MacDon A40D, A40DX Operator's Manual

A40D and A40DX

Self-Propelled Windrower

Auger Header

Operator ’s Manual

214804 Revision A

Original Instruction

The harvesting specialists.

MacDon A40D Self-Propelled Windrower Auger Header

Published: November 2018

EC Declaration of Conformity

Figure 1. EC Declaration of Conformity Page 1

214804 i Revision A

Figure 2. EC Declaration of Conformity Page 2

214804 ii Revision A

Introduction

This manual describes the operating and maintenance procedures for MacDon model A40D and A40DX Self­Propelled Windrower Auger Headers, including a Grass Seed version.

An A40D auger header is factory-configured to connect to an M Series Self-Propelled Windrower, while an A40DX
auger header is factory-configured to connect to an M1 Series Windrower.

NOTE:

A40D auger header grass seed (GSS) version can be used on an M1 Series Windrower ONLY if conversion kit
MD #B5998 and MD #318022 have been installed on the auger header. This kit is optional when converting the
A40D for use on M1 Series windrowers.

Model Description

A40D,

A40DX

When setting up the machine or making adjustments, review and follow the recommended machine settings in all
relevant MacDon publications. Failure to do so may compromise machine function and machine life and may result
in a hazardous situation.

Use this manual as your first source of information about the machine. Use 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 here, your header will work well for many years.

Keep this manual handy for frequent reference, and to pass on to new Operators or Owners. Contact your Dealer if
you need assistance, information, or additional copies of this manual.

CAREFULLY READ THE INFORMATION PROVIDED IN THIS MANUAL BEFORE ATTEMPTING TO OPERATE
OR MAINTAIN AN A40D OR A40DX AUGER HEADER.

MacDon provides warranty for Customers who operate and maintain their equipment as described in this manual.
A copy of the MacDon Industries Limited Warranty Policy, which explains this warranty, should have been provided
to you by your Dealer. Damage resulting from any of the following conditions will void the warranty:

• Accident

Auger header

with conditioner

Configuration Knife Size m (ft.)

Self-propelled

only

Double

4.3, 4.9, and 5.5
(14, 16, and 18)

Features

Separate hydraulic

auger, knife, and

reel drives,

grass seed option

• Misuse

• Abuse

• Improper maintenance or neglect

• Abnormal or extraordinary use of the machine

• Failure to use the machine, equipment, component, or part in accordance with the manufacturer’s instructions

Conventions

The following conventions are used in this document:

• Right and left are determined from the operator’s position. The front of the header is the side that faces the crop;
the back of the header is the side that connects to the windrower.

214804 iii Revision A

• Unless otherwise noted, use the standard torque values provided in Chapter 8.1 Recommended Torques, page

207.

NOTE:

Keep your MacDon publications up-to-date. The most current version can be downloaded from our website (www.

macdon.com) or from our Dealer-only site (https://portal.macdon.com) (login required).

NOTE:

A Russian translation of this manual can be ordered from MacDon, downloaded from the MacDon Dealer Portal
(https://portal.macdon.com) (login required), or downloaded from the MacDon international website (http://www.

macdon.com/world).

214804 iv Revision A

List of Revisions

The following list provides an account of major changes from the previous version of this document.

Summary of Change

Added new Declaration of Conformity EC Declaration of Conformity, page i

Added IMPORTANT and NOTE
to topic

Added MD #170638 1.8 Understanding Safety Signs, page 10

Updated information for MD #166452 1.8 Understanding Safety Signs, page 10

Added MD #259058 1.8 Understanding Safety Signs, page 10

Added information for kit MD #B6604 3.1 Attaching A40DX Header to M1 Series Windrowers, page 25

Added information to topic

Added metric values to table and
corrected formatting issues

Updated graphic

Updated graphic

Updated note Introduction, page iii

Updated table

Updated table – Added reel speeds for
M and M1 Series

Updated table – Added GSS
information

Location

1.2 Signal Words, page 2

Installing and Adjusting Pan Extensions, page 90

2.2 Product Specifications, page 21

1.7 Safety Sign Locations: Self-Propelled Windrower Header, page 8 –

Figure 1.17: Right Side of Header

1.7 Safety Sign Locations: Self-Propelled Windrower Header, page 8 –

Figure 1.18: Decals on Right Side of Header

2.1 Definitions, page 19

2.2 Product Specifications, page 21

2.2 Product Specifications, page 21

Updated information to included M and
M1 Series with and without variable
speed option

Added note

Added note

Updated procedure

Updated illustration

Updated illustration Adjusting Reel Vertical Position, page 66

Updated unload and assembly
instruction part number for model
year 2019

214804 v Revision A

3.6.3 Adjusting Reel Speed, page 61

3.6.4 Setting Auger Position, page 61

3.2 Detaching A40DX Header from M1 Series Windrower, page 29

3.6.9 Checking/Adjusting Float – M Series, page 72

3.3.5 Configuring Reverser Valve Jumper Hose for A40D, page 49

6 Unloading and Assembly, page 197

Model and Serial Number

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: ____________

Header Serial Number: ____________

Year: ______

Figure 3. Header Serial Number Plate Location

214804 vi Revision A

TABLE OF CONTENTS

EC Declaration of Conformity ......................................................................................................................i

Introduction.............................................................................................................................................. iii

List of Revisions ........................................................................................................................................v

Model and Serial Number.......................................................................................................................... vi

Chapter 1: Safety ....................... ............................................................................................................. 1

1.1 Safety Alert Symbols ............................................................................................................................1

1.2 Signal Words .......................................................................................................................................2

1.3 General Safety.....................................................................................................................................3

1.4 Maintenance Safety .............................................................................................................................5

1.5 Hydraulic Safety...................................................................................................................................6

1.6 Safety Signs ........................................................................................................................................7

1.6.1 Installing Safety Decals ...............................................................................................................7

1.7 Safety Sign Locations: Self-Propelled Windrower Header .......................................................................8

1.8 Understanding Safety Signs................................................................................................................ 10

1.9 Owner/Operator Responsibilities.........................................................................................................16

1.10 Operational Safety ...........................................................................................................................17

Chapter 2: Product Overview .............................................................................................. .............. 19

2.1 Definitions .........................................................................................................................................19

2.2 Product Specifications........................................................................................................................21

Chapter 3: Operation ........................................................................................................................... 25

3.1 Attaching 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 Attaching A40D to M150, M155, or M155E4 ................................................................................36

3.3.3 Attaching A40D to M200 ............................................................................................................40

3.3.4 Attaching A40D to M205 ............................................................................................................45

3.3.5 Configuring Reverser Valve Jumper Hose for A40D .....................................................................49

3.3.6 Routing A40D Hydraulic Drive Hoses..........................................................................................50

3.4 Detaching A40D Header from M Series Self-Propelled Windrower ......................................................... 55

3.5 Header Lift Cylinder Lock-Out Valves ..................................................................................................59

3.6 Operating Variables............................................................................................................................60

3.6.1 Setting Lean Bar .......................................................................................................................61

3.6.2 Adjusting Auger Speed ..............................................................................................................61

3.6.3 Adjusting Reel Speed ................................................................................................................61

3.6.4 Setting Auger Position ............................................................................................................... 61

Adjusting Auger Fore-Aft Position ..............................................................................................62

Adjusting Vertical Position .........................................................................................................63

3.6.5 Setting Reel Position .................................................................................................................64

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TABLE OF CONTENTS

Adjusting Reel Fore-Aft Position ................................................................................................64

Adjusting Reel Vertical Position .................................................................................................66

Checking Reel Tine to Header Pan Clearance ............................................................................ 69

3.6.6 Setting Tine Aggressiveness ......................................................................................................69

3.6.7 Adjusting Header Angle .............................................................................................................70

3.6.8 Setting Cutting Height................................................................................................................71

3.6.9 Checking/Adjusting Float – M Series...........................................................................................72

3.6.10 Checking/Adjusting Float – M1 Series.......................................................................................72

Checking Float – M1 Series Windrower ......................................................................................73

Setting the Float ......................................................................................................................73

Removing and Restoring Float ..................................................................................................74

3.6.11 Setting Feed Pan and Rock Drop Tine Position ..........................................................................75

3.6.12 Adjusting Conditioner Roll Gap................................................................................................. 76

3.6.13 Adjusting Conditioner Roll Tension............................................................................................78

3.6.14 Positioning the Forming Shields ............................................................................................... 79

Positioning Side Deflectors........................................................................................................79

Positioning Rear Deflector (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 Grass Seed Special .............................................................................89

3.9.3 Seven-Bat Reel.........................................................................................................................89

3.9.4 Auger Pan Extensions ............................................................................................................... 90

Installing and Adjusting Pan Extensions .....................................................................................90

3.9.5 Windrow Forming Rods .............................................................................................................92

3.10 Selecting Ground Speed...................................................................................................................93

3.11 Tall Crop Dividers .............................................................................................................................94

3.11.1 Adjusting Tall Crop Dividers......................................................................................................94

3.11.2 Removing Tall Crop Dividers.....................................................................................................95

3.12 Haying ............................................................................................................................................97

3.12.1 Haying Tips.............................................................................................................................97

Curing .....................................................................................................................................97

Topsoil Moisture .......................................................................................................................97

Weather and Topography ..........................................................................................................97

Windrow Characteristics ...........................................................................................................98

Driving on Windrow...................................................................................................................98

Raking and Tedding..................................................................................................................98

Using Chemical Drying Agents .................................................................................................. 98

Chapter 4: Maintenance and Servicing ........................................................................................... 99

4.1 Preparing for Servicing .......................................................................................................................99

4.2 Opening/Closing Driveshield............................................................................................................. 100

4.3 Endshields ......................................................................................................................................102

4.4 Maintenance Requirements ..............................................................................................................103

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TABLE OF CONTENTS

4.4.1 Maintenance Schedule/Record ................................................................................................ 104

4.4.2 Break-In Inspection ................................................................................................................. 105

4.4.3 Preseason Checks .................................................................................................................. 105

4.4.4 Storage .................................................................................................................................. 106

4.5 Lubrication ......................................................................................................................................107

4.5.1 Greasing Procedure ................................................................................................................107

4.5.2 Lubrication Points....................................................................................................................107

Lubrication Points: Auger Header ............................................................................................ 108

Lubrication Points: Hay Conditioner ......................................................................................... 111

Lubrication Points: Drivelines .................................................................................................. 112

4.5.3 Knife and Gearbox Oil ............................................................................................................. 114

4.5.4 Installing Sealed Bearings........................................................................................................ 115

4.6 Hydraulics ....................................................................................................................................... 116

4.6.1 Servicing Header Hydraulics .................................................................................................... 116

4.6.2 Checking Hoses and Lines....................................................................................................... 116

4.7 Cutterbar......................................................................................................................................... 117

4.7.1 Replacing Knife Section........................................................................................................... 117

4.7.2 Removing Knife ...................................................................................................................... 118

4.7.3 Installing Knife ........................................................................................................................ 118

4.7.4 Removing Knifehead Bearing................................................................................................... 119

4.7.5 Installing Knifehead Bearing.....................................................................................................120

4.7.6 Removing Spare Knife from Storage.........................................................................................120

4.7.7 Guards ................................................................................................................................... 121

Aligning 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

Adjusting Knife Hold-Down: Center Guard – Double-Knife Header .............................................131

Adjusting Knife Hold-Down: Stub Guard – Double-Knife Header.................................................131

4.7.9 Knife Drive Box ....................................................................................................................... 132

Mounting Bolts .......................................................................................................................132

Removing Knife Drive Box.......................................................................................................133

Installing Knife Drive Box ........................................................................................................134

Removing Pulley ....................................................................................................................136

Installing Pulley ...................................................................................................................... 136

Changing Knife Drive Box Oil ..................................................................................................137

4.7.10 Adjusting Knife Timing ...........................................................................................................137

4.8 Header Drive Systems......................................................................................................................140

4.8.1 Header Knife Drive .................................................................................................................. 140

Checking/Adjusting V-Belt Tension on Left Side ........................................................................ 140

Removing Double V-Belts from Left Side ..................................................................................140

Installing Double V-Belts .........................................................................................................141

Checking/Adjusting Timing Belt Tension on Left Side.................................................................141

Removing Timing Belt from Left Side........................................................................................142

Installing Timing Belt on Left Side ............................................................................................ 144

Checking/Adjusting Timing Belt Tension on Right Side ..............................................................145

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TABLE OF CONTENTS

Removing Timing Belt from Right Side .....................................................................................146

Installing Timing Belt on Right Side .......................................................................................... 147

4.8.2 Header Reel Drive................................................................................................................... 148

4.8.3 Header Auger Drive.................................................................................................................148

4.9 Reel Tines and Tine Bar Bearings ..................................................................................................... 149

4.9.1 Replacing Tine and Bearing: Cam End – Disc #1 .......................................................................149

4.9.2 Replacing Tine and Bearing: Disc #2 ........................................................................................153

4.9.3 Replacing Tine and Bearing: Center Section X ..........................................................................157

4.9.4 Replacing Tine and Bearing: Opposite Cam – Section Y ............................................................159

4.9.5 Replacing Tine: Tine Bar Extension – Section Z......................................................................... 161

4.10 Straightening Auger Pans ...............................................................................................................162

4.11 Replacing Rubber Fingers .............................................................................................................. 163

4.12 Stripper Bar ................................................................................................................................... 164

4.12.1 Removing Stripper Bar...........................................................................................................164

4.12.2 Replacing Stripper Bars ......................................................................................................... 165

4.12.3 Installing Front Stripper Bar Extensions................................................................................... 165

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........................................................................................................174

4.13.6 Removing Header Drive Motor ...............................................................................................176

4.13.7 Installing Header Drive Motor .................................................................................................177

4.13.8 Removing Conditioner Gearbox..............................................................................................178

4.13.9 Installing Conditioner Gearbox ...............................................................................................180

4.13.10 Checking/Adjusting Roll Alignment .......................................................................................183

4.13.11 Checking/Adjusting Roll Timing............................................................................................. 185

4.14 Replacing Skid Shoe Wear Plate .....................................................................................................187

4.15 Gauge Rollers................................................................................................................................ 189

4.15.1 Removing Gauge Rollers .......................................................................................................189

4.15.2 Installing Gauge Rollers.........................................................................................................189

4.16 Maintaining the Electrical System ....................................................................................................191

Chapter 5: Optional Equipment ......................................................................................................193

5.1 Options and Attachments .................................................................................................................193

5.1.1 Additional Skid Shoes.............................................................................................................. 193

5.1.2 Gauge Roller Kit...................................................................................................................... 193

5.1.3 Replacement Reel Bat Kit ........................................................................................................194

5.1.4 Stub Guard Conversion Kit.......................................................................................................194

5.1.5 Tall Crop Divider Kit................................................................................................................. 195

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TABLE OF CONTENTS

Chapter 6: Unloading and Assembly.............................................................................................197

Chapter 7: Troubleshooting.............................................................................................................199

7.1 Header Performance........................................................................................................................199

7.2 Mechanical......................................................................................................................................204

Chapter 8: Reference .........................................................................................................................207

8.1 Recommended Torques ...................................................................................................................207

8.1.1 Torque Specifications .............................................................................................................. 207

SAE Bolt 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-Ring Boss Hydraulic Fittings – Non-Adjustable......................................................................215

O-Ring Face Seal Hydraulic Fittings.........................................................................................216

Tapered Pipe Thread Fittings ................................................................................................... 217

8.2 Conversion Chart.............................................................................................................................218

Index.......................................................................................................................................................219

Recommended Fluids and Lubricants ............................................................. Inside Back Cover

214804 xi Revision A

1 Safety

1.1 Safety Alert Symbols

This safety alert symbol indicates 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
accompanying this symbol.

Why is safety important to you?

• Accidents disable and kill

• Accidents cost

• Accidents can be avoided

Figure 1.1: Safety Symbol

214804 1 Revision A

SAFETY

1.2 Signal Words

Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Two
signal words, IMPORTANTand NOTE, identify non-safety related information. Signal words are 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.

IMPORTANT:

Indicates a situation that, if not avoided, could result in a malfunction or damage to the machine.

NOTE:

Provides additional nonessential information or advice.

214804 2 Revision A

SAFETY

1.3 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 protective clothing and personal safety devices
that could be necessary for job at hand. Do NOT 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

• Be aware that exposure to loud noises can cause hearing

impairment or loss. Wear suitable hearing protection
devices such as earmuffs or earplugs to help protect
against loud noises.

Figure 1.2: Safety Equipment

Figure 1.3: Safety Equipment

• Provide a first aid kit for use in case of emergencies.

• Keep a fire extinguisher on the machine. Be sure fire

extinguisher is properly maintained. Be familiar with its
proper use.

• Keep young children away from machinery at all times.

• Be aware that accidents often happen when Operator is

tired or in a hurry. Take time to consider safest way.

NEVER ignore warning signs of fatigue.

Figure 1.4: Safety Equipment

214804 3 Revision A

SAFETY

• Wear close-fitting clothing and cover long hair. NEVER
wear dangling items such as scarves or bracelets.

• Keep all shields in place. NEVER alter or remove safety
equipment. Make sure driveline guards can rotate
independently of shaft and can telescope freely.

• Use only service and repair parts made or approved by
equipment manufacturer. Substituted parts may not meet
strength, design, or safety requirements.

• Keep hands, feet, clothing, and hair away from moving
parts. NEVER attempt to clear obstructions or objects
from a machine while engine is running.

• Do NOT modify machine. Unauthorized modifications
may impair machine function and/or safety. It may also
shorten machine’s life.

Figure 1.5: Safety around Equipment

• To avoid bodily injury or death from unexpected startup of
machine, ALWAYS stop the engine and remove the key
from the ignition before leaving the operator’s seat for
any reason.

• Keep 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

Figure 1.7: Safety around Equipment

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SAFETY

1.4 Maintenance Safety

To ensure your safety while maintaining machine:

• Review operator’s manual and all safety items before
operation and/or maintenance of machine.

• Place all controls in Neutral, stop the engine, set the park
brake, remove the ignition key, and wait for all moving
parts to stop before servicing, adjusting, and/or repairing.

• Follow good shop practices:

– Keep service areas clean and dry

– Be sure electrical outlets and tools are properly

grounded

– Keep work area well lit

• Relieve pressure from hydraulic circuits before servicing

and/or disconnecting machine.

• Make sure all components are tight and that steel lines,

hoses, and couplings are in good condition before
applying pressure to hydraulic systems.

Figure 1.8: Safety around Equipment

• Keep hands, feet, clothing, and hair away from all

moving and/or rotating parts.

• Clear area of bystanders, especially children, when

carrying out any maintenance, repairs, or adjustments.

• Install transport lock or place safety stands under frame

before working under machine.

• If more than one person is servicing machine at same

time, be aware that rotating a driveline or other
mechanically-driven component by hand (for example,
accessing a lubricant fitting) will cause drive components
in other areas (belts, pulleys, and knives) to move. Stay
clear of driven components at all times.

• Wear protective gear when working on machine.

• Wear heavy gloves when working on knife components.

Figure 1.9: Equipment NOT Safe for Children

Figure 1.10: Safety Equipment

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SAFETY

1.5 Hydraulic Safety

• Always place all hydraulic controls in Neutral before
dismounting.

• Make sure that all components in hydraulic system are
kept clean and in good condition.

• Replace any worn, cut, abraded, flattened, or crimped
hoses and steel lines.

• Do NOT attempt any makeshift repairs to hydraulic lines,
fittings, or hoses by using tapes, clamps, cements, or
welding. The hydraulic system operates under extremely
high-pressure. Makeshift repairs will fail suddenly and
create hazardous and unsafe conditions.

• Wear proper hand and eye protection when searching for
high-pressure hydraulic leaks. Use a piece of cardboard
as a backstop instead of hands to isolate and identify
a leak.

Figure 1.11: Testing for Hydraulic Leaks

• If injured by a concentrated high-pressure stream of
hydraulic fluid, seek medical attention immediately.
Serious infection or toxic reaction can develop from
hydraulic fluid piercing the skin.

• Make sure all components are tight and steel lines,
hoses, and couplings are in good condition before
applying pressure to a hydraulic system.

Figure 1.12: Hydraulic Pressure Hazard

Figure 1.13: Safety around Equipment

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SAFETY

1.6 Safety Signs

• Keep safety signs clean and legible at all times.

• Replace safety signs that are missing or illegible.

• If original part on which a safety sign was installed is

replaced, be sure the repair 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.

Figure 1.14: Operator’s Manual Decal

2. Decide on exact location before you remove decal backing paper.

3. Remove smaller portion of split backing paper.

4. Place decal in position and slowly peel back remaining paper, smoothing decal as it is applied.

5. Prick small air pockets with a pin and smooth out.

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SAFETY

1.7 Safety Sign 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: Decals on Left Side of Header

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Figure 1.17: Right Side of Header

SAFETY

A - MD #184422 B - MD #170638 C - MD #166452

Figure 1.18: Decals on Right Side of Header

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SAFETY

1.8 Understanding Safety Signs

MD #36651

Rotating driveline

DANGER

• Rotating driveline contact can cause death—keep away!

Do NOT operate without:

• Stopping the engine and removing the key before opening
shield.

• All driveline guards, tractor, and equipment shields
in place.

MD #113482

General hazard pertaining to machine operation and
servicing

Figure 1.19: MD #36651

CAUTION

To avoid injury or death from improper or unsafe machine
operation:

• Read the operator’s manual and follow all safety

instructions. If you do not have a manual, obtain one from
your 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 clear of machine before starting engine and during operation.

• Keep riders off the machine.

• Keep all shields in place and stay clear of moving parts.

• Disengage header drive, put transmission in Neutral, and wait for all movement to stop before leaving

operator’s position.

• Stop the engine and remove the key before servicing, adjusting, lubricating, cleaning, or unplugging machine.

• Engage safety props to prevent lowering of header or reel before servicing in the raised position.

• Use slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited

by law.

Figure 1.20: MD #113482

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SAFETY

MD #166452

Hand and arm entanglement hazard

WARNING

• Do NOT open or remove safety shields while the engine
is running.

• To avoid injury, stop the engine and remove the key
before opening shield.

MD #166466

High-pressure oil hazard

WARNING

• Do not go near leaks.

Figure 1.21: MD #166452

• 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.

• Do not use finger or skin to check for leaks.

• Lower load or relieve hydraulic pressure before loosening

fittings.

MD #170638

Reel entanglement hazard

CAUTION

• To avoid injury from entanglement with rotating reel,
stand clear of header while machine is running.

Figure 1.22: MD #166466

Figure 1.23: MD #170638

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SAFETY

MD #171279

Crushing hazard

DANGER

• Read the operator’s manual and follow all safety
instructions.

• Rest header on ground or engage hydraulic lock-out
valves before going under unit.

MD #171281

Hot fluid under pressure

CAUTION

• Coolant is under pressure and may be hot. Never remove
radiator cap when engine is hot.

Figure 1.24: MD #171279

MD #171288

Entanglement hazard

CAUTION

• To avoid injury from entanglement with rotating auger,
stand clear of header while machine is running.

Figure 1.25: MD #171281

Figure 1.26: MD #171288

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SAFETY

MD #174436

High-pressure oil hazard

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.

• Do not use finger or skin to check for leaks.

• Lower load or relieve hydraulic pressure before loosening

fittings.

MD #174632

Reel entanglement hazard

CAUTION

• To avoid injury from entanglement with rotating reel,
stand clear of header while machine is running.

Figure 1.27: MD #174436

Figure 1.28: MD #174632

MD #184372

General hazard pertaining to machine operation and
servicing

CAUTION

To avoid injury or death from improper or unsafe machine
operation:

• Read the operator’s manual and follow all safety
instructions. If you do not have a manual, obtain one from
your Dealer.

• Do not allow untrained persons to operate the machine.

• Review safety instructions with all Operators annually.

Figure 1.29: MD #184372

• 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 and stay clear of moving parts.

214804 13 Revision A

SAFETY

• Disengage header drive, put transmission in Neutral, and wait for all movement to stop before leaving
operator’s position.

• Stop the engine and remove the key from the ignition before servicing, adjusting, lubricating, cleaning, or
unplugging machine.

• Engage safety props to prevent lowering of raised unit before servicing in the raised position.

• Use slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited

by law.

MD #184422

Chain drive hand and arm entanglement hazard

WARNING

• Do not open or remove safety shields while engine is
running.

• To avoid injury, stop the engine and remove the key
before opening shield.

MD #194464

Shut down for service

WARNING

• Stop the engine and remove the key.

• Read the windrower and header manuals for inspection

and maintenance instructions.

Figure 1.30: MD #184422

Figure 1.31: MD #194464

214804 14 Revision A

SAFETY

MD #194521

Auger entanglement hazard

CAUTION

• To avoid injury from entanglement with rotating auger,
stand clear of header/mower while machine is running.

General hazard pertaining to machine operation and
servicing.

CAUTION

• Read the operator’s manual and follow safety
instructions. If you do not have a manual, obtain one from
your 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 clear of machine before starting

engine and during operation.

• Keep riders off the machine.

• Keep all shields in place and stay clear of moving parts.

Figure 1.32: MD #194521

• Disengage header drive, put transmission in Neutral, and
wait for all movement to stop before leaving operator’s position.

• Stop the engine and remove the key from the ignition before servicing, adjusting, lubricating, cleaning, or
unplugging machine.

• Engage locks to prevent lowering of header or reel before servicing in the raised position.

• Use slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited

by law.

214804 15 Revision A

SAFETY

1.9 Owner/Operator Responsibilities

CAUTION

• It is your responsibility to read and understand this manual completely before operating the header.
Contact your Dealer if an instruction is not clear to you.

• Follow all safety messages in the manual and on safety signs on the machine.

• Remember that YOU are the key to safety. Good safety practices protect you and the people

around you.

• Before allowing anyone to operate the header, for however short a time or distance, make sure they
have been instructed in its safe and proper 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 mistakes immediately, before an accident occurs.

• Do not modify the machine. Unauthorized modifications may impair the function and/or safety and
affect machine life.

• Safety information given in this manual does not replace safety codes, insurance needs, or laws
governing your area. Be sure your machine meets the standards set by these regulations.

• Ensure that windrower is properly equipped to safely operate header. This may include adding ballast
according to the tractor operator’s manual requirements for attachments of this size and mass.

214804 16 Revision A

SAFETY

1.10 Operational Safety

CAUTION

• Follow all safety and operational instructions given in your operator's manual. If you do not have a
windrower manual, get one from your Dealer and read it thoroughly.

• Never attempt to start windrower engine or operate the machine, except from the operator’s seat.

• Check the operation of all controls in a safe clear area before starting work.

• Do not allow riders on windrower.

• Never start or move the machine until you are sure all bystanders have cleared the area.

• Avoid travelling over loose fill, rocks, ditches or holes.

• Drive slowly through gates and doorways.

• If cutting ditch banks, use extreme caution. If the header hits an obstruction, 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.

• Never attempt to get on or off a moving windrower.

• Do not get off the windrower while the machine is in operation.

• To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove

key from ignition before adjusting or removing plugged material from the machine.

• Operate only in daylight or good artificial light.

CAUTION

Check for excessive vibration and unusual noises. If there is any indication of trouble, shut down and
inspect machine. Follow proper shutdown procedure as follows:

• Engage windrower brake.

• Disengage PTO.

• Turn engine OFF, and remove key.

• Wait for all movement to stop.

• Dismount and engage cylinder stops before inspecting raised machine.

214804 17 Revision A

2 Product Overview

2.1 Definitions

The following terms and acronyms may be used in this manual:

Term

A Series header MacDon A40D, A40DX, and Grass Seed auger headers

API American Petroleum Institute

ASTM American Society of Testing and Materials

Bolt

Cab-forward Windrower operation with Operator and cab facing in direction of travel

CDM Cab display module on a windrower

Center-link

CGVW Combined gross vehicle weight

DK

DKD

DWA Double Windrow Attachment

ECM

Export header

FFFT

Finger tight

Definition

A headed and externally threaded fastener that is designed to be paired with a nut

A hydraulic cylinder link between header and machine used to change header angle

Double knife

Double-knife drive

Engine control module

Header configuration typical outside North America

Flats from 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
fitting is no longer loose

GSS Grass Seed

GVW Gross vehicle weight

Hard joint

Header A machine that cuts and lays crop into a windrow and is attached to a windrower

Hex key

hp Horsepower

JIC

Knife A cutting device which uses a reciprocating cutter (also called a sickle)

n/a

N-DETENT

214804 19 Revision A

A joint made with use of a fastener where joining materials are highly
incompressible

A tool of hexagonal cross-section used to drive bolts and screws that have a
hexagonal socket in head (internal-wrenching hexagon drive); also known as an
Allen key and various other synonyms

Joint Industrial Council: A standards body that developed standard sizing and shape
for original 37° flared fitting

Not applicable

The slot opposite the NEUTRAL position of M Series SP Windrowers on operator’s
console

PRODUCT OVERVIEW

Term

North American header

NPT

Nut

ORB

ORFS

RoHS (Reduction of
Hazardous Substances)

rpm

Definition

Header configuration typical in North America

National Pipe Thread: A style of fitting used for low-pressure port openings. Threads
on NPT fittings are uniquely tapered for an interference fit

An internally threaded fastener that is designed to be paired with a bolt

O-ring boss: A style of fitting commonly used in port openings on manifolds, pumps,
and motors

O-ring face seal: A style of fitting commonly used for connecting hoses and tubes.
This style of fitting is also commonly called ORS, which stands for O-ring seal

A directive by the European Union to restrict use of certain hazardous substances
(such as hexavalent chromium used in some yellow zinc platings)

Revolutions per minute

SAE Society of Automotive Engineers

Screw

Self-Propelled (SP)
Windrower

A headed and externally threaded fastener that threads into preformed threads or
forms its own thread into a mating part

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
experience relaxation over a period of time

spm

Tension

TFFT

Timed knife drive

Torque

Torque angle

Torque-tension

Washer

WCM

Windrower

WOT

Strokes per minute

Axial load placed on a bolt or screw, usually measured in Newtons (N) or
pounds (lb.)

Turns from finger tight

Synchronized motion applied at cutterbar to two separately driven knives from a
single hydraulic motor

The product of a force X lever arm length, usually measured in Newton-meters (Nm)
or foot-pounds (lbf∙ft)

A tightening procedure where fitting is assembled to a precondition (finger tight) and
then nut is turned farther a number of degrees to achieve its final position

The relationship between assembly torque applied to a piece of hardware and axial
load it induces in bolt or screw

A thin cylinder with a hole or slot located in the center that is to be used as a spacer,
load distribution element, or locking mechanism

Windrower control module

Power unit of a self-propelled header

Wide open throttle

214804 20 Revision A

PRODUCT OVERVIEW

2.2 Product Specifications

NOTE:

Specifications and design are subject to change without notice, or obligation to revise previously sold units.

Table 2.1 A40D, A40DX Self-Propelled Windrower Auger Header Specifications

Cutterbar

Effective cutting width 4.3 m (14 ft.) header 4496 mm (14 ft. 9 in.)

Effective cutting width

Effective cutting width

Double-knife drive: hydraulic motor to two “B” belts/timing belts to enclosed
heavy duty (MD) knife drive boxes

Knife stroke

Knife speed (strokes per minute)

Knife speed (strokes per minute)

Knife speed (strokes per minute)

Knife speed (strokes per minute) Switching pulleys

Double heat-treated forged pointed guards
(GSS headers fitted with stub guards)

Bolted over-serrated knife sections – 9 serrations per inch Standard

Center overlap

Cutterbar lift range (measured at
guard tip)

Cutterbar lift range (measured at
guard tip)

Guard angle (cutterbar on ground) 7 to 17 1/2 degrees

4.9 m (16 ft.) header 4953 mm (16 ft. 3 in.)

5.5 m (18 ft.) header 5410 mm (17 ft. 9 in.)

Standard

76 mm (3 in.)

Factory

Factory Load

Switching pulleys

Below ground

Above ground

No load

No load 1400–1950

Load

1400–1950

1400–1950

1400–1950

Standard

3 mm (1/8 in.)

150 mm

(5 3/4 in.)

900 mm

(35 3/8 in.)

Replaceable, abrasion-resistant cutterbar wear plates

Inner skid shoes, adjustable set of two (can be relocated to outboard location)

Outer skid shoes or gauge rollers

(Required for GSS header)

Outer gauge rollers

Auger

Diameter

Diameter

Undershot, center feed

Flighting

Flighting Thickness

Pitch

214804 21 Revision A

Overall

Tube O.D.

Width

Standard

Standard

Optional

Optional

508 mm (20 in.)

254 mm (10 in.)

Standard

127 mm (5 in.)

6 mm (1/4 in.)

590 mm (23 1/4 in.)

PRODUCT OVERVIEW

Table 2.1 A40D, A40DX Self-Propelled Windrower Auger Header Specifications (continued)

Rubber feed fingers

Stripper bars (three per side)

Auger drive

Auger speed

Hydraulic, 15.9 cu in. (261 cc) per rev
direct mounted motor

SP windrower

Replaceable high density polyethylene auger pans: two-piece design

Rock drop tines at discharge opening with discharge angle adjustment

Delivery opening width

Reel

Oval closed section bats with end caps.
NOTE: Grass Seed Special model has standard seven-bat reel

Steel fingers

Reel radius (to finger tip)

Single piece tine bar with replaceable polyethylene bearings

Sectioned tine bar with regreasable ball bearings

Drive

Hydraulic motor: 14.2 cu in.
(232 cc) /rev to enclosed gearbox

Standard

Standard

Standard

230–320 rpm

Standard

Standard

2430 mm (95 11/16 in.)

6 bats

optional 7 bat

6 mm (1/4 in.) diameter

540 mm (22 in.)

N/A

Standard

Standard

Reel speed

Reel speed

Reel speed

Reel speed

M100/M105/M205 SP hydraulic variable

M150/M155/M155E4/M200 SP hydraulic
variable

M1170/M1240 SP hydraulic variable
(with variable speed kit installed)

M1170/M1240 SP hydraulic variable
(standard reel)

50–85 rpm

15–85 rpm

15–85 rpm

50–85 rpm

Hay Conditioner

Roll-type Intermeshing steel bars

Roll size

Roll size

Roll size

Length

Overall 233 mm (9 3/16 in.)

Tube

Drive: 44 cc. hydraulic piston motor to enclosed gearbox

Roll speed

SP windrower

2590 mm (102 in.)

168 mm (6 5/8 in.)

Standard

601–810 rpm

Plug Prevention / Unplugging

Reverse hydraulic flow to three motors

Self-propelled

(reverses knife, auger, reel, and

Optional

conditioner)

214804 22 Revision A

PRODUCT OVERVIEW

Table 2.1 A40D, A40DX Self-Propelled Windrower Auger Header Specifications (continued)

Swath Forming Shield

Swath width range

915 mm (36 in.) to
2540 mm (100 in.)

Header-mounted adjustable baffle Standard

Attachment Windrower

Adjustable side deflectors Standard

Frame And Structure

Two amber transport lights

Header width

Standard

Nominal cut width plus

480 mm (18 7/8 in.)

Header attachment Windrower

Spare knife storage

Tool and parts storage compartment

Lean bar

N/A

Header Hydraulics Connection

Direct coupled hoses

Hydraulic quick couplers

N/A

Standard

Attachments And Accessories

Header reversing wrench and guard straightening tool

Standard

Double Windrow Attachment (DWA) M150/M155/M200/M205 windrowers
(non GSS headers only)

Optional

214804 23 Revision A

3 Operation

This chapter will describe the operating procedures for the A40D and A40DX SP Windrower Auger Header.

3.1 Attaching A40DX Header to M1 Series Windrowers

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.

This procedure also applies to A Series Headers equipped with the Auger Header Compatibility kit (MD #B5998) or
the A40D SP Grass Seed Auger Conversion kit (MD #B6384). Refer to your windrower operator’s manual for
procedures to mechanically attach an A40DX 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 Series Conversion kit
(MD #B5998) or the A40D SP Grass Seed Auger Conversion kit (MD #B6384) must first be installed. These kits
include a new manifold and hose bundle required for operation with an M1 Series Windrower, and effectively
converts an A40D header into an A40DX header.

Header drive hydraulic hoses and electrical harness are located on the left, cab-forward side of the windrower. To
connect the hydraulic and electrical bundle from an A40DX header to an M1 Series Windrower, follow these steps:

1. Route header hose bundle through hose guide (A) on

header as shown.

Figure 3.1: Hose Bundle

214804 25 Revision A

OPERATION

2. Insert hose support (B) into hole (A) in the windrower
left leg, and route header hose bundle (C) under the
windrower to the hydraulic and electrical couplers.

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 3.2: Hose Support

NOTE:

M1170 Windrowers with standard auger/draper
configuration don’t require the knife drive hose; only the
two multicouplers (A) are used to connect the
auger header.

Figure 3.3: M1170/M1240 – Disc Header
Configured

Figure 3.4: M1170 Standard Configuration –
Auger/Draper Ready

214804 26 Revision A

OPERATION

4. Clean multicouplers and receptacles to prevent
contamination.

5. Push button (A) on rear multicoupler receptacle and pull
handle (B) away from windrower.

6. Open cover (C) and position multicoupler (D) onto
receptacle. Align pins in coupler with slots in handle (B),
and push handle toward windrower so that coupler is
locked onto receptacle and button (A) snaps out.

7. Push button (E) on front multicoupler receptacle and
pull handle (F) away from windrower.

8. Open cover (H) and position multicoupler (G) onto
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.

9. Remove cover from receptacle (A) and connect
electrical harness from header.

Figure 3.5: Multicouplers

Figure 3.6: Windrower Electrical Connector

A40DX GSS headers and A40DX headers equipped with Reel Speed Control kit (MD #B6604)

A40DX GSS headers have a factory-installed reel speed kit and includes a second electrical connection required
for attaching to an M1 Series windrower. The Reel Speed Control kit (MD #B6604) is an available option for an
A40DX header.

Complete the following step when connecting an A40DX GSS header (or an A40DX header with MD #B6604
equipped) to an M1 Series windrower:

214804 27 Revision A

OPERATION

10. Remove cover from receptacle (A) on windrower and
connect electrical harness (B) from header.

Figure 3.7: Electrical Connection

214804 28 Revision A

OPERATION

3.2 Detaching A40DX Header from M1 Series Windrower

Refer to your windrower operator’s manual for procedures to mechanically detach the auger header from the
M1 Series Windrower. To detach an A40DX header’s hydraulics and electrical from an M1 Series Windrower, follow
these steps:

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.

1. Disconnect header electrical harness from
receptacle (A) on windrower multicoupler.

NOTE:

Upper harness connection also needs to be
disconnected if reel speed kit option is connected.

2. Push button (E) on front multicoupler, and pull
handle (F) away from windrower.

3. Remove multicoupler (G) from receptacle and set
aside. Clean multicouplers and receptacles to prevent
contamination. Install caps and plugs on hoses and
fittings (if equipped).

4. Close cover (H) and push handle (F) towards windrower
until button (E) snaps out.

5. Push button (A) on rear multicoupler, and pull
handle (B) away from the windrower.

6. Remove multicoupler (D) from receptacle and set aside.
Clean multicouplers and receptacles to prevent
contamination. Install caps and plugs on hoses and
fittings (if equipped).

7. Close cover (C) and push handle (B) towards
windrower until button (A) snaps out.

Figure 3.8: Windrower Electrical Connector

Figure 3.9: Multicouplers

214804 29 Revision A

OPERATION

8. Remove hose support (B) from hole (A) in windrower
left leg, and remove header hose bundle (C) from the
windrower.

9. Keeping hose bundle (A) in hose guide (B), store hose
bundle on top of header walkway (C), away from the
windrower.

10. Detach header from windrower. For instructions, refer to
your windrower operator’s manual.

Figure 3.10: Hose Support

Figure 3.11: Detached Header
Hydraulics Bundle

214804 30 Revision A

OPERATION

3.3 Attaching A40D Headers to M Series SP Windrowers

Header drive hydraulic hoses and electrical harness are located on the left cab-forward side of the windrower.
Refer to the following procedures for electrical and hydraulic connections:

IMPORTANT:

M150, M155, M155E4, and M200 Windrowers with M Series Reverser kit (MD #B4656) installed need to have the
reverser valve hose plumbing changed if switching between a D Series Draper Header with a conditioner to an
A40D Auger Header. Changing this plumbing prevents improper operation and damaging the reel drive motor.

Refer to 3.3.5 Configuring Reverser Valve Jumper Hose for A40D, page 49 and (if necessary) to M Series Reverser
Kit Installation Instructions (MD #169213), available from our dealer-only site (https://portal.macdon.com) (login
required).

NOTE:

Header reel motor hose routing must be properly configured before attaching the header to a windrower. Hose
routing on the header is factory-configured for M150, M155, M155E4, and M200 Self-Propelled Windrowers.
Header hose routing must be reconfigured if the header is being used on M100, M105, or M205 Self-Propelled
Windrowers and back again.

Refer to the following procedures:

• 3.3.4 Attaching A40D to M205, page 45

• 3.3.6 Routing A40D Hydraulic Drive Hoses, page 50

Refer to your windrower operator’s manual for procedures to mechanically attach the auger header to the self­propelled windrower, and for modifications (if required) to the windrower hydraulic connections.

3.3.1 Attaching A40D to M100 or M105

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.

M100 and M105 Self-Propelled Windrowers are
factory-equipped with four header drive hoses (A) on the
left side.

Figure 3.12: Header Drive Hoses

214804 31 Revision A

OPERATION

1. Disengage rubber latch (A) and open driveline
shield (B).

2. Remove cap (A) from the electrical connector and
remove the connector from the support bracket.

3. Disengage and rotate lever (B) counterclockwise to fully
up position to release the hose bundle (C).

Figure 3.13: Driveline Shield

4. Move hose/electrical bundle (A) to header.

5. Route bundle (A) from windrower through support (B)
and access hole (C) in header frame alongside existing
hose bundle (D) from header.

6. Remove cover on header electrical receptacle (E).

7. Push connector onto receptacle and turn collar on
connector to lock it in place.

8. Attach cover to mating cover on windrower wiring
harness.

9. Remove caps from hydraulic couplers. Clean if
necessary.

Figure 3.14: Support Bracket and Hose Bundle

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)

214804 32 Revision A

OPERATION

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 illustrations
at right.

Figure 3.16: A40D Header – 4.3 m and 4.9 m
(14 ft. and 16 ft.) Header Shown (5.5 m [18 ft.]
Header Similar)

A - Reel Pressure
B - Knife and Conditioner Return
C - Case Drain
D - Knife and Conditioner Pressure

Figure 3.17: A40D Grass Seed Header Hose
Connectors

A - Reel and Auger Pressure
B - Knife and Conditioner Return
C - Case Drain
D - Knife and Conditioner Pressure

214804 33 Revision A

OPERATION

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).

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 3.18: Auger Return and Reel Pressure
Hose Bundle

14. 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.

Figure 3.19: Valve Block Configuration

Figure 3.20: Auger/Reel Pressure and
Auger/Reel Return Hose Couplers – 4.3 m and

4.9 m (14 ft. and 16 ft.) Header Shown (5.5 m
[18 ft.] Header Similar)

214804 34 Revision A

15. Check 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.

OPERATION

Figure 3.21: Auger/Reel Pressure and
Auger/Reel Return Valve Block Receptacles

16. For procedure to change hose routing for M100 or
M105 Windrowers, refer to 3.3.6 Routing A40D

Hydraulic Drive Hoses, page 50.

Figure 3.22: Factory Routing M150, M155,
and M200

A - Reel Motor B - Auger Motor

Figure 3.23: Modified Routing M100, M105,
and M205

214804 35 Revision A

OPERATION

3.3.2 Attaching A40D to M150, M155, or M155E4

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.

M150, M155, and M155E4 self-propelled windrowers are
factory-equipped with four header drive hoses (A) on the
left side.

Figure 3.24: Header Drive Hoses

1. Disengage rubber latch (A) and open driveline
shield (B).

Figure 3.25: Driveline Shield

214804 36 Revision A

OPERATION

2. Remove the cap (A) from electrical connector and
remove connector from support bracket.

3. Disengage and rotate lever (B) counterclockwise to fully
up position to release the hose bundle (C).

4. Move hose/electrical bundle (A) to header.

5. Route bundle (A) from windrower through support (B)
and access hole (C) in header frame alongside existing
hose bundle (D) from header.

6. Remove cover on header electrical receptacle (E).

Figure 3.26: Support Bracket and Hose Bundle

7. Push connector onto receptacle and turn collar on
connector to lock it in place.

8. Attach cover to mating cover on windrower wiring
harness.

9. Remove caps from hydraulic couplers. Clean if
necessary.

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 illustrations
at right.

Figure 3.27: 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)

Figure 3.28: A40D Header – 4.3 m and 4.9 m
(14 ft. and 16 ft.) Header Shown (5.5 m [18 ft.]
Header Similar)

A - Reel Pressure
B - Knife and Conditioner Return
C - Case Drain
D - Knife and Conditioner Pressure

214804 37 Revision A

OPERATION

11. Route auger return and reel pressure hose bundle (A)
from header to windrower and position bundle above
existing hose support (C) as shown.

Figure 3.29: Grass Seed Header Hose
Connectors

A - Reel and Auger Pressure
B - Knife and Conditioner Return
C - Case Drain
D - Knife and Conditioner Pressure

12. Secure with three straps (D), and lower lever (B).

13. If valve blocks are NOT configured as shown at right,
install required fittings as described in the A40D Self­Propelled Windrower Auger Header Unloading and
Assembly Instructions, which were supplied with your
A40D Auger Header.

Figure 3.30: Auger Return and Reel Pressure
Hose Bundle

Figure 3.31: M150/M155/M155E4 with
Reverser Valve

214804 38 Revision A

OPERATION

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 3.32: M150/M155/M155E4 without
Reverser Valve

16. Push auger pressure (A) and auger/reel return (B) hose
couplers onto mating receptacles on valve block until
collar on receptacle snaps into lock position.

Figure 3.33: Auger Pressure and Auger/Reel
Return Hose Couplers – 4.3 m and 4.9 m (14 ft.
and 16 ft.) Header Shown (5.5 m [18 ft.] Header
Similar)

Figure 3.34: M150/M155/M155E4 with
Reverser Valve

214804 39 Revision A

3.3.3 Attaching A40D to M200

CAUTION

OPERATION

Figure 3.35: M150/M155/M155E4 without
Reverser Valve

To prevent accidental movement of windrower, return ground speed lever (GSL) to Park, center steering
wheel to lock, shut off engine, and remove key.

The M200 Windrower requires four drive hoses (A) to run
an A40D Auger Header.

Figure 3.36: Drive Hoses

214804 40 Revision A

OPERATION

If only three drive hoses are present, before following the
procedure below, configure the M200 to run an A40D Auger
Header by installing kit MD #B4651. The kit includes an
additional hose (A), hardware, and installation instructions.

1. Disengage rubber latch (A), and open driveline
shield (B).

Figure 3.37: Auger Header Drive and Draper
Header Reel Drive and Lift Plumbing Kit
(MD #B4651)

2. Remove cap (A) from electrical connector, and remove
connector from support bracket.

3. Disengage and rotate lever (B) counterclockwise to fully
up position to release the hose bundle (C).

Figure 3.38: Driveline Shield

Figure 3.39: Support Bracket and Hose Bundle

214804 41 Revision A

OPERATION

4. Move hose/electrical bundle (A) to header.

5. Route bundle (A) from windrower through support (B)
and access hole (C) in header frame alongside existing
hose bundle (D) from header.

6. Remove cover on header electrical receptacle (E).

7. Push connector onto receptacle, and turn collar on
connector to lock it in place.

8. Attach cover to mating cover on windrower wiring
harness.

9. Remove caps from hydraulic couplers. Clean if
necessary.

10. Push hose connectors onto mating receptacles as
shown until collars on receptacles snap into lock
position.

Figure 3.40: 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)

NOTE:

Hoses attached to connectors not shown in illustrations
at right.

Figure 3.41: A40D Header – 4.3 m and 4.9 m
(14 ft. and 16 ft.) Header Shown (5.5 m [18 ft.]
Header Similar)

A - Reel Pressure
B - Knife and Conditioner Return
C - Case Drain
D - Knife and Conditioner Pressure

214804 42 Revision A

OPERATION

11. Route auger return and reel pressure hose bundle (A)
from header to windrower, and position bundle above
existing hose support (C) as shown.

Figure 3.42: Grass Seed Header Hose
Connectors

A - Reel and Auger Pressure
B - Knife and Conditioner Return
C - Case Drain
D - Knife and Conditioner Pressure

12. Secure with three straps (D), and lower lever (B).

13. If valve blocks are NOT configured as shown at right,
install required fittings as described in the unloading
and assembly instructions supplied with your A40D
Auger Header.

Figure 3.43: Auger Return and Reel Pressure
Hose Bundle

Figure 3.44: M200 with Reverser Valve

214804 43 Revision A

14. Locate the auger pressure (A) and auger/reel
return (B) hoses.

OPERATION

Figure 3.45: M200 without Reverser Valve

15. Push auger pressure (A) and auger/reel return (B) hose
couplers onto mating receptacles on valve block until
collar on receptacle snaps into lock position.

16. If valve blocks are NOT configured as shown above,
install required fittings as described in the unloading
and assembly instructions supplied with your A40D
Auger Header.

Figure 3.46: Auger Pressure and Auger/Reel
Return Hose Couplers – 4.3 m and 4.9 m (14 ft.
and 16 ft.) Header Shown (5.5 m [18 ft.] Header
Similar)

Figure 3.47: M200 with Reverser Valve

214804 44 Revision A

OPERATION

Figure 3.48: M200 without Reverser Valve

17. Proceed to 3.3.5 Configuring Reverser Valve Jumper Hose for A40D, page 49.

3.3.4 Attaching A40D to M205

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.

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 kits shown in the
table below. Instructions are supplied with the kits.

Kit Description MacDon Part Number

Base kit

Reverser kit

Coupler MD #B5497

1

MD #B5491

MD #B5492

Figure 3.49: Auger Drive Basic Kit and
Completion Kit Installed

1. Reverser kit is optional and not required, although most A40D Headers have a Reverser kit (MD #B5492)
ordered for the windrower. Install prior to hook-up if required.

214804 45 Revision A

OPERATION

1. Disengage rubber latch (A), and open driveline
shield (B).

2. Remove cap (A) from the electrical connector, and
remove the connector from the support bracket.

3. Disengage and rotate lever (B) counterclockwise to fully
up position to release the hose bundle (C).

4. Move hose/electrical bundle (C) to header.

Figure 3.50: Driveline Shield

5. Route bundle (A) from windrower through support (B)
and access hole (C) in header frame alongside existing
hose bundle (D) from header.

6. Remove cover on header electrical receptacle (E).

7. Push connector onto receptacle, and turn collar on
connector to lock it in place.

8. Attach cover to mating cover on windrower wiring
harness.

9. Remove caps from hydraulic couplers. Clean if
necessary.

Figure 3.51: Support Bracket and Hose Bundle

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)

214804 46 Revision A

OPERATION

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 illustrations
at right.

Figure 3.53: A40D Header – 4.3 m and 4.9 m
(14 ft. and 16 ft.) Header Shown (5.5 m [18 ft.]
Header Similar)

A - Reel Pressure
B - Knife and Conditioner Return
C - Case Drain
D - Knife and Conditioner Pressure

Figure 3.54: Grass Seed Header Hose
Connectors

A - Reel and Auger Pressure
B - Knife and Conditioner Return
C - Case Drain
D - Knife and Conditioner Pressure

214804 47 Revision A

OPERATION

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).

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.

Figure 3.55: Auger Return and Reel Pressure
Hose Bundle

14. Check 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.

Figure 3.56: Auger/Reel Pressure and
Auger/Reel Return Hose Couplers

Figure 3.57: Factory Routing M150, M155,
M155E4, and M200

A - Reel Motor B - Auger Motor

214804 48 Revision A

OPERATION

15. For procedure to change hose routing for M205
Windrowers, refer to 3.3.6 Routing A40D Hydraulic

Drive Hoses, page 50.

Figure 3.58: Modified Routing M100, M105,
and M205

3.3.5 Configuring Reverser Valve Jumper Hose for A40D

An optional reverser valve block (A) to reverse the header
drive in the event of plugging may have been installed on
M150, M155, and M200 Self-Propelled Windrowers. 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

NOT operate the header unless hose is routed as shown.

NOTE:

ONLY for draper headers with conditioner installed and
ONLY for the M150, M155, and M200 windrowers: CR is

routed to port R4 (not shown) on reverser block. When
switching from draper header to auger header, jumper
hose (B) must be routed according to the header being
operated to prevent draper header reel damage and
improper operation.

To reroute jumper hose from draper header position to
A40D position, follow these steps:

Figure 3.59: A40D Hose (B) Position (A40D on
M200 Shown; M150, M155, and M155E4 Similar)

214804 49 Revision A

OPERATION

1. Move left windrower platform to open position to expose
hydraulic valve blocks.

2. Disconnect jumper hose (B) from 90 degree fitting (C)
at port R4 on the reverser valve block (A).

3. Rotate 90 degree fitting (D) under reverser valve block
so hose can be routed to port C2 at (C) as shown in
Figure 3.61, page 50.

4. Remove cap from port C2 fitting (A) on the header drive
valve block (B).

5. Connect jumper hose (C) to port C2 fitting (A) on
header drive valve block (B).

Figure 3.60: Draper Header Hose Position (M150
Shown; M200, M155, and M155E4 Similar)

6. Install previously removed cap onto 90 degree fitting in
port R4 on reverser valve block (D).

7. Move left windrower platform back to normal operating
position.

NOTE:

The draper header reverser function is suppressed
unless hay conditioner is activated in Windrower Setup
using the cab display module (CDM).

Figure 3.61: Connected Jumper Hose

3.3.6 Routing A40D Hydraulic Drive Hoses

The A40D Auger Header hydraulic drive hose routing depends on the windrower model to which the header is
being attached.

A40D Headers are factory-configured for M150, M155, M155E4, and M200 SP Windrowers as shown in
Figure 3.66, page 52.

To route hoses for M100, M105, and M205 SP Windrowers, proceed as follows:

214804 50 Revision A

OPERATION

1. Press screwdriver against latch in opening (A) and lift to
open header left driveshield. Shield will latch at
location (B) to stay open.

2. Disengage rubber latch (A), and open driveline
shield (B).

Figure 3.62: Left Driveshield

3. Loosen bulkhead nut (A) on auger and reel pressure
coupler (B). This allows auger and reel pressure
hose (C) to rotate freely.

Figure 3.63: Driveline Shield

Figure 3.64: Auger and Reel Pressure Coupler
and Hose – 4.3 m and 4.9 m (14 ft. and 16 ft.)
Header Shown

214804 51 Revision A

Hydraulic hose connections:

4. Disconnect hoses as follows:

a. Disconnect hose (A) from tee (B).

OPERATION

Figure 3.65: Auger and Reel Pressure Coupler
and Hose – 5.5 m (18 ft.) Header Shown

b. Disconnect tee (B) from reel motor upper port.

c. Disconnect hose (C) from reel motor lower port.

5. Cut cable ties (D) at locations shown in illustration.

6. Reconnect hoses as follows:

a. Reroute hose (E) behind hose (A) and (F) to

hose (C) and connect tee (B) to lower port fitting.

b. Reroute hose (C) above hose (E) and (F) and

connect hose (C) to tee (B). Tighten hose (C).

c. Loosen 45 degree fittings at both ports. This allows

room for wrenches when tightening tee (B) to
lower port.

d. Connect hose (A) to upper port fitting as shown

and check orientation of 45 degree fitting.

Figure 3.66: Factory Configuration (M150, M155,
M155E4, and M200)

NOTE:

Ensure that hose (A) is routed in front of hose (C)
and hose (E).

214804 52 Revision A

Figure 3.67: Adjusted Configuration (M100,
M105, and M205)

e. Confirm orientation of upper port 45 degree fitting,

back-off tee (B), and tighten upper port fitting in
position determined. Tighten hose (A).

f. Check orientation of lower port 45 degree fitting

and tighten.

g. Connect tee (B) to lower port 45 degree fitting and

tighten.

Electrical harness routing:

7. Secure electrical harness (B), motor case drain
hose (C), and hose (D) together with cable ties (A),
as shown.

IMPORTANT:

Ensure there is at least 25 mm (1 in.) clearance
between hose bundle (E) and knife drive timing belt (F).

OPERATION

8. Rotate coupler (B) and hose (C) downward as shown
until slack has been sufficiently reduced. Tighten
bulkhead nut (A).

Figure 3.68: Adjusted Configuration (M100,
M105, and M205)

Figure 3.69: Auger and Reel Pressure Coupler
and Hose – 4.3 m and 4.9 m (14 ft. and 16 ft.)
Header Shown

214804 53 Revision A

OPERATION

9. Close driveline shield (B) and engage rubber latch (A).

10. Close driveshield before engaging header.

Figure 3.70: Auger and Reel Pressure Coupler
and Hose – 5.5 m (18 ft.) Header Shown

Figure 3.71: Driveline Shield

214804 54 Revision A

OPERATION

3.4 Detaching A40D Header from M Series Self-Propelled

Windrower

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.

1. Move left cab-forward platform to rear of windrower.

2. Disconnect the two hydraulic hoses (A) and (B) from
windrower valve(s).

Figure 3.72: M100 and M105

Figure 3.73: M150 with Reverser Valve
(M155 and M155E4 Similar)

214804 55 Revision A

OPERATION

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

214804 56 Revision A

OPERATION

3. Raise lever (B) on hose support (C), and undo three
adjustable straps (D).

4. Move hose bundle (A) to store on header walkway.

Figure 3.77: M205

5. Install caps on connectors and hose ends (if equipped).

6. At the header, disconnect electrical connector by
turning collar counterclockwise, and pulling connector
to disengage.

7. Disconnect hoses from hydraulic motor, auger, and reel
pressure hose.

Figure 3.78: Hose Bundle

Figure 3.79: Standard Header

A - Reel/Auger Pressure
B - Knife and Conditioner Return
C - Case Drain
D - Knife and Conditioner Pressure

214804 57 Revision A

OPERATION

8. Move hose bundle (A) from header, and position on
windrower left side with hose ends in support (B) and
under lever (C).

Figure 3.80: Grass Seed Header

A - Knife Return (Male Fitting at Header) (Not Shown in This Image)
B - Auger and Reel Pressure
C - Knife Pressure (Female Fitting at Header)
D - Case Drain

9. Rotate lever (C) clockwise, and push to engage
bracket.

10. Position electrical harness through support (B), and
attach cap to electrical connector.

11. Close driveline shield, and move windrower platform to
closed position.

12. Check to ensure hoses and electrical harness clear tire.

13. Detach header from windrower. For instructions, refer to
your windrower operator’s manual.

Figure 3.81: Hose Bundle Storage

214804 58 Revision A

OPERATION

3.5 Header Lift Cylinder Lock-Out Valves

Refer to your windrower operator’s manual for information about the lift cylinder lock-out valves.

214804 59 Revision A

OPERATION

3.6 Operating Variables

Satisfactory function of the header in all situations requires making proper adjustments to suit various crops and
conditions.

Correct operation reduces crop loss and allows cutting of more acres. As well, proper adjustments and timely
maintenance will increase the length of service you receive from the machine.

The variables listed below and detailed on the following pages will affect the performance of the header. You will
quickly become adept at adjusting the machine to give you the desired results.

Table 3.1 Header Adjustments

Variable

Lean bar position

Auger speed

Reel speed

Auger position

Reel position

Tine aggressiveness adjustment

Cutting height

Header angle 3.6.7 Adjusting Header Angle, page 70

Header float 3.6.9 Checking/Adjusting Float – M Series, page 72

Feed pan / rock drop tine position 3.6.11 Setting Feed Pan and Rock Drop Tine Position, page 75

Roll gap

Roll timing

Roll alignment

Roll tension

Forming shields

Refer to

3.6.1 Setting Lean Bar, page 61

3.6.2 Adjusting Auger Speed, page 61

3.6.3 Adjusting Reel Speed, page 61

3.6.4 Setting Auger Position, page 61

3.6.5 Setting Reel Position, page 64

3.6.6 Setting Tine Aggressiveness, page 69

3.6.8 Setting Cutting Height, page 71

3.6.12 Adjusting Conditioner Roll Gap, page 76

4.13.11 Checking/Adjusting Roll Timing, page 185

4.13.10 Checking/Adjusting Roll Alignment, page 183

3.6.13 Adjusting Conditioner Roll Tension, page 78

3.6.14 Positioning the Forming Shields, page 79

Tall crop dividers

Ground speed 3.10 Selecting Ground Speed, page 93

214804 60 Revision A

3.11.1 Adjusting Tall Crop Dividers, page 94

OPERATION

3.6.1 Setting Lean Bar

Use the lean bar adjustment to accommodate different crop
heights. The lean bar (A) should strike the upper portion of
the crop (roughly 2/3 of the crop height), leaning it away
from the header, and exposing the stalks to the knife.

IMPORTANT:

To prevent structural damage to the header, do NOT operate
with lean bar removed.

To extend or retract lean bar (A), reposition hardware in
adjustment holes as required.

In crops over 1.52 m (5 ft.) high, an optional tall crop divider
kit (MD #B4690) is available that includes lean bar
extensions to raise the lean bar. For more information refer
to 3.11.1 Adjusting Tall Crop Dividers, page 94.

Figure 3.82: Auger Header Lean Bar

3.6.2 Adjusting Auger Speed

An A40 auger header features a hydraulic direct drive auger with operating speed range of 230 to 320 rpm, and is
controlled from the operator’s station on the self-propelled windrower.

For instructions, refer to your windrower operator’s manual.

3.6.3 Adjusting 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 configuration.
Operating speed ranges of 15 to 85 rpm are available for M150, M155, M155E4, as well as M1170 and M1240
models with reel variable speed kit installed.

NOTE:

A40DX GSS headers are factory fitted with reel variable speed option.

For instructions, refer to your windrower operator’s manual.

3.6.4 Setting Auger Position

CAUTION

To avoid personal injury, before servicing header or opening drive covers, follow procedures in .

Auger position has been factory-set, and should not normally require adjustment.

For nearly all conditions, the auger performs best when set as close as possible to the stripper bars without
rubbing. This is especially important in grass and other crops that have a tendency to wrap.

Component wear may cause clearances to become excessive, resulting in feeding problems and uneven
windrows.

To make adjustments to auger position, refer to these sections depending on your equipment:

• Adjusting Auger Fore-Aft Position, page 62

• Adjusting Vertical Position, page 63

214804 61 Revision A

OPERATION

Figure 3.83: Clearance between Auger and
Stripper Bars on the Auger Pan

A - Auger
B - Clearance 1–4 mm (1/32–5/32 in.)

NOTE:

In heavier crops it may be necessary to remove the front stripper bar for smoother crop flow across the auger. Refer
to 4.12 Stripper Bar, page 164.

NOTE:

Auger to stripper bar adjustment is most accurately checked and set with the header in the working position.
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 Position

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.

1. Shut off engine and remove key.

2. Open left endshield.

3. Loosen four nuts (A).

4. Loosen jam nut on adjuster bolt (B), and turn bolt (B) to
adjust auger fore-aft position.

5. Tighten jam nut.

6. Tighten nuts (A).

Figure 3.84: A40D Left Side

214804 62 Revision A

OPERATION

7. Open right endshield.

8. Loosen four nuts (A).

9. Loosen jam nut on adjuster bolt (B), and turn bolt (B) to
adjust auger fore-aft position.

10. Tighten jam nut.

11. Tighten nuts (A).

12. Close shields before engaging header.

Figure 3.85: A40D Right Side

Adjusting Vertical Position

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.

1. Shut off engine and remove key.

2. Open left endshield

3. Loosen four nuts (A).

4. Loosen jam nuts on adjuster bolts (B), and turn bolts (B)
to adjust auger vertical position.

5. Tighten jam nuts.

6. Tighten nuts (A).

7. Open right endshield.

8. Loosen four nuts (A).

9. Loosen jam nut on adjuster bolts (B), and turn bolts (B)
to adjust auger fore-aft position.

10. Tighten jam nut.

11. Tighten nuts (A).

Figure 3.86: A40D Left Side

12. Close shields before engaging header.

Figure 3.87: A40D Right Side

214804 63 Revision A

OPERATION

3.6.5 Setting Reel Position

Reel position has been found to be a critical factor in achieving good results in adverse conditions. Reel position is
factory-set for average straight standing crop. It can be adjusted both vertically and horizontally (fore-aft) for
different crop conditions.

See table below for recommended reel position in unusual crop conditions:

Crop Condition

Crop down or lodged Forward and down (also increase reel speed)

Wet or dead material collects on cutterbar and plugs knife Back and down (close to guards)

Short crop

Thick stemmed or heavy standing

To make adjustments to reel position, refer to the following sections:

• Adjusting Reel Fore-Aft Position, page 64

• Adjusting Reel Vertical Position, page 66

Reel Position

Back

Up and forward

Adjusting Reel Fore-Aft Position

The reel fore-aft offset is factory-set to 816 mm (32 3/8 in.)
as measured from the inside edge of the reel tube to the
back frame member as shown in the illustration at right.

NOTE:

The reel must be adjusted equally on both sides.

Figure 3.88: Measuring Reel Fore-Aft Offset

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.

214804 64 Revision A

OPERATION

1. Shut off engine and remove key.

2. Open left endshield.

3. Loosen four nuts (A).

4. Loosen jam nut on adjuster bolt (B), and turn bolt (B) to
adjust reel fore-aft position.

5. Tighten jam nut.

6. Tighten nuts (A).

7. Open right endshield.

8. Loosen four nuts (A).

9. Loosen jam nut on adjuster bolt (B), and turn bolt (B) to
adjust reel fore-aft position.

Figure 3.89: Auger Header Left Side

10. Tighten jam nut.

11. Tighten nuts (A).

12. Close driveshields before engaging header.

Figure 3.90: Auger Header Right Side

214804 65 Revision A

OPERATION

Adjusting Reel Vertical Position

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.

1. Shut off engine and remove key.

2. Open left endshield.

3. Loosen four nuts (A).

Figure 3.91: Auger Header Left Side

4. Loosen jam nuts on adjuster bolts (A), and turn bolts (A)
to raise or lower reel.

5. Tighten jam nuts (A).

Figure 3.92: Auger Header Left Side

214804 66 Revision A

6. Tighten nuts (A).

7. Open right endshield.

8. Loosen four nuts (A).

OPERATION

Figure 3.93: Auger Header Left Side

9. Loosen jam 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
aggressiveness has changed, then the adjuster bolt
offset may not equal factory settings. Always measure
the adjuster bolt offset and maintain throughout the
vertical adjustment.

10. Tighten jam nut.

Figure 3.94: Auger Header Right Side

Figure 3.95: Auger Header Left Side

214804 67 Revision A

11. Tighten nuts (A).

12. Close shields before engaging header.

13. Check 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 tine length varies considerably. Remove any sharp
edges or burrs from tine.

14. Check that reel is evenly adjusted.

OPERATION

Figure 3.96: Auger Header Right Side

214804 68 Revision A

OPERATION

Checking Reel Tine to Header Pan Clearance

IMPORTANT:

The dimensions at right are provided as guidelines only. Tines may slightly contact the guards, but NOT the knife
sections or the auger pan.

1. Rotate reel slowly by hand, and check tine clearance at
knife and pan. Flex tines to simulate crop-loaded
position to ensure tine clearances 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 correct height, trim the longer
tines to match the rest. Be sure to adjust both sides of
the reel.

Ensure that tines do NOT contact plastic header pan.

Figure 3.97: Reel Tine Clearance

A-2–10 mm (2/25–2/5 in.)
B - 2 mm (2/25 in.) Minimum to Knife Section
C - Flex Fingers Back when Checking Clearance

3.6.6 Setting Tine Aggressiveness

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.

1. Shut off engine and remove key.

2. Open right endshield.

3. At right side of reel (cam end) ONLY, loosen four
nuts (A).

Figure 3.98: Auger Header Right Side

214804 69 Revision A

OPERATION

4. Loosen jam nuts on bolts (A), and turn bolts to rotate
cam to desired position. Viewed from right side, rotate
cam clockwise to obtain more aggressive tine action.

NOTE:

The factory setting at forward adjuster bolt should be
12 mm (0.47 in.) lower than at rear adjuster bolt. If tine
aggressiveness has changed, then the adjuster bolt
offset may not equal factory settings. Always measure
the adjuster bolt offset and maintain throughout the
vertical adjustment.

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 pan clearance to ensure that
there is no contact between reel tines and the header
pan. Refer to Checking Reel Tine to Header Pan

Clearance, page 69.

Figure 3.99: Auger Header Right Side

3.6.7 Adjusting Header Angle

Header angle can be hydraulically adjusted from the cab
using hydraulic cylinder (A), without shutting down the
windrower.

NOTE:

Some M100, M105, M150, and M155 models are equipped
with a mechanical link. For instructions on adjusting header
angle, refer to your windrower operator’s manual.

Figure 3.100: Auger Header Right Side

Figure 3.101: Header Angle Hydraulic Cylinder

214804 70 Revision A

OPERATION

3.6.8 Setting Cutting Height

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.

1. Raise header, and engage header lift cylinder lock-out
valves.

2. Remove pins (A) at each skid shoe or gauge roller.

3. Raise or lower skid shoe or gauge roller to desired
position.

4. Replace pins (A).

Figure 3.102: Skid Shoe

Figure 3.103: Gauge Roller

5. Check that skid shoes or gauge rollers are adjusted to the same position.

6. Check header float, and adjust if required. Refer to 3.6.9 Checking/Adjusting Float – M Series, page 72 for
more information.

NOTE:

The two inboard skid shoes are standard equipment. The inboard shoes can be moved to the outboard position
OR outboard positions can be fitted with either gauge rollers or skid shoes.

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OPERATION

3.6.9 Checking/Adjusting Float – M Series

The windrower float springs are NOT used to level the header.

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.

IMPORTANT:

Always check the float with the header set in working position (with the header fully lowered to the ground and the
header angle set to the desired cutting height per crop type and conditions).

To check/adjust the float, follow these steps:

1. Start the engine, and lower the header to the ground.

2. Using the header tilt switches on the in-cab controls, set the header center-link to the mid-range position
(5.0 on the cab display module). Refer to your windrower operator’s manual for detailed instructions.

3. Lower 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 detailed instructions.

5. Shut down the engine and remove the key.

6. Check float by grasping the lean bar and lifting. Lifting force should be 335–380 N (75–85 lbf) and should be
approximately the same at both ends.

7. If necessary, perform the following steps to adjust
the float:

a. Raise header fully, shut down engine, and

remove key.

b. Turn drawbolt (A) clockwise to increase float

(makes header lighter) or counterclockwise to
decrease float (makes header heavier).

NOTE:

Illustration shows top of windrower wheel leg
member.

c. Recheck the float.

Figure 3.104: Drawbolt

3.6.10 Checking/Adjusting Float – M1 Series

Header float on M1170 and M1240 Windrowers is completely adjustable from the cab through the Harvest
Performance Tracker (HPT).

The windrower float springs are NOT used to level the header.

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OPERATION

Checking Float – M1 Series Windrower

WARNING

To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and
remove the key from the ignition before leaving the operator’s seat for any reason.

CAUTION

Before starting the machine, check to be sure all bystanders have cleared the area.

1. Start the engine.

2. Use the HEADER TILT switches (A) on the ground
speed lever (GSL) to set the center-link to the
mid-range position (5.0 on the Harvest Performance
Tracker [HPT]).

3. Using the HEADER DOWN switch (B), lower header
fully with lift cylinders fully retracted.

4. Turn engine off, and remove the ignition 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.

Figure 3.105: GSL

6. Restart the engine, and adjust float as required. Refer to Setting the Float , page 73.

NOTE:

Increasing the float value on the HPT makes the header feel lighter.

Setting the Float

The float can be set for windrowing with the cutterbar on the ground.

The optimum float setting lets the header follow the contour of the terrain. Proceed as follows:

1. Set center-link to mid-range position (5.0 on the Harvest
Performance Tracker [HPT]). Refer to the windrower
operator’s manual.

2. Lower the header until the cutterbar is on the ground.

NOTE:

To minimize scooping rocks when operating at the
flattest header angle, lower the header skid shoes.
Refer to your header operator’s manual.

Figure 3.106: Header Float – Cutterbar
on Ground

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OPERATION

3. Press rotary scroll knob (A) on the HPT to display the
QuickMenu system.

4. Rotate scroll knob (A) to highlight header float icon (B)
and press scroll knob to select.

5. Turn scroll knob (A) to highlight left (B) or right (C) float
and press knob (A) to activate selection.

6. Rotate scroll knob (A) to adjust float setting and press
knob when finished. Float is 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.

Figure 3.107: HPT Run Screen

7. Use soft key 3 (D) to remove/resume float and deck
position to previous setting for the attached header.

Figure 3.108: HPT Left/Right Float Settings

Removing and Restoring Float

Follow these steps to remove and restore the header float settings:

1. Press rotary scroll knob (A) on Harvest Performance
Tracker (HPT) to display the QuickMenu system or
press F1 on the console.

2. Rotate scroll knob (A) to highlight header float icon (B)
and press scroll knob to select.

Figure 3.109: HPT Run Screen

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OPERATION

3. Press soft key 3 (A) to remove or restore the
header float.

NOTE:

If the header float is active, the icon at soft key 3 will say
REMOVE FLOAT; if header float has been removed, the
icon will say RESTORE FLOAT.

Figure 3.110: HPT Display – Adjusting Float

3.6.11 Setting Feed Pan and Rock Drop Tine Position

The rear of the feed pan is adjustable up and down to raise or lower the feed pan 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 raised machine, always lock-out lift cylinders before going
under header for any reason.

1. Raise header fully, and engage safety props.

2. Stop engine and remove key.

3. Loosen nut (A) both sides, and align pointer (B) at each
side of rock drop tine support with one of the slots (C) to
match crop condition.

Figure 3.111: Rock Drop Tine Support

Crop Condition

Slot

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Light Normal Heavy

Upper

Center

Lower

OPERATION

4. Tighten hardware on both sides.

5. Disengage safety props.

3.6.12 Adjusting Conditioner Roll Gap

The roll gap determines the amount of conditioning:

• To reduce conditioning, increase roll gap.

• To increase conditioning, decrease roll gap.

The conditioner roll gap is factory-set at 6 mm (1/4 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.

1. Loosen and back-off upper jam nut (A), on both sides of
conditioner.

2. To increase roll gap, turn lower nut (B) clockwise to
raise link, and increase the gauge (C) setting.

3. To decrease roll gap, turn lower nut (B)
counterclockwise to lower link, and decrease the
gauge (C) setting.

4. Tighten jam nuts (A), both sides.

Figure 3.112: Roll Gap Adjustment Gauge

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OPERATION

5. Loosen bolt (A), and rotate cover (B) to expose access
port (C).

6. Inspect space between roll bars at both ends of the rolls
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 when reducing roll gap.
Refer to:

• 4.13.11 Checking/Adjusting Roll Timing, page 185

• 4.13.10 Checking/Adjusting Roll Alignment, page

183

8. Close cover (B), and tighten bolt (A).

Figure 3.113: Conditioner Roll Access Port

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OPERATION

3.6.13 Adjusting Conditioner Roll Tension

The roll tension (the force holding the rolls together) is factory-set, and is adjustable. There is a spring 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 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.

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OPERATION

1. Lower header fully.

2. Stop engine, and remove key.

3. To increase the roll tension, loosen jam nut (B) at
spring insert, and turn spring drawbolt (C) clockwise to
tighten the spring. Tighten jam nut (B).

4. To decrease the roll tension, loosen jam nut (B) at
spring insert, and turn spring drawbolt (C)
counterclockwise to loosen the spring. Tighten jam
nut (B).

Figure 3.115: Roll Tension Spring

3.6.14 Positioning the Forming Shields

WARNING

Keep hands and feet away from discharge opening. Keep everyone several hundred feet away from your
operation. Never direct the discharge toward anyone. Stones or other foreign objects can be ejected
with force.

The position of the forming shields controls the width and placement of the windrow. The decision on forming shield
position (settings between 915–2346 mm [36–92 in.]) should 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 generally dry faster and more evenly, resulting in less protein loss. Fast drying is especially
important in areas where the weather allows only a few days to cut and bale. Refer to 3.12 Haying, page 97 for
more information.

Where weather conditions permit or when drying is not critical, for example, when cutting for silage or green feed, a
narrower windrow may be preferred for ease of pick up.

Positioning Side Deflectors

The position of the side forming shields controls the width and placement of the windrow.

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.

To ensure windrow placement is centered with respect to carrier/drive wheels, adjust both side deflectors to the
same hole position on the adjuster bar.

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OPERATION

1. Set forming shield side deflectors to desired width by
repositioning adjuster bars as follows:

a. Remove lynch pin (A).

b. Move adjuster bar (B) to another hole.

c. Reinstall lynch pin (A).

2. If forming shield attachment is too tight or too loose,
tighten or loosen nut (A) as required.

Figure 3.116: Forming Shield Side Deflector

Figure 3.117: Forming Shield Adjustment Nut

Positioning Rear Deflector (Fluffer Shield)

The rear deflector (A) slows the crop exiting the conditioner rolls, directs the flow downward, and fluffs the material.

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.

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OPERATION

1. Shut off engine and remove key.

2. For more crop control in light material, lower the
deflector (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 deflector (A) by pulling up
on one side, and then on the other side.

NOTE:

For even windrow formation, be sure the deflector is

NOT twisted.

Figure 3.118: Rear Deflector

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OPERATION

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.

214804 82 Revision A

Roll Gap

mm (in.)

16 (5/8)

16 (5/8)

13 (1/2)

13 (1/2)

10 (3/8)

10 (3/8)

Refer to

above

Refer to

above

10 (3/8)

10 (3/8)

6 (1/4)

6 (1/4)

Refer to

above

Refer to

above

19 (3/4)

Feed Pan

Float

Auger

Reel

Speed

Knife

Speed

Position

Speed

High Normal Lower slot

(rpm)

(spm)

1600–1800 73–77 High Light Lower slot

slot

Center

Normal Normal

1600–1800 70–75

slot

Center

1600–1800 70–75 Normal Light

Upper slot

Heavy

Normal/

1600–1800 65–70 Low

1600–1800 65–70 Low Light Upper slot

1800 73–77 High Heavy Variable

1600–

Variable

Light/

Normal

1600–1800 73–77 High

Normal Lower slot

High

Normal/

1850–1950 70–75

Light Lower slot

High

Normal/

1850–1950 70–75

slot

Center

1850–1950 65–70 Low Normal

slot

Center

1850–1950 65–70 Low Light

Heavy Variable

High

Normal/

1850–1950 70–75

Variable

Light/

Normal

High

Normal/

1850–1950 70–75

1700–1850 70–75 High Normal Lower slot

Field Conditions Operating Variables

Table 3.3 Recommended Operating Settings

Angle

Header

Height

Stubble

Terrain

Crop

(tons per

Condition

Crop Type

mm (in.)

acre)

Alfalfa >3 Smooth 0 Steep 1600–1800 73–77

Steep

Shallow

0

Smooth

>3 Rocky 0

2–3

Alfalfa

Alfalfa

Shallow

2–3 Rocky 0

Alfalfa

Steep

Shallow

0

Smooth

<2

<2 Rocky 0

Alfalfa

Alfalfa

Steep

0

Smooth

Lodged

Alfalfa

Shallow

64–76

Lodged Rocky 0

Alfalfa

Steep

64–76

(2.5–3)

Smooth

Timothy >2.5

Shallow

64–76

(2.5–3)

Timothy >2.5 Rocky

Steep

64–76

(2.5–3)

Smooth

Timothy <2.5

Shallow

64–76

(2.5–3)

Timothy <2.5 Rocky

Steep

64–76

(2.5–3)

Smooth

Timothy Lodged

Shallow

152

(2.5–3)

Timothy Lodged Rocky

Sudan/Tall

Steep

(6)

Smooth

>3

Crop

214804 83 Revision A

OPERATION

Roll Gap

Feed Pan

Float

Auger

Reel

Speed

Knife

Speed

mm (in.)

Position

Speed

(rpm)

(spm)

19 (3/4)

1700–1850 70–75 High Light Lower slot

16 (5/8)

slot

Center

1700–1850 65–70 Low Normal

16 (5/8)

slot

Center

1700–1850 65–70 Low Light

above

Refer to

Heavy Variable

High

Normal/

above

Refer to

Variable

Light/

Normal

High

Normal/

1700–1850 70–75

25 (1)

1600–1800 70–75 High Normal Lower slot

25 (1)

1600–1800 70–75 High Light Lower slot

25 (1)

slot

Center

Heavy

Normal/

High

Normal/

1600–1800 60–65

25 (1)

slot

Center

Light

High

Normal/

above

Refer to

Heavy Variable

High

Normal/

above

Refer to

Variable

Light/

Normal

High

Normal/

1600–1800 70–75

Stubble

Crop

Field Conditions Operating Variables

Table 3.3 Recommended Operating Settings (continued)

Angle

Header

Height

mm (in.)

Terrain

acre)

(tons per

Condition

Crop Type

Shallow

(6)

152

>3 Rocky

Crop

Sudan/Tall

Steep

(6)

152

Smooth

<3

Crop

Sudan/Tall

Shallow

(6)

152

<3 Rocky

Crop

Sudan/Tall

Steep 1700–1850 70–75

(6)

152

Smooth

Lodged

Crop

Sudan/Tall

Shallow

(6)

152

Lodged Rocky

Crop

Sudan/Tall

Steep

0

Smooth

>10

(winter

Triticale

forage)

Triticale

Shallow

>10 Rocky 0

(winter

forage)

Steep

0

Smooth

<10

(winter

Triticale

forage)

Triticale

<10 Rocky 0 Medium 1600–1800 60–65

(winter

forage)

Smooth 0 Steep 1600–1800 70–75

Lodged

(winter

Triticale

forage)

Triticale

Medium

0

Lodged Rocky

(winter

forage)

214804 84 Revision A

OPERATION

Roll Gap

Feed Pan

Float

Auger

Reel

Speed

Knife

Speed

mm (in.)

Position

Speed

(rpm)

(spm)

10 (3/8)

1850–1950 73–77 High Normal Lower slot

10 (3/8)

High Light Lower slot

6 (1/4)

slot

Center

1850–1950 70–75 Normal Normal

6 (1/4)

slot

Center

1850–1950 70–75 Normal Light

6 (1/4)

Upper slot

Heavy

Normal/

Low/

Normal

1850–1950 65–70

6 (1/4)

Upper slot

Light/

Normal

Low/

Normal

–70

above

Refer to

Heavy Variable

High

Normal/

1850–1950 73–77

above

Refer to

Variable

Light/

Normal

High

Normal/

Stubble

Crop

Field Conditions Operating Variables

Table 3.3 Recommended Operating Settings (continued)

Angle

Header

Height

mm (in.)

Terrain

acre)

(tons per

Condition

Crop Type

Steep

0

Smooth

>3.5

Wild/

Grass Hay

0 Shallow 1850–1950 73–77

Rocky

>3.5

Wild/

Grass Hay

Steep

0

Smooth

2–3

Wild/

Grass Hay

Shallow

2–3 Rocky 0

Wild/

Grass Hay

Steep

0

Smooth

<2

Wild/

Grass Hay

<2 Rocky 0 Medium 1850–1950 65

Wild/

Grass Hay

Steep

0

Smooth

Lodged

Wild/

Grass Hay

Lodged Rocky 0 Medium 1850–1950 73–77

Wild/

Grass Hay

214804 85 Revision A

OPERATION

3.8 Unplugging Conditioner and Knife

M1 Series windrowers are equipped with a header drive reversing function as standard equipment. M Series
windrowers (including M150, M155, M155E4, and M200) can be equipped with the Header Drive Reverser kit
(MD #B4656). This kit is not available for M100 or M105 windrowers.

On windrowers with this equipment installed, reverse the hydraulic flow to the knife, auger, reel, and conditioner
hydraulic motors to help remove any plugged material from the header.

If reverser is not installed, proceed through the following instructions.

CAUTION

To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key
from ignition before leaving operator’s seat for any reason.

1. Stop forward movement of windrower, and shut down header.

2. Lift cutterbar about 300 mm (12 in.).

3. Back up about 1 m (3 ft.) while slowly engaging the header.

4. If plug does not clear, raise machine, apply windrower brake, shut off engine, and remove key.

5. Engage header lift cylinder lock-out valves.

WARNING

Exercise caution when working around the cutterbar. Blades are sharp and can cause serious injury. Wear
heavy gloves when working around or handling knife.

6. Clean off cutterbar and area under reel by hand.

7. Retrieve wrench (A) from storage inside the left drive
compartment.

Figure 3.119: Wrench Location – A40D

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