MacDon A40-D User manual

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

A40-D Self-Propelled Windrower Auger Header
Published October, 2014

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).
169957 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
Added note regarding access to updated manuals to
Introduction. Introduction, page i
Added List of Revisions. List of Revisions, page ii
Updated definitions. 4Definitions, page 19
Updated illustrations to show new orientation of amber
hazard lights.
6.9 Adjusting Transport Lights, page 34
8.8 Checking Lights, page 94
Added note to clarify that center deflectors should be
oriented with narrow end toward front of cover and
deep end toward rear. 6.10 Assembling Forming Shield, page 35
Revised attaching header to windrower procedures. All sections throughout 6.12 Attaching an A-Series
Header to an SP Windrower, page 41
Added note regarding reel motor hose configuration
prior to attaching header to M100, M105, or M205
Windrower.
6.12 Attaching an A-Series Header to an SP
Windrower, page 41
Updated procedure and added new illustrations for
routing hoses at the reel motor.
6.12.1 Attaching A40-D Header to M100 or M105, page
41
6.12.4 Attaching A40-D Header to M205, page 54
6.16 Hose Routing, page 73
Added note regarding check valve MD #167344 when
attaching an A40-D Auger Header to an M100 or M105
Self-Propelled Windrower.
Removed reference to Routing Reverser Valve Jumper
Hose when modifying M100 or M105 hydraulics.
6.13.1 Modifying Hydraulics on an M100 or M105,
page 58
Added note regarding routing reverser valve jumper
hose when switching from draper header to auger
header. 6.14 Routing Reverser Valve Jumper Hose, page 66
Added new hose connection illustrations. 6.15 Attaching Hydraulics, page 67
Updated illustration with correct left-hand driveshield
image. 6.16 Hose Routing, page 73
Updated image to show correct oiling points. 7.6 Oiling, page 84
Changed title Checking Header Flotation to Checking
Header Float to match content. 8.4 Checking Header Float, page 88
Replaced skid shoe illustration to match quality of
gauge roller illustration. 8.7 Checking Skid Shoes/Gauge Rollers, page 93
Updated illustration with correct right end header
image.
Updated header run-up steps 3 and 4 to correctly
check knife speed and knife drive box pulley speed.
8.9 Running Up Header, page 95
169957 iiRevision A

Summary of Change Location
Added Checking Knife Speed sections to Predelivery
Checks. 8.10 Checking Knife Speed, page 96
Updated illustration to show new manuals case.
Removed manual part numbers and revised
instructions to have A-Series manuals placed in the
manual case.
8.12 Checking Manuals, page 100
Added check knife speed item to Predelivery Checklist. Predelivery Checklist, page 101
Revised text and formatting to improve readability. Various locations throughout
Added and revised figure titles. Various locations throughout
169957 iii 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 Recommended Torques ........................................................................................................................ 5
2.1 Torque Specifications....................................................................................................................... 5
2.1.1 SAE Bolt Torque Specifications................................................................................................. 5
2.1.2 Metric Bolt Specifications.......................................................................................................... 7
2.1.3 Metric Bolt Specifications Bolting into Cast Aluminum............................................................... 10
2.1.4 Flare-Type Hydraulic Fittings................................................................................................... 10
2.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)................................................................... 12
2.1.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) ........................................................... 14
2.1.7 O-Ring Face Seal (ORFS) Hydraulic Fittings............................................................................ 15
3 Conversion Chart................................................................................................................................ 17
4Definitions........................................................................................................................................... 19
5 Unloading the Machine........................................................................................................................ 21
5.1 Unloading the Header.................................................................................................................... 21
5.1.1 Unloading the Header from a Truck Flatbed............................................................................. 21
6 Assembling the Machine..................................................................................................................... 23
6.1 Removing Underside Shipping Stand.............................................................................................. 23
6.2 Installing Skid Shoes...................................................................................................................... 24
6.3 Installing Gauge Rollers ................................................................................................................. 25
6.4 Lowering the Header...................................................................................................................... 27
6.5 Removing Shipping Stands ............................................................................................................ 30
6.6 Installing Tall Crop Divider Kit ......................................................................................................... 31
6.7 Adjusting Lean Bar ........................................................................................................................ 32
6.8 Adjusting Pan Extensions: Grass Seed Special............................................................................... 33
6.9 Adjusting Transport Lights.............................................................................................................. 34
6.10 Assembling Forming Shield............................................................................................................ 35
6.11 Installing Forming Shield................................................................................................................ 38
6.12 Attaching an A-Series Header to an SP Windrower.......................................................................... 41
6.12.1 Attaching A40-D Header to M100 or M105............................................................................... 41
6.12.2 Attaching A40-D Header to M150 or M155............................................................................... 46
6.12.3 Attaching A40-D Header to M200............................................................................................ 50
6.12.4 Attaching A40-D Header to M205............................................................................................ 54
6.13 Modifying Hydraulics...................................................................................................................... 58
6.13.1 Modifying Hydraulics on an M100 or M105............................................................................... 58
6.13.2 Modifying Hydraulics on an M150 or M155............................................................................... 60
6.13.3 Modifying Hydraulics on an M200 with a Reverser Valve........................................................... 62
6.13.4 Modifying Hydraulics on an M200 without a Reverser Valve...................................................... 63
6.13.5 Modifying Hydraulics on an M205............................................................................................ 65
6.14 Routing Reverser Valve Jumper Hose............................................................................................. 66
6.15 Attaching Hydraulics...................................................................................................................... 67
6.16 Hose Routing ................................................................................................................................ 73
6.17 Repositioning Knife Drive Box Breather........................................................................................... 77
7 Lubricating the Machine...................................................................................................................... 79
7.1 Greasing Procedure....................................................................................................................... 79
7.2 Lubrication Points: Left Side of Header...........................................................................................80
7.3 Lubrication Points: Right Side of Header......................................................................................... 81
7.4 Lubrication Points: Hay Conditioner................................................................................................ 82
169957 vRevision A

TABLE OF CONTENTS
7.5 Lubrication Points: Drivelines ......................................................................................................... 83
7.6 Oiling............................................................................................................................................ 84
8 Performing Predelivery Checks........................................................................................................... 85
8.1 Checking Drive Belts and Chains.................................................................................................... 85
8.2 Checking Auger Stripper Bar Clearance.......................................................................................... 86
8.3 Checking Reel Tine to Header Pan Clearance................................................................................. 87
8.4 Checking Header Float .................................................................................................................. 88
8.5 Checking Header Levelling............................................................................................................. 89
8.6 Checking Conditioner Rolls ............................................................................................................ 91
8.7 Checking Skid Shoes/Gauge Rollers...............................................................................................93
8.8 Checking Lights............................................................................................................................. 94
8.9 Running Up Header....................................................................................................................... 95
8.10 Checking Knife Speed.................................................................................................................... 96
8.10.1 Setting Knife Speed on an M100 or M105................................................................................ 96
Setting Knife Speed (With Expansion Module MD #4666 Installed) .................................... 96
Setting Knife Speed (Without Expansion Module MD #B4666)........................................... 98
8.11 Adjusting Knife .............................................................................................................................. 99
8.12 Checking Manuals........................................................................................................................100
Predelivery Checklist ....................................................................................................................101
169957 viRevision A

1Safety
1.1 Signal Words
Three signal words, “DANGER”, “WARNING”, and “CAUTION”, are used to alert you to hazardous situations. The
appropriate signal word for each situation has been selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. 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 unsafe practices.
169957 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:
• A hard hat
• Protective footwear with slip resistant soles
• Protective glasses or goggles
• Heavy gloves
• Wet weather gear
• A respirator or filter mask
Figure 1.1: Safety Equipment
• Be aware that exposure to loud noise can cause
impairment or loss of hearing. 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 to get finished. Take the
time to consider the safest way. Never ignore warning
signs of fatigue.
Figure 1.3: Safety Equipment
169957 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.
• Stop the engine and remove thekey from ignition before
leaving operator’s seat for any reason. A child or even
a pet could engage an idling machine.
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, are 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
169957 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 your Dealer
Parts Department.
Figure 1.7: Operator’s Manual Decal
169957 4Revision A

2 Recommended Torques
2.1 Torque Specifications
The following tables provide the correct torque values for various bolts, cap screws, and hydraulic fittings.
• Tighten all bolts to the torque values specified in the charts (unless otherwise noted throughout this manual).
• Replace hardware with the same strength and grade of bolt.
• Use the torque value tables as a guide and periodically check tightness of bolts.
• Understand torque categories for bolts and cap screws by using their identifying head markings.
2.1.1 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 2.1 SAE Grade 5 Bolt and Grade 5 Free
Spinning Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
1/4-20 *106 *117 11.9 13.2
5/16-18*218 *241 24.6 27.1
3/8-16 32 36 44 48
7/16-14 52 57 70 77
1/2-13 79 87 106 118
9/16-12 114 126 153 170
5/8-11 157 173 212 234
3/4-10 281 311 380 420
7/8-9 449 496 606 669
1-8611676825912
Figure 2.1: Bolt Grades
A-NominalSize B-SAE-8
C - SAE-5 D - SAE-2
169957 5Revision A

RECOMMENDED TORQUES
Table 2.2 SAE Grade 5 Bolt and Grade F Distorted
Thread Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
1/4-20 *72 *80 8.1 9
5/16-18 *149 *164 16.7 18.5
3/8-16 22 24 30 33
7/16-14 35 39 48 53
1/2-13 54 59 73 80
9/16-12 77 86 105 116
5/8-11 107 118 144 160
3/4-10 192 212 259 286
7/8-9 306 338 413 456
1-8 459 507 619 684
Figure 2.2: Bolt Grades
A-NominalSize B-SAE-8
C - SAE-5 D - SAE-2
Table 2.3 SAE Grade 8 Bolt and Grade G Distorted
Thread Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
1/4-20 *150 *165 16.8 18.6
5/16-18 18 19 24 26
3/8-16 31 34 42 46
7/16-14 50 55 67 74
1/2-13 76 84 102 113
9/16-12 109 121 148 163
5/8-11 151 167 204 225
3/4-10 268 296 362 400
7/8-9 432 477 583 644
1-8 647 716 874 966
Figure 2.3: Bolt Grades
A-NominalSize B-SAE-8
C - SAE-5 D - SAE-2
169957 6Revision A

RECOMMENDED TORQUES
Table 2.4 SAE Grade 8 Bolt and Grade 8 Free
Spinning Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
1/4-20 *150 *165 16.8 18.6
5/16-18 26 28 35 38
3/8-16 46 50 61 68
7/16-14 73 81 98 109
1/2-13 111 123 150 166
9/16-12 160 177 217 239
5/8-11 221 345 299 330
3/4-10 393 435 531 587
7/8-9 633 700 855 945
1-8 863 954 1165 1288
Figure 2.4: Bolt Grades
A-NominalSize B-SAE-8
C - SAE-5 D - SAE-2
2.1.2 Metric Bolt Specifications
Table2.5MetricClass8.8BoltsandClass9Free
Spinning Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
3-0.5 *13 *14 1.4 1.6
3.5-0.6 *20 *22 2.2 2.5
4-0.7 *29 *32 3.3 3.7
5-0.8 *59 *66 6.7 7.4
6-1.0 *101 *112 11.4 12.6
8-1.25 20 23 28 30
10-1.5 40 45 55 60
12-1.75 70 78 95 105
14-2.0 113 124 152 168
16-2.0175 193 236 261
20-2.5 341 377 460 509
24-3.0 589 651 796 879
Figure 2.5: Bolt Grades
169957 7Revision A

RECOMMENDED TORQUES
Table2.6MetricClass8.8BoltsandClass9Distorted
Thread Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
3-0.5 *9 *10 11.1
3.5-0.6 *14 *15 1.5 1.7
4-0.7 *20 *22 2.3 2.5
5-0.8 *40 *45 4.5 5
6-1.0 *69 *76 7.7 8.6
8-1.25 *167 *185 18.8 20.8
10-1.5 28 30 37 41
12-1.7548536572
14-2.0 77 85 104 115
16-2.0 119 132 161 178
20-2.5 233 257 314 347
24-3.0 402 444 543 600
Figure 2.6: Bolt Grades
Table 2.7 Metric Class 10.9 Bolts and Class 10 Free
Spinning Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
3-0.5 *18 *19 1.8 2
3.5-0.6 *27 *30 2.8 3.1
4-0.7 *41 *45 4.2 4.6
5-0.8 *82 *91 8.4 9.3
6-1.0 *140 *154 14.3 15.8
8-1.25 28 31 38 42
10-1.5 56 62 75 83
12-1.75 97 108 132 145
14-2.0 156 172 210 232
16-2.0 242 267 326 360
20-2.5 472 521 637 704
24-3.0815 901 1101 1217
Figure 2.7: Bolt Grades
169957 8Revision A

RECOMMENDED TORQUES
Table 2.8 Metric Class 10.9 Bolts and Class 10
Distorted Thread Nut
Torque (ft·lbf)
(*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
3-0.5 *12 *13 1.3 1.5
3.5-0.6 *19 *21 2.1 2.3
4-0.7 *28 *31 3.1 3.4
5-0.8 *56 *62 6.3 7
6-1.0 *95 *105 10.7 11.8
8-1.25 19 21 26 29
10-1.5 38 42 51 57
12-1.7566739099
14-2.0 106 117 143 158
16-2.0 165 182 222 246
20-2.5 322 356 434 480
24-3.0 556 614 750 829
Figure 2.8: Bolt Grades
169957 9Revision A

RECOMMENDED TORQUES
2.1.3 Metric Bolt Specifications Bolting into Cast Aluminum
Table 2.9 Metric Bolt Bolting into Cast Aluminum
Bolt Torque
8.8
(Cast Aluminum) 10.9
(Cast Aluminum)
Nominal
Size (A)
ft·lbf N·m ft·lbf N·m
M3 ––1–
M4 –– 2.6 4
M5 ––
5.5 8
M6 6 9 9 12
M8 14 20 20 28
M10 28 40 40 55
M12 52 70 73 100
M14 ––––
M16 ––––
Figure 2.9: Bolt Grades
2.1.4 Flare-Type Hydraulic Fittings
1. Check flare (A) and flare seat (B) for defects 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 shown in Table 2.10 Flare-Type Hydraulic Tube
Fittings, page 11.
4. Use two wrenches to prevent fitting (D) from rotating.
Place one wrench on the fitting body (D), and tighten
nut (E) with the other wrench to the torque shown.
5. Assess the final condition of the connection. Figure 2.10: Hydraulic Fitting
169957 10 Revision A

RECOMMENDED TORQUES
Table 2.10 Flare-Type Hydraulic Tube Fittings
Torque Value1Flats from Finger
Tight (FFFT)
SAE No. Tube Size
O.D.(in.) Thread
Size (in.)
Nut Size
Across Flats
(in.) ft·lbf N·m Flats Turns
33/16 3/8 7/16 681
1/6
41/4 7/16 9/16 91211/6
55/16 1/2 5/8 12 16 1 1/6
63/8 9/16 11/16 18 24 1 1/6
81/2 3/4 7/8 34 46 1 1/6
10 5/8 7/8 146621
1/6
12 3/41-1/161-1/4 75 102 3/4 1/8
14 7/8 1-3/8 1-3/8 90 122 3/4 1/8
16 1 1-5/16 1-1/2 105 142 3/4 1/8
1. Torque values shown are based on lubricated connections as in reassembly.
169957 11Revision A

RECOMMENDED TORQUES
2.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)
1. Inspect O-ring (A) and seat (B) for dirt or
obvious defects.
2. Back off the lock nut (C) as far as possible. Ensure that
washer (D) is not loose and is pushed toward the lock
nut (C) as far as possible.
3. Check that O-ring (A) is NOT on the threads and adjust
if necessary.
4. Apply hydraulic system oil to the O-ring (A).
Figure 2.11: 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 final condition of the fitting.
Figure 2.12: Hydraulic Fitting
169957 12Revision A