOT supplied, proceed to 3.4 Lowering the Header, page 11. Otherwise, proceed as follows.
NOTE:
This kit may be installed later in the header assembly sequence, but it may be easier prior to laying the
header down.
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. Inserttabs on roller assembly into slots (A) on cutterbar
at outboard mounting locations on frame.
Figure 3.6: Gauge Roller Mounting Location
147913 9Revision A

ASSEMBLING THE MACHINE
5. Secure to support bracket with locking pin (B) atlowest
position.
6. Attach clips (A) with bolts and nuts removed earlier in
this procedure to secure roller assembly to cutterbar.
7. Tighten nuts.
NOTE:
Useasocketa
nd 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
147913 10 Revision A

ASSEMBLING THE MACHINE
3.4 Lowering the Header
To lower the header to the ground, follow these steps:
1. Attach either a spreader bar or chain to forks.
CAUTION
Ensure spreader bar or chain is secured to the forks so that it cannot slide off the forks or towards the
mast as the header is lowered to the ground.
2. Drive lifting vehicle to approach header from its
underside.
3. Attach chain 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 trailer.
This procedure is only for laying the machine over
into working position.
4. Raise forks until lift chains are fully tensioned. Figure 3.9: Header with Forklift
147913 11 Revision A

ASSEMBLING THE MACHINE
Figure 3.10: Header with Crane
A-1.2m(48in.)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

ASSEMBLING THE MACHINE
7. Attach chain to center-link anchor (A) on frame tube
and raise rear of header approximately305 mm (12 in.)
off ground.
Figure 3.12: Center-Link Anchor
8. Remove lynch pin from clevis pin (A) in header stand
at right side of header.
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

ASSEMBLING THE MACHINE
3.5 Removing Shipping Stands
To remove shipping stands, follow these steps:
1. Remove two bolts (A) from shipping stand (B).
2. Remove hairpin from pin (C).
3. Hold shipping stand (B), remove pin (C), and remove
stand. Discard stand and hardware.
Figure 3.15: Shipping Stands
4. Remove four bolts (A) and remove angle (B). Discard
angle and hardware.
Figure 3.16: Shipping Stands
147913 14 Revision A