MacDon A30-S Unloading And Assembly Instructions
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MacDon A30-S Unloading And Assembly Instructions

Auger self-propelled windrower header
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A30-S and A40-D Auger
Self-Propelled Windrower Header
Unloading and Assembly Instructions
Published: August, 2012
169078
Revision E

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  • Page 1 A30-S and A40-D Auger Self-Propelled Windrower Header Unloading and Assembly Instructions Published: August, 2012 169078 Revision E...
  • Page 2 INTRODUCTION This instructional manual describes the unloading, set-up and pre-delivery requirements for the MacDon Model A30-S and A40-D Auger Headers, including a Grass Seed version. Use the Table of Contents to guide you to specific areas. CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE, OR USE THE MACHINE.

  • Page 3: Table Of Contents

      STEP 13. ATTACH HEADER TO WINDROWER ..................... 18     STEP 14. MODIFY HYDRAULICS ........................23     A30-S ............................23     A40-D ............................23     STEP 15. CONFIGURE REVERSER VALVE JUMPER HOSE ............... 29    ...

  • Page 4: Introduction

    SAFETY GENERAL SAFETY CAUTION following general farm safety precautions that should part your operating procedure for all types of machinery.  Provide a first-aid kit for use in case of emergencies.  Protect yourself.  Keep a fire extinguisher on the machine. ...
  • Page 5 SAFETY  Do not modify the machine. Unauthorized modifications may impair the function and/or safety and affect machine life.  Stop engine, and remove key from ignition before leaving Operator's seat for any reason. A child or even a pet could engage an idling machine.

  • Page 6: Recommended Torques

    GENERAL RECOMMENDED TORQUES C. METRIC BOLTS STD COARSE BOLT TORQUE* A. GENERAL BOLT 10.9 DIA. "A" The tables shown below give correct torque lbf·ft N·m lbf·ft N·m values for various bolts and capscrews.  Tighten all bolts to the torques specified in chart, unless otherwise noted throughout this manual.

  • Page 7: Hydraulic Fittings

    GENERAL O-RING TYPE D. HYDRAULIC FITTINGS FITTING LOCKNUT FLARE TYPE WASHER O-RING FLARE GROOVE SEAT BODY FLARESEAT a. Inspect O-ring and seat for dirt or obvious a. Check flare and flare seat for defects that might defects. cause leakage. b. Align tube with fitting before tightening. c.
  • Page 8 GENERAL a. Check components to ensure that the sealing O-RING FACE SEAL (ORFS) HYDRAULIC surfaces and fitting threads are free of burrs, FITTINGS nicks, and scratches, or any foreign material. b. Apply lubricant (typically Petroleum Jelly) to O-ring and threads. If O-ring is not already installed, install O-ring.

  • Page 9: Conversion Chart

    GENERAL CONVERSION CHART INCH-POUND UNITS SI UNITS (METRIC) QUANTITY FACTOR UNIT NAME ABBR. UNIT NAME ABBR. Area acres acres x 0.4047 = hectares Flow US gallons per minute x 3.7854 = liters per minute L/min Force pounds force x 4.4482 = Newtons inch x 25.4 =...

  • Page 10: Step 1. Unload Header

    UNLOADING AND ASSEMBLY STEP 1. UNLOAD HEADER CAUTION To avoid injury to bystanders from being struck by machinery, do not allow persons to stand in unloading area. CAUTION Equipment used for unloading must meet or exceed the requirements specified below. TOPSIDE Using inadequate equipment may result in chain breakage, vehicle tipping or machine...

  • Page 11: Step 2. Remove Underside Shipping Stand

    UNLOADING AND ASSEMBLY STEP 2. REMOVE UNDERSIDE SHIPPING STAND CAUTION Keep feet clear when removing final bolts. d. Insert tabs on skid shoe into slots (E) on cutterbar at inboard mounting locations on a. Remove four bolts (A), and remove shipping frame, and secure with clevis pin (C).

  • Page 12: Step 4. Install Gauge Rollers

    UNLOADING AND ASSEMBLY e. Attach clips (B) with bolts and nuts removed at STEP 4. INSTALL GAUGE step c. to secure roller assembly to cutterbar. ROLLERS Tighten nuts. NOTE If kit is not supplied proceed to STEP 5. LOWER Use a socket and ratchet wrench to HEADER.

  • Page 13: Step 5. Lower Header

    UNLOADING AND ASSEMBLY IMPORTANT STEP 5. LOWER HEADER See table below for minimum chain specifications. Also, chain length must be a. Attach either a spreader bar or chain to forks. sufficient to provide a minimum 4 feet (1.2 m) vertical chain height. CAUTION Overhead Lifting Chain Type...

  • Page 14: Step 6. Remove Shipping Stands

    UNLOADING AND ASSEMBLY STEP 6. REMOVE SHIPPING STANDS h. Remove lynch pin from clevis pin (C) in header stand at right side of header. Hold stand (D), and remove clevis pin (C). a. Remove two bolts (E) from shipping stand (F). b.

  • Page 15: Step 7. Install Tall Crop Divider

    UNLOADING AND ASSEMBLY STEP 7. INSTALL TALL CROP DIVIDER If kit is not supplied, proceed to STEP 8. ADJUST LEAN BAR. Otherwise, proceed as follows: d. Attach LH divider assembly (E) to LH end of a. Remove hardware on both sides of lean bar, lean bar with two bolts (F) and nuts provided.

  • Page 16: Step 8. Adjust Lean Bar

    UNLOADING AND ASSEMBLY STEP 8. ADJUST LEAN BAR NARROW a. Lean bar is fully retracted for shipping. Remove hardware on both sides, and install lean bar in field position at position suitable for crop (normally 2/3 of the crop height). b.

  • Page 17: Step 11. Assemble Forming Shield

    UNLOADING AND ASSEMBLY Tighten jam nut (D) against cover while holding STEP 11. ASSEMBLE FORMING bolt (B). SHIELD a. Unpack and remove shipping material. b. Lay cover (A) upside down on a flat surface. g. Remove lynch pin (G) from adjuster rod (H), and locate rod in hole in side deflector (C).

  • Page 18: Step 12. Install Forming Shield

    UNLOADING AND ASSEMBLY STEP 12. INSTALL FORMING SHIELD a. Remove header from the windrower (if attached) for ease of installing the forming shield. NOTE Do not install the two triangular shaped plates. e. Locate forming shield onto bolts windrower legs, and secure with clevis pins (C) and lynch pin.
  • Page 19 UNLOADING AND ASSEMBLY BOTH SIDES g. Set forming shield side deflectors to desired width by re-positioning adjuster bars (F). Use the same hole location on both sides.  Position deflectors at the narrowest setting for a narrow windrow (silage for example).

  • Page 20: Step 13. Attach Header To Windrower

    UNLOADING AND ASSEMBLY STEP 13. ATTACH HEADER TO WINDROWER REEL DOWN REEL UP HEADER UP HEADER TILT UP HEADER TILT DOWN HEADER DOWN b. Start windrower engine, and activate HEADER DOWN button on the GSL to fully retract header lift cylinders. IMPORTANT a.
  • Page 21 UNLOADING AND ASSEMBLY 2. Without the self-alignment kit, re-locate the pin (G) at the frame linkage as required to raise the center-link (E). 1. Adjust position of the center-link cylinder (E) with the REEL UP and REEL DOWN switches, and HEADER TILT switches on the GSL to position the hook above the header attachment pin.
  • Page 22 UNLOADING AND ASSEMBLY HYDRAULIC LINK WITHOUT MECHANICAL LINK SELF-ALIGNMENT KIT DANGER Stop engine, and remove key from ignition before leaving Operator's seat for any REEL DOWN REEL UP reason. A child or even a pet could engage an idling machine. 1.
  • Page 23 UNLOADING AND ASSEMBLY IMPORTANT DANGER Ensure pin (N) is fully inserted, and hairpin is installed behind bracket. To avoid bodily injury from fall of raised header, always engage header lift cylinder stops when working on or around raised header, and before going under header for any reason.
  • Page 24 UNLOADING AND ASSEMBLY CAUTION Check to be sure all bystanders have cleared the area. REEL DOWN REEL UP HEADER UP HEADER TILT UP HEADER TILT DOWN HEADER DOWN p. Start engine, and activate HEADER DOWN switch on GSL to lower header fully. 169078 Revision E...

  • Page 25: Step 14. Modify Hydraulics

    UNLOADING AND ASSEMBLY STEP 14. MODIFY HYDRAULICS A. A30-S The M100, M105, M150 and M155 are factory- configured with A30-S header hydraulics and electrical harness. Proceed to STEP 15. CONFIGURE REVERSER VALVE JUMPER HOSE. M200 hydraulics need to be reconfigured to run an A Series header.
  • Page 26 UNLOADING AND ASSEMBLY 4. Install large coupler (O) onto fitting at port ‘R1’ on valve block (D). IMPORTANT Make sure O-ring is on JIC threads in port ‘R1’ to ensure a proper seal with the coupler (O). If O-ring is missing, re-use O-ring from fitting (N). SMALL COUPLER ASSEMBLY (G) 5.
  • Page 27 UNLOADING AND ASSEMBLY II. M150, M155 a. Open LH maintenance platform, and modify valve blocks as follows: WITH REVERSER VALVE WITH REVERSER VALVE WITHOUT REVERSER VALVE 3. Install smaller coupler assembly (C) in ‘R2’ port in valve block (A), and the larger coupler assembly (D) in ‘R2’...
  • Page 28 UNLOADING AND ASSEMBLY III. M200 M200 WITH REVERSER VALVE IMPORTANT For windrowers with Reverser Kit B4656: To prevent draper header reel damage improper operation: switching between A40 Auger Header and Draper Header, hose plumbing to reverser valve must be changed to suit the header type.
  • Page 29 UNLOADING AND ASSEMBLY M200 WITHOUT REVERSER VALVE WITHOUT REVERSER VALVE d. Install larger coupler (H) onto fitting at port ‘R2’ on valve block (B). e. Remove cap from smaller coupler assembly (C) and install assembly in port ‘R2’ on valve (A). IMPORTANT Make sure O-ring is on JIC threads in port ‘R1’...
  • Page 30 UNLOADING AND ASSEMBLY IV. M205 a. The M205 hydraulics need to be modified to accept an A Series auger header, and kits B5491, B5492, and B5497 should have been supplied with your header. AUGER HEADER HYDRAULICS b. Install kits in accordance with the instructions that were supplied with the kits to achieve the configuration shown above.

  • Page 31: Step 15. Configure Reverser Valve Jumper Hose

    Move LH windrower platform to open position to expose hydraulic valve blocks. VALVE JUMPER HOSE c. To route hose (B) from A40-D position to A30-S An optional valve block to reverse the header drive position: in the event of plugging may have been installed on the M150, M155, and M200 windrowers.
  • Page 32 UNLOADING AND ASSEMBLY d. To route hose (B) from A30-S position to A40-D position: 1. Disconnect jumper hose (B) at 90° fitting in port ‘R4’. 2. Rotate 90° fitting (D) under reverser valve block (A) so that hose can be routed to port ‘C2’...

  • Page 33: Step 16. Attach Hydraulics

    UNLOADING AND ASSEMBLY STEP 16. ATTACH HYDRAULICS A. A30-S DANGER Stop engine, and remove key from ignition before leaving Operator's seat for any reason. A child or even a pet could engage an idling machine. d. Move hose bundle (E) to header.
  • Page 34 UNLOADING AND ASSEMBLY RETURN CASE DRAIN HEADER DRIVE Push hose connectors onto mating receptacles as shown until collars on receptacles snap into lock position. k. Activate header tilt cylinder switches to extend and retract center-link. Check for sufficient clearance between hoses electrical harness.
  • Page 35 UNLOADING AND ASSEMBLY B. A40-D DANGER Stop engine, and remove key from ignition before leaving Operator's seat for any reason. A child or even a pet could engage an idling machine. d. Move hose bundle (E) to header. e. Rotate lever (D) clockwise, and engage in bracket to store.
  • Page 36 UNLOADING AND ASSEMBLY If not already installed, install Velcro straps on windrower as follows: REEL and AUGER PRESSURE 1. Retrieve package of three Velcro straps shipped with the header. KNIFE and CONDITIONER RETURN CASE DRAIN KNIFE and CONDITIONER PRESSURE STANDARD HEADER AUGER and REEL KNIFE RETURN PRESSURE...
  • Page 37 UNLOADING AND ASSEMBLY III. M200 o. Connect auger/reel pressure and reel/auger return hoses from header to receptacles on windrower valve block. Refer to applicable section below for your equipment: REEL/AUGER RETURN M100, M105 AUGER PRESSURE REEL/AUGER RETURN M200 WITHOUT REVERSER VALVE AUGER/REEL PRESSURE REEL/AUGER RETURN REEL/AUGER RETURN...

  • Page 38: Step 17. Configure Hose Routing: A-40D Only

    UNLOADING AND ASSEMBLY d. Re-connect hoses as follows: STEP 17. CONFIGURE HOSE ROUTING: A-40D ONLY The A40-D header drive hose routing depends on the windrower model to which the header is being attached. M100 / M105 / M205 1. Relocate tee (E) to upper port. 2.

  • Page 39: Step 19. Lubricate Header

    Refer to illustrations on following pages for c. Leave excess grease on fitting to keep out dirt. lubrication points. A30-S HEADER RH SIDE High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base.
  • Page 40 UNLOADING AND ASSEMBLY LUBRICATE HEADER (cont’d) A30-S HEADER LH SIDE High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base. AUGER DRIVE BEARING - 1 PLC REEL SHAFT BEARING - 1 PLC SICKLE HEAD BEARING - 1 PLC...
  • Page 41 UNLOADING AND ASSEMBLY LUBRICATE HEADER (cont’d) A40-D HEADER LH SIDE High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base. TINE BAR BEARING (4 PLCS EACH TINE BAR) SICKLE DRIVE BEARING - 1 PLC SICKLE HEAD BEARING - 1 PLC GAUGE ROLLER BEARINGS - 2 PLCS NOTE...
  • Page 42 UNLOADING AND ASSEMBLY LUBRICATE HEADER (cont’d) A40-D HEADER RH SIDE High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base. REEL SHAFT BEARING - 1 PLC SICKLE DRIVE BEARING - 1 PLC SICKLE HEAD BEARING - 1 PLC AUGER SHAFT BEARING - 1 PLC NOTE To prevent binding and/or excessive...
  • Page 43 UNLOADING AND ASSEMBLY LUBRICATE HEADER (cont’d) HAY CONDITIONER High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base. ROLL PIVOT (1 PLC - BOTH SIDES) ROLL SHAFT BEARINGS - 2 PLCS ROLL SHAFT BEARINGS - 2 PLCS 169078 Revision E...
  • Page 44 LUBRICATE HEADER (cont’d) DRIVELINES High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide A30-S (NLGI Grade 2) Lithium Base. DRIVELINE UNIVERSALS - 2 PLCS 10% MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINTS ONLY CROSS SHAFT - 1 PLC...
  • Page 45 OIL KNIFE DAILY EXCEPT IN SANDY SOIL AUGER DRIVE CHAIN - 1 PLC REEL DRIVE CHAIN - 1 PLC SICKLE DRIVE BOX (A30-S - 1 PLC) (A30-D/A40-D - 2 PLCS) (CHECK OIL LEVEL WITH TOP OF CHECK ROLL GEARBOX - 1 PLC SICKLE DRIVE BOX HORIZONTAL)

  • Page 46: Step 20. Perform Pre-Delivery Checks

    PRE-DELIVERY CHECKS STEP 20. PERFORM PRE- DELIVERY CHECKS DANGER Stop engine, and remove key from ignition before leaving Operator's seat for any reason. A child or even a pet could engage an idling machine. IMPORTANT To avoid machine damage, check that no shipping dunnage fallen...

  • Page 47: Drive Belts And Drive Chains

    Refer to the appropriate section for your particular header. I. A30-S SINGLE KNIFE a. Open shield on header RH side. A40-D b. Sickle drive timing belt (M) should deflect 0.55 inch (14 mm) when a load of 5–6.5 lbf (22–30 N) is applied at mid-span).

  • Page 48: Auger Stripper Bar Clearance

    PRE-DELIVERY CHECKS B. AUGER STRIPPER BAR C. REEL TINE TO HEADER PAN CLEARANCE CLEARANCE FLEX TINE BACK 0.08 in. (2 mm) 0.08–0.39 in. (2–10 mm) IMPORTANT The above dimensions are provided as guidelines only. Tines may slightly contact the guards but not the knife a.

  • Page 49: Header Flotation

    PRE-DELIVERY CHECKS D. HEADER FLOTATION The windrower float springs are not used to level the header. To adjust float, proceed as follows: a. Check float by grasping the lean bar and lifting. force lift should 75–85 (335–380 N), and should be approximately the same at both ends.

  • Page 50: Header Levelling

    PRE-DELIVERY CHECKS E. HEADER LEVELLING 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 leveling linkages. The float springs are not used to level the header.

  • Page 51: Conditioner Rolls

    PRE-DELIVERY CHECKS F. CONDITIONER ROLLS = 0.5 in. (12 mm) DANGER Stop engine, and remove key from ignition before leaving Operator's seat for any reason. A child or even a pet could engage an idling machine. a. Lower header fully, stop engine, and remove key.

  • Page 52: Skid Shoes/Gauge Rollers

    PRE-DELIVERY CHECKS G. SKID SHOES/GAUGE ROLLERS H. LIGHTS Hazard lights, which are mounted on both ends WARNING of the header, are activated by switches in the M Series windrower cab. avoid bodily injury death from Check for operation during run-up. unexpected start-up or fall of raised machine, stop engine, remove key and engage lift cylinder lockout valves before going under...

  • Page 53: Run-Up The Header

    Position tool as shown, and pull up. c. Check actual speed of sickle drive box pulley using a hand-held optical tachometer during run-up. Speed should be 775 rpm for A30-S, and 950 rpm for A40-D with the engine at maximum operating rpm.

  • Page 54: Manuals

    PRE-DELIVERY CHECKS K. MANUALS a. Place the following in storage case in the windrower cab:  A Series Auger Header Quick Card (MD Part # 169407)  Operator’s Manual (MD Part # 169000/ 169040)  Parts Catalog (MD Part # 169002) b.
  • Page 55 NOTES 169078 Revision E...
  • Page 56 MacDon Inc. 10708 N. Pomona Avenue Kansas City, Missouri United States 64153-1924 t. (816) 891-7313 f. (816) 891-7323 MacDon Australia Pty. Ltd. A.C.N. 079 393 721 P.O. Box 243 Suite 3, 143 Main Street Greensborough, Victoria Australia 3088 t. 03 9432 9982 f.

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A40-d

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