A40-D and A40-DX Self-Propelled Windrower Auger Header

Transcription

1 40-D and 40-DX Self-Propelled Windrower uger Header Unloading and ssembly Instructions Revision 2018 Model Year Original Instruction The harvesting specialists.

2 40-D Self-Propelled Windrower uger Header Published 19 May 2017

3 Introduction This instructional manual describes the unloading, setup, and predelivery requirements for the MacDon 40-D and 40-DX Self-Propelled Windrower uger Headers, including a Grass Seed version for both models. Use the Table of ontents to guide you to specific topics. Follow the procedures provided in this manual in the order given. REFULLY RED THE INFORMTION PROVIDED IN THIS MNUL EFORE TTEMPTING TO UNLOD, SSEMLE, OR USE THE MHINE. 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 ( (login required) i Revision

4 List of Revisions The following list provides an account of major changes from the previous version of this document. Summary of hange dded reference to 40-DX Headers. dded reference to M1 Series onversion kit (MD #5998) Location Introduction, page i 5.13 hecking Knife Speed, page ttaching 40-D Headers to M Series SP Windrowers, page ttaching 40-DX Header to M1 Series SP Windrower, page Hydraulic Drive Hose Routing (Later-uild 2015, 2016 and Later 40-D), page Hydraulic Drive Hose Routing (M1 Series Windrowers), page 73 dded 40-DX attachment procedure. dded hose routing for M1 Series Windrowers ttaching 40-DX Header to M1 Series SP Windrower, page Hydraulic Drive Hose Routing (M1 Series Windrowers), page 73 dded M1 Series float check/adjustment procedure. 5.5 hecking/djusting Float M1 Series, page 87 dded M1 Series header leveling procedure. 5.7 Leveling the Header M1 Series, page 92 dded Recommended Fluids and Lubricants. Inside back cover ii Revision

5 TLE OF ONTENTS Introduction...i List of Revisions... ii hapter 1: Safety Signal Words General Safety Safety Signs...4 hapter 2: Unloading the Machine Unloading the Header Unloading the Header from a Truck Flatbed...5 hapter 3: ssembling the Machine Removing Underside Shipping Stand Installing Skid Shoes Installing Gauge Rollers Lowering the Header Removing Shipping Stands Installing Tall rop Divider Kit djusting Lean ar djusting Pan Extensions: Grass Seed Special djusting Transport Lights ssembling Forming Shield Installing Forming Shield ttaching 40-D Headers to M Series SP Windrowers ttaching 40-D to M100 or M ttaching 40-D to M150, M155, or M155E ttaching 40-D to M ttaching to 40-D to M ttaching 40-DX Header to M1 Series SP Windrower Modifying Hydraulics Modifying Hydraulics M100, M Modifying Hydraulics M150, M155, M155E Modifying Hydraulics M200 with Reverser Valve Modifying Hydraulics M200 without Reverser Valve Modifying Hydraulics M Routing Reverser Valve Jumper Hose M Series ttaching Hydraulics M Series Hydraulic Drive Hose Routing (Later-uild 2015, 2016 and Later 40-D) Hydraulic Drive Hose Routing (Early-uild 2015, 2014 and Earlier 40-D) Hydraulic Drive Hose Routing (M1 Series Windrowers) iii Revision

6 TLE OF ONTENTS 3.20 Repositioning Knife Drive ox reather...75 hapter 4: Lubricating the Machine Greasing Procedure Lubrication Points: Left Side of Header Lubrication Points: Right Side of Header Lubrication Points: Hay onditioner Lubrication Points: Drivelines Knife and Gearbox Oil...82 hapter 5: Performing Predelivery hecks hecking Drive elts and hains hecking uger Stripper ar learance hecking Reel Tine to Header Pan learance hecking/djusting Float M Series hecking/djusting Float M1 Series hecking Float Setting the Float Removing and Restoring Float Leveling the Header M Series Leveling the Header M1 Series hecking onditioner Rolls hecking onditioner Gearbox Oil Level hecking Skid Shoes / Gauge Rollers hecking Lights Running Up Header hecking Knife Speed Setting Knife Speed on an M100 or M Setting Knife Speed (with Expansion Module MD #4666) Setting Knife Speed (without Expansion Module MD #4666) djusting Knife and Guards hecking Manuals hapter 6: Reference Recommended Torques Torque Specifications SE olt Torque Specifications Metric olt Specifications Metric olt Specifications olting into ast luminum Flare-Type Hydraulic Fittings O-Ring oss (OR) Hydraulic Fittings (djustable) O-Ring oss (OR) Hydraulic Fittings (Non-djustable) O-Ring Face Seal (ORFS) Hydraulic Fittings iv Revision

7 TLE OF ONTENTS Tapered Pipe Thread Fittings onversion hart Definitions Predelivery hecklist Recommended Fluids and Lubricants... Inside ack over v Revision

8

9 1 Safety 1.1 Signal Words Three signal words, DNGER, WRNING, and UTION, are used to alert you to hazardous situations. The appropriate signal word for each situation has been selected using the following guidelines: DNGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. WRNING 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. UTION 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 Revision

10 SFETY 1.2 General Safety UTION 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 e aware that exposure to loud noises can cause hearing impairment or loss. Wear suitable hearing protection devices such as ear muffs or ear plugs to help protect against loud noises. Figure 1.1: Safety Equipment Provide a first aid kit for use in case of emergencies. Keep a fire extinguisher on the machine. e sure fire extinguisher is properly maintained. e familiar with its proper use. Keep young children away from machinery at all times. e 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 1.2: Safety Equipment Figure 1.3: Safety Equipment Revision

11 SFETY 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 Figure 1.4: Safety around Equipment Keep hands, feet, clothing, and hair away from moving parts. NEVER attempt to clear obstructions or objects from a machine while engine is running. Do NOT modify machine. Unauthorized modifications may impair machine function and/or safety. It may also shorten machine s life. To avoid bodily injury or death from unexpected startup of machine, LWYS stop the engine and remove the key from the ignition before leaving the operator s seat for any reason Figure 1.5: Safety around Equipment Keep service area clean and dry. Wet or oily floors are slippery. Wet spots can be dangerous when working with electrical equipment. e 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. lean 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 Revision

12 SFETY 1.3 Safety Signs Keep safety signs clean and legible at all times. Replace safety signs that are missing or become illegible. If original parts on which a safety sign was installed are replaced, be sure repair part also bears current safety sign. Safety signs are available from your MacDon Dealer Figure 1.7: Operator s Manual Decal Revision

13 2 Unloading the Machine Follow each procedure in this chapter in order. 2.1 Unloading the Header UTION To avoid injury to bystanders from being struck by machinery, do NOT allow anyone to stand in unloading area. UTION Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment may result in chain breakage, vehicle tipping, or machine damage. Table 2.1 Lifting Vehicle Minimum apacity 1 Minimum Fork Length 3630 kg (8000 lb) 1981 mm (78 in.) IMPORTNT: Forklifts are normally rated for a load located 610 mm (24 in.) ahead of back end of the forks. To obtain the forklift capacity at 1220 mm (48 in.), check with your forklift distributor. WRNING e sure forks are secure before moving away from load. Stand clear when lifting Unloading the Header from a Truck Flatbed IMPORTNT: Do NOT unload using lean bar for lifting. hain hook slots in lean bar are only for laying the machine over into working position after it is on the ground. NOTE: Take care not to bend parts on backtube. To unload the header, follow these steps: 1. t 1220 mm (48 in.) from back end of forks Revision

14 UNLODING THE MHINE 1. Remove hauler s tie-down straps and chains. 2. pproach header from either its underside or topside and slide forks () in underneath lifting framework as far as possible. NOTE: When possible, approach from the underside to minimize potential for scratching the unit. 3. Raise header off deck. IMPORTNT: If load is two wide, take care not to contact the other machine. Figure 2.1: Forks in Position ack up until unit clears trailer and slowly lower to 150 mm (6 in.) from ground. 5. Take to storage or setup area. 6. Set header down securely on level ground. 7. Repeat for other header if required. 8. heck for shipping damage and missing parts Figure 2.2: Topside of Header in Shipping onfiguration Figure 2.3: Underside of Header in Shipping onfiguration Revision

15 3 ssembling the Machine Once all unloading procedures have been completed, it is time to set up the machine. Follow each procedure in this chapter in order. 3.1 Removing Underside Shipping Stand UTION Keep feet clear when removing final bolts. 1. Remove four bolts () and remove shipping stand (). Discard stand and hardware Figure 3.1: Underside Shipping Stand Revision

16 SSEMLING THE MHINE 3.2 Installing Skid Shoes If kit is NOT supplied, proceed to 3.3 Installing Gauge Rollers, page 9. Otherwise, proceed as follows: NOTE: This kit may be installed later in the header assembly sequence, but it may be easier prior to laying the header down. 1. Unpack skid shoe bundle. 2. Remove two clevis pins () from each skid shoe. 3. Remove nuts, bolts, and clips () from skid shoe Figure 3.2: Skid Shoe undle 4. Position skid shoe below cutterbar and insert tabs on skid shoe into slots () in frame. Secure with clevis pin () Figure 3.3: Skid Shoe Hardware 5. ttach clips () with bolts and nuts removed earlier in this procedure to secure skid shoe to cutterbar. NOTE: Use a socket and ratchet wrench to access the nuts. 6. Tighten nuts. 7. Remove clevis pin () and adjust skid shoe to desired height. Reinstall two clevis pins () and secure with lynch pins. 8. Repeat previous steps for opposite side. Set both skid shoes to the same position Figure 3.4: Skid Shoe Installed Revision

17 SSEMLING THE MHINE 3.3 Installing Gauge Rollers If kit is NOT supplied, proceed to 3.4 Lowering the Header, page 11. Otherwise, proceed as follows. NOTE: This kit may be installed later in the header assembly sequence, but it may be easier prior to laying the header down. 1. Unpack gauge roller bundle. 2. Remove two locking pins () from each assembly. 3. Remove nuts, bolts, and clips () from assembly Figure 3.5: Gauge Roller in Shipping onfiguration 4. Insert tabs on roller assembly into slots () on cutterbar at outboard mounting locations on frame Figure 3.6: Gauge Roller Mounting Location Revision

18 SSEMLING THE MHINE 5. Secure to support bracket with locking pin () at lowest position. 6. ttach clips () with bolts and nuts removed earlier in this procedure to secure roller assembly to cutterbar. 7. Tighten nuts. NOTE: Use a socket and ratchet wrench to access the nuts Remove locking pin () and adjust rollers to desired height. Reinstall both locking pins (). 9. Ensure that nut () on each pin registers in adjacent hole in support bracket. 10. Secure pins with hairpins (). 11. Repeat previous steps for opposite side. Set both gauge rollers to the same position. Figure 3.7: Gauge Roller Figure 3.8: Gauge Roller and Locking Pin Revision

19 SSEMLING THE MHINE 3.4 Lowering the Header To lower the header to the ground, follow these steps: 1. ttach either a spreader bar or chain to forks. UTION Ensure spreader bar or chain is secured to the forks so that it cannot slide off the forks or towards the mast as the header is lowered to the ground. 2. Drive lifting vehicle to approach header from its underside. 3. ttach chain hooks to lean bar at slots as shown. IMPORTNT: See table below for minimum chain specifications. lso, chain length must be sufficient to provide a minimum 1.2 m (4 ft.) vertical chain height Figure 3.9: Header with Forklift Table 3.1 hain Specifications hain Type Minimum Working Load Overhead lifting quality (1/2 in.) 2270 kg (5000 lb.) UTION Stand clear when lowering, as machine may swing. NOTE: Do NOT lift at lean bar when unloading from trailer. This procedure is only for laying the machine over into working position. 4. Raise forks until lift chains are fully tensioned Revision

20 SSEMLING THE MHINE Figure 3.10: Header with rane m (48 in.) Minimum 5. ack up SLOWLY, while simultaneously lowering machine, so that cutterbar skid shoes rest on blocks (). 6. Remove chain hooks from lean bar Figure 3.11: Header on locks Revision

21 SSEMLING THE MHINE 7. ttach chain to center-link anchor () on frame tube and raise rear of header approximately 305 mm (12 in.) off ground Figure 3.12: enter-link nchor 8. Remove lynch pin from clevis pin () in header stand at right side of header. 9. Hold stand () and remove clevis pin () Figure 3.13: Header Stand in Shipping Position 10. Invert stand () and reinstall on header leg in upper hole location with clevis pin (). Secure clevis pin () with lynch pin. NOTE: In soft conditions, use a wooden block under the stand. 11. Lower header onto stand () Figure 3.14: Header Stand Revision

22 SSEMLING THE MHINE 3.5 Removing Shipping Stands To remove shipping stands, follow these steps: 1. Remove two bolts () from shipping stand (). 2. Remove hairpin from pin (). 3. Hold shipping stand (), remove pin (), and remove stand. Discard stand and hardware Figure 3.15: Shipping Stands 4. Remove four bolts () and remove angle (). Discard angle and hardware Figure 3.16: Shipping Stands Revision

23 SSEMLING THE MHINE 3.6 Installing Tall rop Divider Kit If kit is NOT supplied, proceed to 3.7 djusting Lean ar, page 16. Otherwise, proceed as follows: 1. Unpack kit and disassemble hardware from divider. NOTE: If tall crop extension angles are not required, proceed to Step 5, page Remove hardware () on both sides of lean bar and remove lean bar from header Figure 3.17: Lean ar 3. ttach extension angles () to each end of lean bar () with four 1/2 x 1.0 in. hex bolts () and nuts provided. 4. Reinstall lean bar on header with existing hardware. Tighten bolts Figure 3.18: Extension ngles ttached to Ends of Lean ar 5. Position left divider () at left side of lean bar and attach with U-bolt (), two 3/8 in. nuts, and two 1/2 x 1.0 in. hex bolts () and nuts provided. NOTE: The divider may be positioned as shown or using the optional mounting hole (D). D 6. djust to desired position and tighten hardware. 7. Repeat the previous two steps for the right side Figure 3.19: Tall rop Divider Installed Revision

24 SSEMLING THE MHINE 3.7 djusting Lean ar The lean bar is fully retracted for shipping. djust as follows: 1. Remove hardware () on both sides and install lean bar in field position. heck that field position is suitable for the crop (normally 2/3 of crop height). NOTE: If optional tall crop divider kit is supplied, it can be installed prior to reinstalling the lean bar. Refer to 3.6 Installing Tall rop Divider Kit, page Figure 3.20: Lean ar Revision

25 SSEMLING THE MHINE 3.8 djusting Pan Extensions: Grass Seed Special The grass seed header auger pan extensions are factory-installed for the widest delivery. djust as follows: 1. Remove two bolts () and loosen bolt () Figure 3.21: Pan Extension Wide Setting Revision

26 SSEMLING THE MHINE 2. Slide pan extensions () and swath forming rods inboard to desired position and align holes. 3. Reinstall two bolts (). Tighten bolts () and (). 4. Repeat for opposite pan extension Figure 3.22: Pan Extension Narrow Setting Revision

27 SSEMLING THE MHINE 3.9 djusting Transport Lights 1. Position amber light support () perpendicular to header. 2. heck that pivot bolt () is tight enough to hold light support () in upright position, yet allows the light to pivot out of the way of obstructions. NOTE: Do NOT overtighten mounting hardware. 3. Ensure base of light housings and bolted connections on light supports provide proper electrical grounding. D 4. mber reflector () should face direction of travel. If required, remove bolts (D), flip reflector assembly, and reinstall bolts. Figure 3.23: mber Hazard Light Revision

28 SSEMLING THE MHINE 3.10 ssembling Forming Shield 1. Unpack and remove shipping material. 2. Remove bolts () from side deflectors () Figure 3.24: Forming Shield in Shipping onfiguration 3. Install rubber strap () to the side bracket () using bolt (), washer (D), and nut (E). 4. Repeat for the other side. D E Figure 3.25: Rubber Strap 5. Lay cover () upside down on a flat surface. 6. Install the center deflectors () using three bolts () on each side. E NOTE: Orient deflectors () so that narrow end (D) is toward the front of the cover () and deep end (E) is toward the rear as shown in Figure 3.26, page 20. D Figure 3.26: enter Deflectors Revision

29 SSEMLING THE MHINE 7. ssemble side deflectors () to cover with bolt (), jam nut (E), washer (D), and nut () from previous step. 8. Tighten flange nut () enough to hold deflectors () in position, but still allow deflectors to move. 9. Tighten jam nut (E) against cover while holding bolt (). E D Figure 3.27: Side Deflectors 10. Remove lynch pin () from adjuster rod () and locate rod in hole in side deflector (). Secure with lynch pin (). 11. Repeat for other deflector Figure 3.28: djuster Rod Revision

30 SSEMLING THE MHINE 12. Invert forming shield to installation position as shown Figure 3.29: Forming Shield in Installation Position Revision

31 SSEMLING THE MHINE 3.11 Installing Forming Shield To install the forming shield, follow these steps: 1. If attached, remove header from the windrower for ease of installing the forming shield. Refer to windrower operator s manual for procedure. NOTE: Do NOT install the two triangular shaped plates from the forming shield kit. Triangular plates are used with rotary headers Figure 3.30: Triangular Plate 2. Install bolt () with spacer () and nut on each leg in the upper hole. Hardware is supplied with forming shield kit Figure 3.31: Windrower Leg 3. Remove two clevis pins () from forward end of forming shield. Figure 3.32: Forming Shield Revision

32 SSEMLING THE MHINE 4. Position forming shield () under windrower frame Figure 3.33: Forming Shield Under Windrower 5. Position forming shield onto bolts () in windrower legs and secure with clevis pins () and hairpin Figure 3.34: Forming Shield ttached to Windrower Legs Revision

33 SSEMLING THE MHINE 6. Lift aft end of the forming shield and attach straps () to pins () on windrower frame. Install washer and hairpin to secure strap. Use the middle hole and adjust height to suit the crop Figure 3.35: Forming Shield ttached to Windrower Frame 7. Set forming shield side deflectors to desired width by positioning adjuster bars (). Use the same hole location on both sides. Position deflectors at the narrowest setting for a narrow windrow (silage for example). Position deflectors at the widest setting for a wide windrow. 8. djust fluffer shield () to middle position. Loosen handles () if required Figure 3.36: Side Deflectors and Fluffer Shield Revision

34 SSEMLING THE MHINE 3.12 ttaching 40-D Headers to M Series SP Windrowers Refer to your windrower operator s manual for procedures to mechanically attach the auger header to the self-propelled windrower and for modifications if required to the windrower hydraulic connections. Refer to the following procedures for electrical and hydraulic connections. Header drive hydraulic hoses and electrical harness are located on the left cab-forward side of the windrower. IMPORTNT: If attaching an 40-D Header to an M1170 or M1240 Windrower, the M1 Series onversion kit MD #5998 must first be installed. The kit includes a new manifold and hydraulic hoses required for operation with an M1 Series Windrower. 40-DX Headers are factory-configured for M1170 and M1240 Windrowers. Refer to 3.13 ttaching 40-DX Header to M1 Series SP Windrower, page 47. IMPORTNT: For M150, M155, M155E4, and M200 Windrowers with Reverser kit MD #4656 installed, hose plumbing to the reverser valve must be changed if switching between a D Series Draper Header with a conditioner and an 40-D uger Header to prevent draper header reel damage and improper operation. Refer to 3.15 Routing Reverser Valve Jumper Hose M Series, page 59 and if necessary to instruction MD # (Reverser Kit Installation Instructions), available from our Dealer-only site ( (login required). NOTE: Header reel motor hose routing must be properly configured before attaching the header to a windrower. The header is factory-configured for M150, M155, M155E4, and M200 Windrowers. For M100, M105, or M205 Windrowers, refer to: ttaching 40-D to M100 or M105, page ttaching to 40-D to M205, page ttaching 40-D to M100 or M105 UTION To prevent accidental movement of windrower, return ground speed lever (GSL) to N-DETENT, center steering wheel to lock, shut off engine, and remove key. M100 and M105 Self-Propelled Windrowers are factory-equipped with four header drive hoses () on the left side Figure 3.37: Header Drive Hoses Revision

35 SSEMLING THE MHINE 1. Disengage rubber latch () and open driveline shield (). Figure 3.38: Driveline Shield Remove the cap () from electrical connector and remove connector from support bracket. 3. Disengage and rotate lever () counterclockwise to fully up position to release the hose bundle () Figure 3.39: Support racket and Hose undle 4. Move hose/electrical bundle () to header. 5. Route bundle () from windrower through support () and access hole () 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. ttach cover to mating cover on windrower wiring harness. 9. Remove caps from hydraulic couplers. lean if necessary. E Figure 3.40: Hose and Electrical undle 14-Ft. and 16-Ft. Header Shown (18-Ft. Similar) D Revision

36 SSEMLING THE MHINE NOTE: t location (), later-built 2015, 2016 and later units will have a tee going to case drain on square reel motor only. 10. Push hose connectors onto mating receptacles as shown until collars on receptacles snap into lock position. D Figure 3.41: Early-uild 2015, 2014 and Earlier Standard Header 14-Ft. and 16-Ft. Header Shown (18-Ft. Similar) - Reel Pressure - Knife and onditioner Return - ase Drain D - Knife and onditioner Pressure D Figure 3.42: 2015 Grass Seed Header Hose onnectors - Reel and uger Pressure - Knife and onditioner Return - ase Drain D - Knife and onditioner Pressure Revision

37 SSEMLING THE MHINE D Figure 3.43: 2014 and Earlier Grass Seed Header - Knife Return (Male Fitting at Header) (Hidden in this Image) - uger and Reel Pressure - Knife Pressure (Female Fitting at Header) D - ase Drain 11. Route auger return and reel pressure hose bundle () from header to windrower, and position bundle above existing hose support () as shown. 12. Secure with three straps (D), and lower lever (). D Figure 3.44: uger Return and Reel Pressure Hose undle 13. If valve blocks are NOT configured as shown (), refer to Modifying Hydraulics M100, M105, page Figure 3.45: Valve lock onfiguration Revision

38 SSEMLING THE MHINE 14. Push auger/reel pressure () and auger/reel return () hose couplers onto mating receptacles on valve block until collar on receptacle snaps into lock position Figure 3.46: uger/reel Pressure and uger/reel Return Hose ouplers 14-Ft. and 16-Ft. Header Shown (18-Ft. Similar) Figure 3.47: uger/reel Pressure and uger/reel Return Valve lock Receptacles 15. Open header left driveshield and check hose routing at the reel motor. NOTE: Reel drive motor may not be exactly as shown. Later-build 2015, 2016 and later 40-D units have a square reel motor; Early-build 2015, 2014 and earlier 40-D units have a round reel motor. The image at the right shows a square reel motor and so is a later-build model. The hose routing depends on which windrower model the header is being attached to. The header is factory-configured for M150, M155, and M200 Windrowers. Figure 3.48: Factory Routing M150, M155, and M200 Later-uild 2015 Shown - Reel Motor - uger Motor Revision

39 SSEMLING THE MHINE 16. For procedure to change hose routing for M100 or M105 Windrowers, refer to the section based on the year of manufacture: Later-build 2015, 2016 and later: 3.17 Hydraulic Drive Hose Routing (Later-uild 2015, 2016 and Later 40-D), page 66 Early-build 2015, 2014 and earlier: 3.18 Hydraulic Drive Hose Routing (Early-uild 2015, 2014 and Earlier 40-D), page Figure 3.49: Modified Routing M100, M105, and M205 Later-uild 2015 Shown ttaching 40-D to M150, M155, or M155E4 UTION To prevent accidental movement of windrower, return ground speed lever (GSL) to N-DETENT, center steering wheel to lock, shut off engine, and remove key. M150, M155, and M155E4 self-propelled windrowers are factory-equipped with four header drive hoses () on the left side Figure 3.50: Header Drive Hoses Revision

40 SSEMLING THE MHINE 1. Disengage rubber latch () and open driveline shield (). Figure 3.51: Driveline Shield Remove the cap () from electrical connector and remove connector from support bracket. 3. Disengage and rotate lever () counterclockwise to fully up position to release the hose bundle () Figure 3.52: Support racket and Hose undle 4. Move hose/electrical bundle () to header. 5. Route bundle () from windrower through support () and access hole () 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. E D 8. ttach cover to mating cover on windrower wiring harness. 9. Remove caps from hydraulic couplers. lean if necessary Figure 3.53: Hose and Electrical undle 14-Ft. and 16-Ft. Header Shown (18-Ft. Similar) Revision

41 SSEMLING THE MHINE NOTE: t location (), later-built 2015, 2016 and later units will have a tee going to case drain on square reel motor only. 10. Push hose connectors onto mating receptacles as shown until collars on receptacles snap into lock position. D Figure 3.54: Early-uild 2015, 2014 and Earlier Standard Header 14-Ft. and 16-Ft. Header Shown (18-Ft. Similar) - Reel and uger Pressure - Knife and onditioner Return - ase Drain D - Knife and onditioner Pressure D Figure 3.55: 2015 Grass Seed Header Hose onnectors - Reel and uger Pressure - Knife and onditioner Return - ase Drain D - Knife and onditioner Pressure Revision

42 SSEMLING THE MHINE D Figure 3.56: 2014 and Earlier Grass Seed Header - Knife Return (Male Fitting at Header) (Hidden in this Image) - uger and Reel Pressure - Knife Pressure (Female Fitting at Header) D - ase Drain 11. Route auger return and reel pressure hose bundle () from header to windrower and position bundle above existing hose support () as shown. 12. Secure with three straps (D), and lower lever (). D Figure 3.57: uger Return and Reel Pressure Hose undle 13. If valve blocks are NOT configured as shown at right, refer to Modifying Hydraulics M150, M155, M155E4, page Figure 3.58: M150/M155/M155E4 with Reverser Valve Revision

43 SSEMLING THE MHINE Figure 3.59: M150/M155/M155E4 without Reverser Valve 14. Locate the auger pressure () and auger/reel return () hoses Push auger pressure () and auger/reel return () hose couplers onto mating receptacles on valve block until collar on receptacle snaps into lock position. 16. Proceed to 3.15 Routing Reverser Valve Jumper Hose M Series, page 59. Figure 3.60: uger Pressure and uger/reel Return Hose ouplers 14-Ft. and 16-Ft. Header Shown (18-Ft. Similar) Figure 3.61: M150/M155/M155E4 with Reverser Valve Revision

44 SSEMLING THE MHINE Figure 3.62: M150/M155/M155E4 without Reverser Valve ttaching 40-D to M200 UTION To prevent accidental movement of windrower, return ground speed lever (GSL) to N-DETENT, center steering wheel to lock, shut off engine, and remove key. The M200 Windrower requires four drive hoses () to run an 40-D uger Header Figure 3.63: Drive Hoses Revision

45 SSEMLING THE MHINE If only three drive hoses are present, before following the procedure below, configure the M200 to run an 40-D uger Header by installing kit MD #4651. The kit includes an additional hose (), hardware, and installation instructions Figure 3.64: Kit MD # Disengage rubber latch (), and open driveline shield (). Figure 3.65: Driveline Shield Remove cap () from electrical connector, and remove connector from support bracket. 3. Disengage and rotate lever () counterclockwise to fully up position to release the hose bundle () Figure 3.66: Support racket and Hose undle Revision

46 SSEMLING THE MHINE 4. Move hose/electrical bundle () to header. 5. Route bundle () from windrower through support () and access hole () 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. E D 8. ttach cover to mating cover on windrower wiring harness. 9. Remove caps from hydraulic couplers. lean if necessary Figure 3.67: Hose and Electrical undle 14-Ft. and 16-Ft. Header Shown (18-Ft. Similar) NOTE: t location (), later-build 2015, 2016 and later units will have a tee going to case drain on square reel motor only. 10. Push hose connectors onto mating receptacles as shown until collars on receptacles snap into lock position. D Figure 3.68: Early-uild 2015, 2014, and Earlier Standard Header 14-Ft. and 16-Ft. Header Shown (18-Ft. Similar) - Reel and uger Pressure - Knife and onditioner Return - ase Drain D - Knife and onditioner Pressure Revision

47 SSEMLING THE MHINE D Figure 3.69: 2015 Grass Seed Header Hose onnectors - Reel and uger Pressure - Knife and onditioner Return - ase Drain D - Knife and onditioner Pressure D Figure 3.70: 2015 Grass Seed Header Hose onnectors Side View - Reel and uger Pressure - Knife and onditioner Return - ase Drain D - Knife and onditioner Pressure Revision

48 SSEMLING THE MHINE D Figure 3.71: 2014 and Earlier Grass Seed Header - Knife Return (Male Fitting at Header) (Hidden in This Image) - uger and Reel Pressure - Knife Pressure (Female Fitting at Header) D - ase Drain 11. Route auger return and reel pressure hose bundle () from header to windrower, and position bundle above existing hose support () as shown. 12. Secure with three straps (D), and lower lever (). D Figure 3.72: uger Return and Reel Pressure Hose undle Revision

49 SSEMLING THE MHINE 13. If valve blocks are NOT configured as shown at right, refer to relevant section for your windrower: Modifying Hydraulics M200 with Reverser Valve, page Modifying Hydraulics M200 without Reverser Valve, page Figure 3.73: M200 with Reverser Valve Figure 3.74: M200 without Reverser Valve 14. Locate the auger pressure () and auger/reel return () hoses Figure 3.75: uger Pressure and uger/reel Return Hose ouplers 14-Ft. and 16-Ft. Header Shown (18-Ft. Similar) Revision

50 SSEMLING THE MHINE 15. Push auger pressure () and auger/reel return () hose couplers onto mating receptacles on valve block until collar on receptacle snaps into lock position. 16. Proceed to 3.15 Routing Reverser Valve Jumper Hose M Series, page Figure 3.76: M200 with Reverser Valve Figure 3.77: M200 without Reverser Valve Revision

51 SSEMLING THE MHINE ttaching to 40-D to M205 UTION To prevent accidental movement of windrower, return ground speed lever (GSL) to N-DETENT, center steering wheel to lock, shut off engine, and remove key. The 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 ase kit MD #5491 Reverser kit 2 MD #5492 oupler MD # Figure 3.78: uger Drive asic Kit and ompletion Kit Installed 1. Disengage rubber latch (), and open driveline shield (). Figure 3.79: Driveline Shield Reverser kit is optional and not required, although most 40-D Headers have a Reverser kit (MD #5492) ordered for the windrower. Install prior to hook-up if required Revision

52 SSEMLING THE MHINE 2. Remove cap () from the electrical connector, and remove the connector from the support bracket. 3. Disengage and rotate lever () counterclockwise to fully up position to release the hose bundle (). 4. Move hose/electrical bundle () to header Figure 3.80: Support racket and Hose undle 5. Route bundle () from windrower through support () and access hole () 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. E 8. ttach cover to mating cover on windrower wiring harness. D 9. Remove caps from hydraulic couplers. lean if necessary Figure 3.81: Hose and Electrical undle 14-ft. and 16-Ft. Header Shown (18-Ft. Similar) NOTE: Later-build 2015 and later units have a tee at location () going to case drain on square reel motor only. 10. Push hose connectors onto mating receptacles as shown until collars on receptacles snap into lock position. Reel/auger pressure () Knife and conditioner return () ase drain () Knife and conditioner pressure (D) D Figure 3.82: Early-uild 2015, 2014 and Earlier Standard Header 14-Ft. and 16-Ft. Header Shown (18-Ft. Similar) Revision

53 SSEMLING THE MHINE Reel and auger pressure () Knife and conditioner return () ase drain () Knife and conditioner pressure (D) D Figure 3.83: 2015 Grass Seed Header Hose onnectors Knife return (male fitting at header) (hidden in this image) () uger and reel pressure () Knife pressure (female fitting at header) () ase drain (D) D Figure 3.84: 2014 and Earlier Grass Seed Header 11. Route auger return and reel pressure hose bundle () from header to windrower, and position bundle above existing hose support () as shown. 12. Secure with three straps (D), and lower lever (). D Figure 3.85: uger Return and Reel Pressure Hose undle Revision

54 SSEMLING THE MHINE 13. Push auger/reel pressure () and auger/reel return () hose couplers onto mating receptacles on valve block until collar on receptacle snaps into lock position Figure 3.86: uger/reel Pressure and uger/reel Return Hose ouplers 14. heck hose routing at the reel motor (). The hose routing depends on which windrower model the header is being attached to. The header is factory-configured for M150, M155, M155E4, and M200 windrowers. NOTE: Reel drive motor may not be exactly as shown Figure 3.87: Later-build 2015 Factory Routing M150, M155, M155E4, and M For the procedure to change hose routing for M205 windrowers, refer to the section based on the year of manufacture: Later-build 2015, 2016 and later: 3.17 Hydraulic Drive Hose Routing (Later-uild 2015, 2016 and Later 40-D), page 66 Early-build 2015, 2014 and earlier: 3.18 Hydraulic Drive Hose Routing (Early-uild 2015, 2014 and Earlier 40-D), page Figure 3.88: Modified Routing M100, M105, and M Revision

55 SSEMLING THE MHINE 3.13 ttaching 40-DX Header to M1 Series SP Windrower Refer to your windrower operator s manual for procedures to mechanically attach an 40-DX auger header to an M1 Series Self-Propelled Windrower and for modifications (if required) to the windrower hydraulic connections. IMPORTNT: If attaching an 40-D Header to an M1170 or M1240 Windrower, the M1 Series onversion kit MD #5998 must first be installed. The kit includes a new manifold and hose bundle required for operation with an M1 Series Windrower. 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 40-DX header to an M1 Series SP windrower, follow these steps: NOTE: Header reel motor hose routing must be properly configured before attaching an 40-DX header to an M1 Series SP windrower. 1. Route header hose bundle through hose guide () on header as shown Figure 3.89: Hose undle 2. Insert hose support () into hole in the windrower left leg, and route the header hose bundle () under the windrower to the hydraulic and electrical couplers Figure 3.90: Hose Support Revision

56 SSEMLING THE MHINE 3. If attaching to a disc-ready windrower, ensure knife drive hose () is connected to coupler (). NOTE: Hose () provides power to run the knife/conditioner. Figure 3.91: M1170/M1240 Disc Header onfigured NOTE: M1170 Windrowers with standard auger/draper configuration don t require the knife drive hose; only the two multicouplers () are used to connect the auger header Figure 3.92: M1170 Standard onfiguration uger/draper Ready 4. lean multicouplers and receptacles to prevent contamination. F 5. Push button () on rear multicoupler receptacle and pull handle () away from windrower. 6. Open cover () and position multicoupler (D) onto receptacle. lign pins in coupler with slots in handle (), and push handle toward windrower so that coupler is locked onto receptacle and button () 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. lign 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. E G H Figure 3.93: Multicouplers D Revision

57 SSEMLING THE MHINE 9. Remove cover from receptacle () and connect electrical harness from header Figure 3.94: Windrower Electrical onnector Revision

58 SSEMLING THE MHINE 3.14 Modifying Hydraulics The windrower hydraulics must be modified to work correctly with an 40-D uger Header. Follow the instructions in the relevant section for your windrower model: Modifying Hydraulics M100, M105, page Modifying Hydraulics M150, M155, M155E4, page Modifying Hydraulics M200 with Reverser Valve, page Modifying Hydraulics M200 without Reverser Valve, page Modifying Hydraulics M205, page Modifying Hydraulics M100, M Open left maintenance platform on windrower. 2. t valve () on the valve block, remove cap () from port R1 fitting and plug () from DW tee fitting. Ports may not be identified. NOTE: heck valve (D) is required when attaching an 40-D uger Header to an M100 or M105 Windrowers. ll M105 Windrowers made in 2012 and forward come factory-installed with check valve (D). If required, check valve (MD #167344) can be ordered from MacDon Parts Department. D DW R Figure 3.95: Valve locks in Factory onfiguration Revision

59 SSEMLING THE MHINE 3. Remove female coupler assemblies () and () from auger return and reel pressure hose bundle () from header Figure 3.96: uger Return and Reel Pressure Hose undle 4. Remove and discard cap () and adapter fitting () with O-ring from the large coupler () Figure 3.97: Large oupler ssembly 5. Install large coupler () onto fitting at port R1 on valve block (). IMPORTNT: Make sure O-ring is on JI threads in port R1 to ensure a proper seal with the coupler (). If O-ring is missing, reuse O-ring from discarded adapter fitting in Step 4, page Figure 3.98: Valve lock onfigured for uger Header Revision

60 SSEMLING THE MHINE 6. Remove and discard cap () and adapter fitting () from the small coupler assembly () Figure 3.99: Small oupler ssembly 7. Install the small coupler subassembly () onto the tee () on valve block (). NOTE: Position of adjacent hoses may require slight adjustment to allow access for new hoses Figure 3.100: Valve lock onfigured for uger Header Modifying Hydraulics M150, M155, M155E4 1. Open left maintenance platform on windrower. 2. Remove the plugs from ports R2 on valve blocks () and (). Ports may not be identified. R2 R Figure 3.101: Valve locks with Reverser Valve in Factory onfiguration Revision

61 SSEMLING THE MHINE R2 R Figure 3.102: Valve locks without Reverser Valve in Factory onfiguration 3. Remove female coupler assemblies () and () from hoses in bundle () from header, and remove caps Figure 3.103: Header Hose undle 4. Install smaller coupler assembly () in port R2 on valve block () and the larger coupler assembly (D) in port R2 on valve block (). 5. Proceed to 3.15 Routing Reverser Valve Jumper Hose M Series, page 59. D Figure 3.104: Valve locks with Reverser Valve onfigured for uger Header Revision

62 SSEMLING THE MHINE D Figure 3.105: Valve locks without Reverser Valve onfigured for uger Header Modifying Hydraulics M200 with Reverser Valve IMPORTNT: For windrowers with Reverser kit MD #4656, hose plumbing to reverser valve must be changed to suit the header type if switching between 40-D uger Header and draper header to prevent draper header reel damage and improper operation. See instruction MD # (Reverser Kit Installation Instructions) for proper plumbing articles for each header type. 1. Open left maintenance platform on windrower. 2. Remove the plugs from ports R2 on valve blocks () and (). R2 R Figure 3.106: Valve locks with Reverser Valve in Factory onfiguration Revision

63 SSEMLING THE MHINE 3. Remove female coupler assemblies () and () from hoses in bundle () from header, and remove caps. NOTE: To avoid contact with platform support, the reel/auger return hose uses a 45 degree fitting (MD #50098) Figure 3.107: Header Hose undle 4. Install smaller coupler assembly () in port R2 on valve block () and the larger coupler assembly (D) in port R2 on valve block (). NOTE: Position of adjacent hoses may require slight adjustment to allow access for new hoses. lign larger coupler assembly (D) with R1 hose (E). 5. Proceed to 3.15 Routing Reverser Valve Jumper Hose M Series, page 59. D E Figure 3.108: Valve locks with Reverser Valve onfigured for uger Header Revision

64 SSEMLING THE MHINE Modifying Hydraulics M200 without Reverser Valve 1. Open left maintenance platform on windrower. 2. Remove the plug from port R2 on valve block () and the cap from fitting in port R2 on valve block (). Ports may not be identified. R2 R Figure 3.109: Valve locks without Reverser Valve in Factory onfiguration 3. Remove female coupler assemblies () and () from hoses in bundle () from header Figure 3.110: Header Hose undle Revision

65 SSEMLING THE MHINE 4. Remove and discard the cap () and adapter fitting () with O-ring from the large coupler () Figure 3.111: Large oupler ssembly 5. Install larger coupler (D) onto fitting at port R2 on valve block (). 6. Remove cap from smaller coupler assembly () and install assembly in port R2 on valve (). D IMPORTNT: Make sure O-ring is on JI threads in port R1 to ensure a proper seal with the coupler (D). If O-ring is missing, reuse O-ring from discarded adapter fitting in Step 4, page Figure 3.112: Valve locks without Reverser Valve onfigured for uger Header Revision

66 SSEMLING THE MHINE Modifying Hydraulics M205 The M205 hydraulics need to be modified to accept an -Series uger Header. Kits MD #5491, MD #5492, and MD #5497 should have been supplied with your header. If required, these kits can be ordered from your MacDon Dealer. 1. Install kits in accordance with the instructions that were supplied with the kits to achieve the configuration shown at right. 2. Proceed to 3.16 ttaching Hydraulics M Series, page Figure 3.113: uger Header Hydraulics Revision

67 SSEMLING THE MHINE 3.15 Routing Reverser Valve Jumper Hose M Series n optional valve block to reverse the header drive in the event of plugging may have been installed on an M150, M155, M155E4, or M200 windrower. If reverser valve block is installed, proceed as follows; otherwise, disregard this procedure. IMPORTNT: The jumper hose routing on the reverser valve is specific for each model of header. Do NOT operate the header unless hose is routed correctly. 1. Move left windrower platform to the open position to expose hydraulic valve blocks. 2. Route jumper hose () from 2 conveyor circuit () to R on reverser block () as shown. NOTE: For draper headers, R is routed to port R4 (as shown in image at right) on reverser block. Reroute jumper hose () when switching between draper and auger headers. This prevents draper header reel damage and improper operation, which occurs if reel runs backwards Figure 3.114: Hose () Position (40-D on M200 Shown M150, M155, and M155E4 Similar) NOTE: Jumper hose rerouting is unnecessary if hay conditioner is not installed on draper header. R4 NOTE: The draper header reverser function is suppressed unless hay conditioner is activated in Windrower Setup using the cab display module (DM). R Figure 3.115: Hose Position (Draper Header on M150 Shown M155, M155E4, and M200 Similar) Revision

68 SSEMLING THE MHINE 3.16 ttaching Hydraulics M Series UTION 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. Disengage rubber latch (), and open driveline shield (). Figure 3.116: Driveline Shield Remove cap () from electrical connector, and remove connector from support bracket. 3. Disengage and rotate lever () counterclockwise to the fully up position to release hose bundle () Figure 3.117: Windrower Hoses and Harness in Storage Position Revision

69 SSEMLING THE MHINE 4. Move hose bundle () to header. 5. Rotate lever () clockwise, and engage in bracket to store Figure 3.118: Windrower Hoses and Harness in Working Position 6. Route hoses () from windrower through support () and access hole () in header frame alongside hose bundle (D). NOTE: Hose bundle (D) will be attached later in the procedure. 7. Remove cover on header electrical receptacle (E). E 8. Push connector onto receptacle, and turn collar on connector to lock it in place. D 9. ttach cover to mating cover on windrower wiring harness. 10. Remove caps from hydraulic couplers. lean if necessary Figure 3.119: Windrower Hoses and Harness onnected to Header 14-Ft. and 16-Ft. Header Shown (18-Ft. Similar) 11. onnect the four hoses from windrower to mating receptacles on header. Ensure collar snaps into lock position. Reel/auger pressure () Knife and conditioner return () ase drain () Knife and conditioner pressure (D) D Figure 3.120: Hose onnections on Standard Header 14-Ft. and 16-Ft. Header Shown Revision

70 SSEMLING THE MHINE Reel/auger pressure () Knife and conditioner return () ase drain () Knife and conditioner pressure (D) D Figure 3.121: Hose onnections on Standard Header 14-Ft. and 16-Ft. Header Shown Reel/auger pressure () Knife and conditioner return () ase drain () Knife and conditioner pressure (D) D Figure 3.122: Hose onnections on Standard Header 18-Ft. Header Shown Knife return (male fitting not visible) () uger/reel pressure () Knife pressure (female fitting at header) () ase drain (D) D Figure 3.123: Hose onnections on Grass Seed Header Revision

71 SSEMLING THE MHINE 12. If not already installed, retrieve package of three adjustable straps shipped with the header. 13. Position adjustable strap () through slot and under bracket () on hose support. 14. ttach strap to bracket with 1/2 in. carriage bolt () and locking nut. Install bolt from under bracket. 15. Repeat Step 13, page 63 through Step 14, page 63 at the two other brackets on hose support Route reel/auger return and auger pressure hose bundle () from header to windrower, and position bundle above existing hose support () as shown. 17. Secure with three straps (D), and lower lever (). Figure 3.124: djustable Straps D Figure 3.125: Reel/uger Return and uger Pressure Hose undle Revision

72 SSEMLING THE MHINE 18. onnect auger/reel pressure and reel/auger return hoses from header to receptacles on windrower valve block. Refer to the relevant illustration for your equipment Figure 3.126: M100/M105 - Reel/uger Return - uger/reel Pressure Figure 3.127: M150/M155/M155E4 with Reverser Valve - uger Pressure - Reel/uger Return Figure 3.128: M150/M155/M155E4 without Reverser Valve - uger Pressure - Reel/uger Return Revision

73 SSEMLING THE MHINE Figure 3.129: M200 with Reverser Valve - uger Pressure - Reel/uger Return Figure 3.130: M200 without Reverser Valve - uger Pressure - Reel/uger Return Figure 3.131: M205 - Reel/uger Return - uger/reel Pressure Revision

74 SSEMLING THE MHINE 3.17 Hydraulic Drive Hose Routing (Later-uild 2015, 2016 and Later 40-D) The 40-D uger Header hydraulic drive hose routing depends on the windrower model to which the header is being attached. 40-D Headers are factory-configured for M150, M155, M155E4, and M200 SP Windrowers as shown in Figure 3.137, page DX Headers are factory-configured for M1170 and M1240 SP Windrowers. IMPORTNT: If attaching an 40-D Header to an M1170 or M1240 Windrower, the M1 Series onversion kit (MD #5998) must first be installed. The kit includes a new manifold and hose bundle required for operation with an M1 Series Windrower. Refer to 3.19 Hydraulic Drive Hose Routing (M1 Series Windrowers), page 73 for correct hose routing. To route hoses for M100, M105, and M205 Windrowers, proceed as follows: IMPORTNT: If you have a D SP windrower header, confirm whether you have an early-build or a later-build 2015 unit. If the reel motor is round (), then it is an earlier-build 2015 model. Refer to 3.18 Hydraulic Drive Hose Routing (Early-uild 2015, 2014 and Earlier 40-D), page 71. If the reel motor is square (), then use the following procedure: Figure 3.132: Reel Drive Motor 1. Press screwdriver against latch in opening () and lift to open header left driveshield. Shield will latch at location () to stay open Figure 3.133: Left Driveshield Revision

75 SSEMLING THE MHINE 2. Disengage rubber latch (), and open driveline shield (). Figure 3.134: Driveline Shield Loosen bulkhead nut () on auger and reel pressure coupler (). This allows auger and reel pressure hose () to rotate freely Figure 3.135: uger and Reel Pressure oupler and Hose 14-Ft. and 16-Ft. Header Shown Figure 3.136: uger and Reel Pressure oupler and Hose 18-Ft. Header Shown Revision

76 SSEMLING THE MHINE 4. Disconnect hoses as follows: a. Disconnect hose () from tee (). b. Disconnect tee () from reel motor upper port. c. Disconnect hose () from reel motor lower port. 5. ut cable ties (D) at locations shown in illustration. D D Figure 3.137: Factory onfiguration (M150, M155, M155E4, and M200) 6. Reconnect hoses as follows: a. Reroute hose (E) behind hose () and (F) to hose () and connect tee () to lower port fitting. b. Reroute hose () above hose (E) and (F) and connect hose () to tee (). Tighten hose (). c. Loosen 45 degree fittings at both ports. This allows room for wrenches when tightening tee () to lower port. d. onnect hose () to upper port fitting as shown and check orientation of 45 degree fitting. E F D NOTE: Ensure that hose () is routed in front of hose () and (E). e. onfirm orientation of upper port 45 degree fitting, back-off tee (), and tighten upper port fitting in position determined. Tighten hose (). f. heck orientation of lower port 45 degree fitting and tighten. g. onnect tee () to lower port 45 degree fitting and tighten. Figure 3.138: djusted onfiguration (M100, M105, and M205) Revision

77 SSEMLING THE MHINE 7. Secure electrical harness (), motor case drain hose (), and hose (D) together with cable ties (), as shown. IMPORTNT: Ensure there is at least 25 mm (1 in.) clearance between hose bundle (E) and knife drive timing belt (F). D E F Figure 3.139: djusted onfiguration (M100, M105, and M205) 8. Rotate coupler () and hose () downward as shown until slack has been sufficiently reduced. Tighten bulkhead nut () Figure 3.140: uger and Reel Pressure oupler and Hose 14-Ft. and 16-Ft. Header Shown Figure 3.141: uger and Reel Pressure oupler and Hose 18-Ft. Header Shown Revision

78 SSEMLING THE MHINE 9. lose driveline shield () and engage rubber latch (). 10. lose driveshield before engaging header. Figure 3.142: Driveline Shield Revision

79 SSEMLING THE MHINE 3.18 Hydraulic Drive Hose Routing (Early-uild 2015, 2014 and Earlier 40-D) The 40-D uger Header drive hose routing depends on the windrower model to which the header is being attached. Early build 40-D Headers are for use on M100, M105, and M205 Windrowers Only. IMPORTNT: If you have a D SP windrower header, confirm whether you have an early-build or a later-build 2015 unit. If the reel motor is square (), then it is a later-build 2015 model. Refer to 3.17 Hydraulic Drive Hose Routing (Later-uild 2015, 2016 and Later 40-D), page 66. If the reel motor is round (), then use the following procedure: Figure 3.143: Reel Drive Motor 1. Press screwdriver against latch in opening () and lift to open header left driveshield. Shield will latch at () to stay open. 2. heck hose routing at the reel motor. The header is factory-configured for M150, M155, and M200 Windrowers as shown in Figure 3.145, page Figure 3.144: Left Driveshield Revision

80 SSEMLING THE MHINE To route hoses on early-build 2015, 2014, and earlier 40-D Headers for use on M100, M105, and M205 Windrowers, proceed as follows. 3. Disconnect hoses as follows: a. Disconnect hose () from tee (). b. Disconnect hose () from reel motor upper port. c. Disconnect tee () from reel motor lower port. 4. Reconnect hoses as follows: a. Relocate tee () to reel motor upper port. b. onnect hose () to tee (). c. onnect hose () to reel motor lower port Figure 3.145: Early-uild 2015, 2014, and Earlier Factory onfiguration (M150, M155, M155E4, and M200) Figure 3.146: djusted onfiguration (M100, M105, and M205) lose driveline shield () and engage rubber latch (). 6. lose driveline shield before engaging header. Figure 3.147: Driveline Shield Revision

81 SSEMLING THE MHINE 3.19 Hydraulic Drive Hose Routing (M1 Series Windrowers) 40-DX Headers are factory-configured for operation with M1170 and M1240 SP Windrowers. IMPORTNT: If attaching an 40-D Header to an M1170 or M1240 Windrower, the M1 Series onversion kit (MD #5998) must first be installed. The kit includes a new manifold and hydraulic hoses required for operation with an M1 Series Windrower. The following illustrations show the correct hose routing for M1170 and M1240 Windrowers. Reel pressure () uger/reel return () ase drain () uger pressure (D) D Figure 3.148: M1170/M1240 onfiguration Reel pressure () onnects to tee on port PR2 uger/reel return () onnects to port RET2 ase drain () onnects to tee on knife motor case drain port ase drain (D) onnects to tee on knife motor case drain port and to port DRIN OR1 NOTE: Manifold (E) is included in the M1 Series onversion kit (MD #5998). D E Figure 3.149: M1170/M1240 onfiguration Revision

82 SSEMLING THE MHINE Hose () onnects to tee on knife motor port and to port KP on manifold Hose () onnects to tee on knife motor port and to knife return port OR2 on manifold NOTE: The hose bundle (included in 5998) required for attaching header to windrower is not shown in illustration Figure 3.150: M1170/M1240 onfiguration Revision

83 SSEMLING THE MHINE 3.20 Repositioning Knife Drive ox reather There is one knife drive box at each end of the header. 1. Move breather/dipstick () to back port and install plug () in forward port at knife drive boxes Figure 3.151: Top View of Knife Drive ox 2. With top of knife drive box horizontal, check oil level. It should be between the lower hole () and the end of the dipstick. 3. If required, add SE 85W-140 lubricant Figure 3.152: Side View of Knife Drive ox and lose-up of Dipstick Revision

84

85 4 Lubricating the Machine 4.1 Greasing Procedure WRNING To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key, and engage safety props before going under machine. 1. Wipe grease fitting with a clean cloth before greasing to avoid injecting dirt and grit. 2. Inject grease through fitting with grease gun until grease overflows fitting, except where noted. 3. Leave excess grease on fitting to keep out dirt. 4. Replace any loose or broken fittings immediately. 5. If fitting will not take grease, remove and clean thoroughly. lso clean lubricant passageway. Replace fitting if necessary Figure 4.1: Grease Interval Decal Revision

86 LURITING THE MHINE 4.2 Lubrication Points: Left Side of Header NOTE: High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium ase. To prevent binding and/or excessive wear caused by knife pressing on guards, do NOT over-grease. If more than 6 to 8 pumps of grease gun are required to fill the cavity, replace the seal in the knifehead. Figure 4.2: Header Left Side D Tine ar earing (4 Places Each Tine ar) - Gauge Roller earing (2 Places) (oth Sides if Installed) - Knife Drive earing (1 Place) D - Knifehead earing (1 Place) Revision

87 LURITING THE MHINE 4.3 Lubrication Points: Right Side of Header NOTE: High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium ase. To prevent binding and/or excessive wear caused by knife pressing on guards, do NOT over-grease. If more than 6 to 8 pumps of grease gun are required to fill the cavity, replace the seal in the knifehead. Figure 4.3: Header Right Side D Knife Drive earing (1 Place) - uger Shaft earing (1 Place) - Reel Shaft earing (1 Place) D - Knifehead earing (1 Place) Revision

88 LURITING THE MHINE 4.4 Lubrication Points: Hay onditioner NOTE: High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium ase. Figure 4.4: Hay onditioner Roll Pivot (1 Place - oth Sides) - Roll Shaft earings (2 Places) - Roll Shaft earings (2 Places) Revision

89 LURITING THE MHINE 4.5 Lubrication Points: Drivelines NOTE: High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium ase. Figure 4.5: Drivelines D D Driveline Shafts (2 Places) 3 - Driveline Universals (2 Places) - ross Shafts (2 Places) D - Driveline Universals (2 Places) 3. 10% moly grease is recommended for driveline shaft slip joints ONLY Revision

90 LURITING THE MHINE 4.6 Knife and Gearbox Oil Figure 4.6: Knife and Gearbox Oil Oil Knife Daily Except in Sandy Soil (SE 30) - Knife Drive ox (2 Places) 4 - heck Roll Gearbox (1 Place) 5 4. heck oil level with knife drive box horizontal. 5. Header should be on the ground Revision

91 5 Performing Predelivery hecks UTION 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. IMPORTNT: To avoid machine damage, check that no shipping dunnage has fallen down between auger and pans. 1. Perform final checks and adjustments as listed on the Predelivery hecklist (yellow sheet attached to back of this instruction Predelivery hecklist, page 123) to ensure the machine is field-ready. Refer to the following pages for detailed instructions as indicated on the checklist. 2. The completed checklist should be retained either by the Operator or the Dealer. 5.1 hecking Drive elts and hains 1. Open shield on header right side. 2. heck knife drive timing belt (). It should deflect 14 mm (0.55 in.) when a load of N (5 6.5 lbf) is applied at mid-span Figure 5.1: 40-D Header Right Side 3. Open shield on header left side. 4. heck knife drive timing belt (). It should deflect 14 mm (0.55 in.) when a load of N (5 6.5 lbf) is applied at mid-span. 5. heck knife drive V-belts (). They should deflect 4 mm (3/16 in.) when a load of N (8 12 lbf) is applied to each belt at mid-span. 6. lose shields Figure 5.2: 40-D Header Left Side Revision

92 PERFORMING PREDELIVERY HEKS 5.2 hecking uger Stripper ar learance 1. heck for signs of auger flighting () rubbing stripper bars () after run-up Figure 5.3: uger 2. heck clearance between auger flighting () and stripper bars (). NOTE: The auger flighting () 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 Figure 5.4: End View Diagram Showing uger and Stripper ars Revision

93 PERFORMING PREDELIVERY HEKS 5.3 hecking Reel Tine to Header Pan learance IMPORTNT: The dimensions provided are 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. heck that reel rotates freely. IMPORTNT: If there are a few reel tine fingers that are touching the pan while the rest are at the correct height, trim the longer tines to match the rest. e sure to adjust both sides of the reel. Ensure that tines do NOT contact the plastic header pan Figure 5.5: Reel Tine to Header Pan learance mm ( in.) learance - 2 mm (.08 in.) Minimum to Knife Section - Flex Tines ack When hecking learance Revision

94 PERFORMING PREDELIVERY HEKS 5.4 hecking/djusting Float M Series The windrower float springs are NOT used to level the header. UTION To prevent accidental movement of windrower, return ground speed lever (GSL) to N-DETENT, center steering wheel to lock, shut off engine, and remove key. To adjust the float, follow these steps: 1. heck float by grasping the lean bar and lifting. Lifting force should be N (75 85 lbf) and should be approximately the same at both ends. 2. If necessary, perform the following steps to adjust the float: a. Raise header fully, shut down engine, and remove key. b. Turn drawbolt () clockwise to increase float (makes header lighter) or counterclockwise to decrease float (makes header heavier). c. Recheck the float. Figure 5.6: Drawbolt Top of Windrower Wheel Leg Member Shown Revision

95 PERFORMING PREDELIVERY HEKS 5.5 hecking/djusting Float M1 Series Header float on M1170 and M1240 Self-Propelled Windrowers is completely adjustable from the cab through the Harvest Performance Tracker (HPT). The windrower float springs are NOT used to level the header hecking Float DNGER 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. 1. Start the engine 2. Use the HEDER TILT switches () 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 HEDER DOWN switch (), 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 N (75 85 lbf) and should be the same at both ends Figure 5.7: GSL 6. Restart the engine and adjust float as required. Refer to Setting the Float, page 88. NOTE: Increasing the float value on the Harvest Performance Tracker (HPT) makes the header feel lighter Revision

96 PERFORMING PREDELIVERY HEKS Setting the Float The float can be set for windrowing with the cutterbar on the ground or with the cutterbar off the ground (normally used with the draper header). utterbar on 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 windrower operator s manual. 2. Lower header until 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 5.8: Header Float (utterbar on Ground) 3. Press rotary scroll knob () on HPT to display the QuickMenu system. 4. Rotate scroll knob () to highlight header float icon () and press scroll knob to select Figure 5.9: HPT Run Screen Revision

97 PERFORMING PREDELIVERY HEKS 5. Turn scroll knob () to highlight left () or right () float and press knob () to activate selection. 6. Rotate scroll knob () to adjust float setting and press knob when finished. Float is now set. IMPORTNT: Float adjustments of 1.0 (out of 10) change the header weight at the cutterbar by approximately 91 kg (200 lb.). djust float in increments 0.05 to optimize field performance. D 7. Use soft key 3 (D) to remove/resume float and deck position to previous setting for the attached header Figure 5.10: 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 () on Harvest Performance Tracker (HPT) to display the QuickMenu system or press F1 on the console. 2. Rotate scroll knob () to highlight header float adjust () and press scroll knob to select Figure 5.11: Run Screen HPT Display 3. Press soft key 3 () to remove or restore the header float. NOTE: If the header float is active, the icon at soft key 3 will say REMOVE FLOT; if header float has been removed, the icon will say RESTORE FLOT Figure 5.12: djusting Float HPT Display Revision

98 PERFORMING PREDELIVERY HEKS 5.6 Leveling the Header M Series Windrower linkages are factory-set to provide the proper level for the header and should not normally require adjustment. If the header is NOT level, perform the following checks prior to adjusting the levelling linkages. The float springs are NOT used to level the header. 1. Park windrower on level ground. 2. heck windrower tire pressures. 3. Raise header fully and hold momentarily to allow lift cylinders to rephase. 4. Stop engine and remove key. UTION To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key from ignition before leaving operator s seat for any reason. 5. Place float pins () in locked out position. UTION heck to be sure all bystanders have cleared the area Figure 5.13: Float Pin 6. Start engine and set header approximately 150 mm (6 in.) off ground. heck that member () is against link (). 7. Note high and low end of header Figure 5.14: Member and Link Revision

99 PERFORMING PREDELIVERY HEKS 8. Place wooden blocks () under header cutterbar and legs Figure 5.15: Header on locks 9. Lower header onto blocks so that members () lift off of links (). 10. Shut down engine and remove key Figure 5.16: Member and Link 11. Remove nut, washer, and bolt () that attach shims () to link at the header high end. 12. Remove one or both shims () and reinstall the hardware (). 13. Start engine and raise header slightly. heck level of header. 14. If additional levelling is required, install the removed shim on the opposite linkage. NOTE: If required, additional shims (MD #110854) can be ordered from your MacDon Dealer. NOTE: Float does NOT require adjustment after levelling header. Figure 5.17: Shims Revision

100 PERFORMING PREDELIVERY HEKS 5.7 Leveling the Header M1 Series The windrower lift linkages are factory-set to provide the proper header level, and should not normally require adjustment. If leveling is required, follow these steps: DNGER 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. efore adjusting the header level, remove the float spring tension to ensure that lift linkages are not affected by the springs. 1. Press rotary scroll knob () on Harvest Performance Tracker (HPT) to display the QuickMenu system. 2. Rotate scroll knob () to highlight the header float symbol () and press scroll knob to select. The SET-UP FLOT page displays Figure 5.18: HPT Display 3. Press soft key 3 () to remove float Figure 5.19: HPT Display Revision

101 PERFORMING PREDELIVERY HEKS 4. Park the windrower on level ground. 5. Press the header raise button () on the ground speed lever (GSL). When the header reaches maximum height, continue to hold the header raise button momentarily to allow the lift cylinders to rephase Figure 5.20: GSL 6. Lower the header to approximately 150 mm (6 in.) off the ground. 7. Ensure that member () is against link (). 8. Stop the engine and remove the key from the ignition. 9. Measure the distance to the ground at both ends of the header to determine if the header is level Figure 5.21: Lift Linkage UTION heck to be sure all bystanders have cleared the area. 10. If adjustment is necessary, start engine and resume float. Lower the header onto the ground until member () lifts away from the link () on both sides. 11. Turn off the engine and remove the key Figure 5.22: Lift Linkage Revision

102 PERFORMING PREDELIVERY HEKS 12. On the side that is higher, remove nut, washer, and bolt () that attaches shims () to the linkage. 13. Remove one or both of the shims () and reinstall the hardware (). UTION heck to be sure all bystanders have cleared the area. 14. Repeat Steps 5, page 93 to 9, page 93 to rephase the cylinders and check the header level. 15. If additional adjustment is required, repeat Steps 10, page 93 to 13, page 94, and install one of the removed shims on the opposite linkage. Figure 5.23: Lift Linkage Shims Reset the header float. Refer to Setting the Float, page Revision

103 PERFORMING PREDELIVERY HEKS 5.8 hecking onditioner Rolls UTION 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. Lower header fully, stop engine, and remove key. 2. heck that nut () is tight and top of nut () is at 2 on decal (). 3. If required, adjust gap by loosening nut () and turning adjuster (). Retighten nut (). NOTE: When adjusting roll gap, be sure that the decal reading is the same on both sides of the conditioner roll to achieve consistent intermesh across the rolls Figure 5.24: Roll Gap djustment Hardware 4. Loosen bolt () and rotate cover () to expose access port (). 5. heck roll timing by examining distance X at each end of the rolls (). Each steel bar on one roll should be centered between two bars of the other roll, so that distance X is 12 mm (0.5 in.) X Figure 5.25: ccess Port Exposed Revision

104 PERFORMING PREDELIVERY HEKS If required, adjust the roll timing as follows: 6. Loosen four bolts () in slots of yoke plate on lower roll universal shaft. 7. Turn rolls to achieve best timing. 8. When roll timing is satisfactory, tighten bolts () to secure the position Figure 5.26: Roll Timing djustment Hardware 9. Reposition cover (), and tighten bolt () Figure 5.27: ccess Port overed Revision

105 PERFORMING PREDELIVERY HEKS 5.9 hecking onditioner Gearbox Oil Level 1. Lower header fully, stop engine, and remove key. NOTE: heck that gearbox is level with ground. 2. Remove check plug () and ensure that oil runs out. If oil does not run, fill conditioner gearbox using SE 85W Replace check plug () Figure 5.28: heck Plug Revision

106 PERFORMING PREDELIVERY HEKS 5.10 hecking Skid Shoes / Gauge Rollers WRNING To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key, and engage safety props before going under machine. 1. Raise header and engage safety props. 2. heck that pins () are installed in the same position in all skid shoes/gauge rollers Figure 5.29: Skid Shoe Figure 5.30: Gauge Roller Revision

107 PERFORMING PREDELIVERY HEKS 5.11 hecking Lights Hazard lights, which are mounted on both ends of the header, are activated by switches in the windrower cab. 1. heck that pivot bolt () is tight enough to hold light support () in upright position, yet will permit the light to pivot out of the way of obstructions Figure 5.31: Hazard Light Revision

108 PERFORMING PREDELIVERY HEKS 5.12 Running Up Header UTION Never start or move the machine until you are sure all bystanders have cleared the area. lear the area of other persons, pets etc. Keep children away from machinery. Walk around the machine to be sure no one is under, on, or close to it. efore investigating an unusual sound or attempting to correct a problem, return ground speed lever (GSL) to N-DETENT, center steering wheel to lock, shut off engine, and remove key. Refer to your windrower unloading and assembly instructions or your windrower operator s manual. 1. Start windrower and operate header slowly for 5 minutes, watching and listening FROM THE WINDROWER SET for binding, interfering parts, or unusual noises. 2. Run the machine for 15 minutes at maximum engine operating rpm and perform the run-up check as listed on the Predelivery hecklist (yellow sheet attached to this manual Predelivery hecklist, page 123) to ensure machine is field-ready. 3. heck knife speed in the windrower cab display module (DM) during run-up and adjust knife speed to maximum on the DM. Knife speed should be 1950 spm (actual speed of knife drive box pulley [] should be 975 rpm) with the engine at maximum operating rpm. 4. If speed is incorrect, check the header ID in the windrower DM. The header drive pump may also require adjusting. Refer to 5.13 hecking Knife Speed, page Figure 5.32: Right End of Header Revision

109 PERFORMING PREDELIVERY HEKS 5.13 hecking Knife Speed 40-D Refer to the following sections to check header knife speed when attaching an 40-D uger Header to an M100 or M105 Windrower. Refer to windrower operator s manual to check header knife speed in windrower cab display module (DM) when attaching an 40-D uger Header to an M150, M155, M155E4, M200, or M205 Windrower. 40-DX Refer to windrower operator s manual to check header knife speed on Harvest Performance Tracker (HPT) when attaching an 40-DX uger Header to an M1170 or M1240 Windrower Setting Knife Speed on an M100 or M105 The knife speed is manually set by making adjustments to the knife drive pump and has been preset at the lowest knife rpm. For optimum performance, set the knife speed within the range specified. Refer to Table 5.1, page 101. NOTE: When attaching an 40-D uger Header to an M100 or M105 Windrower for the first time, knife speed should be set to the MXIMUM setting. Table D uger Header Knife Speed Header Description Type Size Knife Speed Minimum Maximum rpm 6 spm 7 rpm 6 spm 7 uger 40-D ll rpm = speed of knife drive box pulley (revolutions per minute) 7. spm = strokes per minute of knife (rpm x 2) Revision

110 PERFORMING PREDELIVERY HEKS Setting Knife Speed (with Expansion Module MD #4666) DNGER 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. 1. Press SELETOR button () on the ground speed lever (GSL) until the DM () displays the knife speed in SPM (strokes per minute). This indicates that optional expansion module MD #4666 is installed. 2. If knife speed is NOT displayed, the optional expansion module is not installed, proceed to Setting Knife Speed (without Expansion Module MD #4666), page ompare reading to Table 5.1, page Figure 5.33: Operator onsole If required, adjust knife speed as follows: 4. Shut down engine, and open engine hood. 5. Locate the knife drive pump () and knife speed adjuster screw () under the right (cab-forward) side of the windrower. NOTE: The knife speed adjuster screw may have a plastic cap () covering it. Pull this cap off to expose the screw Figure 5.34: Knife Drive Pump Revision

111 PERFORMING PREDELIVERY HEKS 6. Loosen jam nut (). 7. Turn adjuster screw () clockwise (screw in) to decrease knife speed, and counterclockwise (screw out) to increase the knife speed. NOTE: One turn of the adjuster screw () will change the knife speed by approximately 116 strokes per minute (spm), or the knife drive box pulley speed by 58 revolutions per minute (rpm). 8. Once adjustment has been made, torque jam nut (). 9. lose hood, start engine, and recheck knife speed. Figure 5.35: Knife Speed djuster Screw Setting Knife Speed (without Expansion Module MD #4666) 1. heck header knife drive box pulley speed with a handheld tachometer. 2. Multiply the rpm reading by two to obtain the knife speed in strokes per minute. 3. ompare reading to Table 5.1, page If required, adjust knife speed. Refer to Step 4, page Figure 5.36: Knife Drive ox on Header Revision

112 PERFORMING PREDELIVERY HEKS 5.14 djusting Knife and Guards WRNING To avoid bodily injury or death from unexpected startup of machine, always stop engine and remove key before making adjustments to machine. 1. Stop engine and remove key. 2. heck guards for signs of heating during run-up due to insufficient clearance between guard and knife. 3. If heating is evident, check gap between knifehead () and pitman arm (). business card should slide easily through gap. If not, adjust gap by loosening bolt and tapping knifehead () with a hammer. Retighten bolt Figure 5.37: Knifehead and Pitman rm 4. djust guard alignment as necessary using guard straightening tool (MD #140135). djust guard tips upwards by positioning tool as shown and pulling up Figure 5.38: Guard Tips Upward djustment Revision

113 PERFORMING PREDELIVERY HEKS 5. djust guard tips downward by positioning tool as shown and pushing down. Figure 5.39: Guard Tips Downward djustment Revision

114 PERFORMING PREDELIVERY HEKS 5.15 hecking Manuals The manual case is located inside the right endshield. 1. Open the right endshield () and remove cable tie () from manual case () Figure 5.40: Manual ase 2. -Series manuals are shipped with shipping documents and auger header unloading and assembly instructions. e sure to place the following manuals in the manual case: -Series uger Header Quick ard -Series Operator s Manual -Series Parts atalog 3. Replace cable tie on manual case and close endshield Figure 5.41: Manuals Revision

115 6 Reference 6.1 Recommended Torques Torque Specifications The following tables provide correct torque values for various bolts, cap screws, and hydraulic fittings. Tighten all bolts to torque values specified in charts (unless otherwise noted throughout this manual). Replace hardware with same strength and grade of bolt. Use torque value tables as a guide and periodically check tightness of bolts. Understand torque categories for bolts and cap screws by using their identifying head markings. Jam nuts When applying torque to finished jam nuts, multiply the torque applied to regular nuts by f=0.65. Self-tapping screws Standard torque is to be used (not to be used on critical or structurally important joints). SE olt Torque Specifications Torque values shown in following tables are valid for non-greased, or non-oiled threads and heads; therefore, do NOT grease or oil bolts or cap screws unless otherwise specified in this manual. Table 6.1 SE Grade 5 olt and Grade 5 Free Spinning Nut Nominal Size () Torque (lbf ft) Torque (Nm) (*lbf in) Min. Max. Min. Max. 1/ *106 *117 5/ *218 *241 3/ / / / / / / Figure 6.1: olt Grades - Nominal Size - SE-5 D - SE-8 D - SE Revision

116 REFERENE Table 6.2 SE Grade 5 olt and Grade F Distorted Thread Nut Nominal Size () Torque (lbf ft) Torque (Nm) (*lbf in) Min. Max. Min. Max. 1/ *72 *80 5/ *149 *164 3/ / / / / / Figure 6.2: olt Grades - Nominal Size - SE-5 D - SE-8 D - SE / Table 6.3 SE Grade 8 olt and Grade G Distorted Thread Nut Nominal Size () Torque (lbf ft) Torque (Nm) (*lbf in) Min. Max. Min. Max. 1/ *150 *165 5/ / / D 1/ / / / Figure 6.3: olt Grades - Nominal Size - SE-5 - SE-8 D - SE / Revision

117 REFERENE Table 6.4 SE Grade 8 olt and Grade 8 Free Spinning Nut Nominal Size () Torque (lbf ft) Torque (Nm) (*lbf in) Min. Max. Min. Max. 1/ *150 *165 5/ / / / / / / Figure 6.4: olt Grades - Nominal Size - SE-5 D - SE-8 D - SE / Metric olt Specifications Table 6.5 Metric lass 8.8 olts and lass 9 Free Spinning Nut Nominal Size () Torque (Nm) Torque (lbf ft) (*lbf in) Min. Max. Min. Max *13 * *20 * *29 * *59 * *101 * Figure 6.5: olt Grades Revision

118 REFERENE Table 6.6 Metric lass 8.8 olts and lass 9 Distorted Thread Nut Nominal Size () Torque (Nm) Torque (lbf ft) (*lbf in) Min. Max. Min. Max *9 * *14 * *20 * *40 * *69 * *167 * Table 6.7 Metric lass 10.9 olts and lass 10 Free Spinning Nut Nominal Size () Torque (Nm) Torque (lbf ft) (*lbf in) Min. Max. Min. Max *18 * *27 * *41 * *82 * *140 * Figure 6.6: olt Grades Figure 6.7: olt Grades Revision

119 REFERENE Table 6.8 Metric lass 10.9 olts and lass 10 Distorted Thread Nut Nominal Size () Torque (Nm) Torque (lbf ft) (*lbf in) Min. Max. Min. Max *12 * *19 * *28 * *56 * *95 * Figure 6.8: olt Grades Revision

120 REFERENE Metric olt Specifications olting into ast luminum Table 6.9 Metric olt olting into ast luminum olt Torque Nominal Size () 8.8 (ast luminum) 10.9 (ast luminum) Nm lbf ft Nm lbf ft M3 1 M M M M M M M14 M16 Figure 6.9: olt Grades Flare-Type Hydraulic Fittings 1. heck flare () and flare seat () for defects that might cause leakage. 2. lign tube () with fitting (D) and thread nut (E) onto fitting without lubrication until contact has been made between flared surfaces. 3. Torque fitting nut (E) to specified number of flats from finger tight (FFFT) or to a given torque value in Table 6.10, page Use two wrenches to prevent fitting (D) from rotating. Place one wrench on fitting body (D), and tighten nut (E) with other wrench to torque shown. 5. ssess final condition of connection. E Figure 6.10: Hydraulic Fitting D Table 6.10 Flare-Type Hydraulic Tube Fittings Torque Value 8 Flats from Finger Tight (FFFT) SE Dash Size Thread Size (in.) Swivel Nut or Nm lbf ft Tube Hose -2 5/ / / / / Torque values shown are based on lubricated connections as in reassembly Revision

121 REFERENE Table 6.10 Flare-Type Hydraulic Tube Fittings (continued) Torque Value 9 Flats from Finger Tight (FFFT) SE Dash Size Thread Size (in.) Swivel Nut or Nm lbf ft Tube Hose -6 9/ /2-8 3/ /2-10 7/ /2 1-1/ / /2 1-1/ / /2 1-1/ / / / / / Torque values shown are based on lubricated connections as in reassembly Revision

122 REFERENE O-Ring oss (OR) Hydraulic Fittings (djustable) 1. Inspect O-ring () and seat () for dirt or obvious defects. 2. ack off lock nut () as far as possible. Ensure that washer (D) is loose and is pushed toward lock nut () as far as possible. 3. heck that O-ring () is NOT on threads and adjust if necessary. 4. pply hydraulic system oil to O-ring (). D Figure 6.11: Hydraulic Fitting 5. Install fitting () into port until back up washer (D) and O-ring () contact part face (E). 6. Position angle fittings by unscrewing no more than one turn. 7. Turn lock nut () down to washer (D) and tighten to torque shown. Use two wrenches, one on fitting () and other on lock nut (). 8. heck final condition of fitting. D E Figure 6.12: Hydraulic Fitting Revision

123 REFERENE Table 6.11 O-Ring oss (OR) Hydraulic Fittings (djustable) Torque Value 10 SE Dash Size Thread Size (in.) Nm lbf ft (*lbf in) -2 5/ * / * / / / / / / / / / / / Torque values shown are based on lubricated connections as in reassembly Revision

124 REFERENE O-Ring oss (OR) Hydraulic Fittings (Non-djustable) 1. Inspect O-ring () and seat () for dirt or obvious defects. 2. heck that O-ring () is NOT on threads and adjust if necessary. 3. pply hydraulic system oil to O-ring. 4. Install fitting () into port until fitting is hand tight. 5. Torque fitting () according to values in Table 6.12, page heck final condition of fitting Figure 6.13: Hydraulic Fitting Table 6.12 O-Ring oss (OR) Hydraulic Fittings (Non-djustable) SE Dash Size Thread Size (in.) Torque Value 11 Nm lbf ft (*lbf in) -2 5/ * / * / / / / / / / / / / / Torque values shown are based on lubricated connections as in reassembly Revision

125 REFERENE O-Ring Face Seal (ORFS) Hydraulic Fittings 1. heck components to ensure that sealing surfaces and fitting threads are free of burrs, nicks, scratches, or any foreign material Figure 6.14: Hydraulic Fitting 2. pply hydraulic system oil to O-ring (). 3. lign tube or hose assembly so that flat face of sleeve () or () comes in full contact with O-ring (). D 4. Thread tube or hose nut (D) until hand-tight. The nut should turn freely until it is bottomed out. 5. Torque fittings according to values in Table 6.13, page 117. NOTE: If applicable, hold hex on fitting body (E) to prevent rotation of fitting body and hose when tightening fitting nut (D). 6. Use three wrenches when assembling unions or joining two hoses together. Figure 6.15: Hydraulic Fitting E heck final condition of fitting. Table 6.13 O-Ring Face Seal (ORFS) Hydraulic Fittings SE Dash Size Thread Size (in.) Tube O.D. (in.) Torque Value 12 Nm lbf ft -3 Note 13 3/16-4 9/16 1/ Note 13 5/ /16 3/ /16 1/ / /16 3/ Torque values and angles shown are based on lubricated connection as in reassembly. 13. O-ring face seal type end not defined for this tube size Revision