MacDon A30-S Operator's Manual
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MacDon A30-S Operator's Manual

Pull-type mower conditioners, self-propelled auger headers
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A30-S and A30-D
Pull-Type Mower Conditioners
A30-S, A30-D and A40-D
Self-Propelled Auger Headers
OPERATOR'S MANUAL
Part #169000 Rev. D
$15

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Summary of Contents for MacDon A30-S

  • Page 1 A30-S and A30-D Pull-Type Mower Conditioners A30-S, A30-D and A40-D Self-Propelled Auger Headers OPERATOR’S MANUAL Part #169000 Rev. D...
  • Page 2 MACDON A40-D SELF-PROPELLED AUGER HEADER MACDON A30-D PULL-TYPE MOWER CONDITIONER...

  • Page 3: Introduction

    1 INTRODUCTION This instructional manual describes the operating and maintenance procedures for the Model A30-S, A30-D, and A40-D Auger Headers, including a Grass Seed version. Your new Auger Header is designed to cut, condition, and lay in windrows a wide variety of grasses and hay crops. The available Double Knife feature expands the operational envelope, especially in heavier crops.

  • Page 4: Table Of Contents

      6.6.3 Configure Reverser Valve Jumper Hose .................. 46     HEADER DETACHMENT: SELF-PROPELLED ................48     6.7.1 A30-S, A30-D Detachment ......................48     6.7.2 A40-D Detachment ........................49     TRANSPORTING MOWER CONDITIONER ..................51    ...
  • Page 5 UNPLUGGING THE HEADER / MOWER CONDITIONER .............. 64     6.16.1 Unplugging Conditioner: Pull Type ................... 64     6.16.2 Unplugging Conditioner: Self-Propelled - A30-S and A30-D ............ 64     6.16.3 Unplugging Sickle ........................64     6.17 HEADER OPERATION ........................65  ...
  • Page 6 Reel Drive Chain: A30-S, A30-D ..................... 145     7.9.2 Reel Drive Belts: A30-S, A30-D ....................146     7.9.3 Reel Tines and Tine Bar Bearings: A30-S, A30-D ..............147     7.10 REEL AND REEL DRIVE: A40-D ....................149     7.10.1 Reel Drive: A40-D ........................
  • Page 7   ADDITIONAL SKID SHOES ......................186     GAUGE ROLLER KIT ........................186     REPLACEMENT REEL BAT KITS: A30-S, A30-D ................. 186     STUB GUARD CONVERSION KIT ....................186     TALL CROP DIVIDER KIT ......................186  ...

  • Page 8: Safety

    SECTION 2 SAFETY 2 SAFETY WARNING 2.1 SAFETY ALERT SYMBOL Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It is also used to alert against unsafe practices. CAUTION Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.

  • Page 9: 3-Panel Safety Sign Locations: Pull-Type

    SECTION 2 SAFETY 2.3.2 3-Panel Safety Sign Locations: Pull- Type #170281 #36651 - DRIVELINES -#142909 - BOTH ENDS #140311 - BOTH SIDES Form 169000 / 169040 Revision D...
  • Page 10 SECTION 2 SAFETY 3-Panel Safety Sign Locations: Pull-Type (cont’d) #115100 - BOTH SIDES #109843 #44944 #171029 #30316 Form 169000 / 169040 Revision D...
  • Page 11 SECTION 2 SAFETY 3-Panel Safety Sign Locations: Pull-Type (cont’d) #142908 - BACK-SIDE #44944 #142912 #28403 - BOTH ENDS #115148 #32738 - BOTH ENDS Form 169000 / 169040 Revision D...

  • Page 12: 3-Panel Safety Sign Locations: Self-Propelled

    SECTION 2 SAFETY 2.3.3 3-Panel Safety Sign Locations: Self- Propelled #134070 #109843 #170281 #36651 - DRIVELINES #142909 BOTH ENDS Form 169000 / 169040 Revision D...
  • Page 13 SECTION 2 SAFETY 3-Panel Safety Sign Locations: Self-Propelled (cont’d) #32738 #28403 Form 169000 / 169040 Revision D...

  • Page 14: 2-Panel Safety Sign Locations: Self-Propelled

    SECTION 2 SAFETY 2.3.4 2-Panel Safety Sign Locations: Self- Propelled #174474 #184372 #184385 #194521 DRIVELINES #194464 Form 169000 / 169040 Revision D...
  • Page 15 SECTION 2 SAFETY 2-Panel Safety Sign Locations: Self-Propelled (cont’d) #174632 #184371 #184371 - BOTH ENDS Form 169000 / 169040 Revision D...

  • Page 16: General Safety

    SECTION 2 SAFETY 2.4 GENERAL SAFETY CAUTION following general farm safety precautions that should be part of your operating procedure types machinery.  Provide a first-aid kit for use in case of  Protect yourself. emergencies.  When assembling, operating ...
  • Page 17 SECTION 2 SAFETY  Use only service and repair parts made approved equipment manufacturer. Substituted parts may not meet strength, design, safety requirements.  Do not modify the machine. Unauthorized modifications may impair the function and/or safety and affect machine life. ...

  • Page 18: Definitions

    SECTION 3 DEFINITIONS 3 DEFINITIONS The following terms may be used in this manual: TERM DEFINITION American Petroleum Institute Articulating Power Tongue American Society Of Testing And Materials ASTM Cab-Forward Windrower operation with the Operator and cab facing in the direction of travel. A hydraulic cylinder or turnbuckle type link between header and the machine that Center Link tilts the header.

  • Page 19: Component Identification

    SECTION 4 COMPONENTS 4 COMPONENT IDENTIFICATION 4.1 PULL-TYPE RESERVOIR CARRIER FRAME STEERING CYLINDER CENTER-LINK ARTICULATING POWER TONGUE (APT) LEAN BAR HEADER REEL CAM LIFT CYLINDER MANUAL CASE HAZARD LIGHT LOCK VALVE FLUFFER SIDE DEFLECTOR LIFT CYLINDER DRIVESHIELD WOBBLE BOX CONDITIONER Form 169000 / 169040 Revision D...
  • Page 20 SECTION 4 COMPONENTS PULL-TYPE (cont’d) HEADER DRIVE HAZARD LIGHT TAIL-LIGHT FORMING SHIELD ADJUSTER BOLTS FLOAT SPRING DRIVESHIELD Form 169000 / 169040 Revision D...
  • Page 21 SECTION 4 COMPONENTS PULL-TYPE (cont’d) ARTICULATING POWER TONGUE STEERING CYLINDER LOCKOUT VALVE CONTROL HOSES DRIVELINE PUMP - 1000 RPM PTO SAFETY CHAIN DRAWBAR HITCH JACK 3-POINT HITCH ADAPTER TOWING ADAPTER Form 169000 / 169040 Revision D...

  • Page 22: Self-Propelled

    SECTION 4 COMPONENTS 4.2 SELF-PROPELLED HYDRAULIC DRIVE FORMING SHIELD WINDROWER HAZARD LIGHT HEADER DRIVE CUTTERBAR LEAN BAR WOBBLE BOX CONDITIONER REEL CAM HAZARD LIGHT REEL BAT DRIVESHIELD SKID SHOE / GAUGE ROLLER WOBBLE BOX - DOUBLE KNIFE AUGER Form 169000 / 169040 Revision D...

  • Page 23: Specifications

    SECTION 5 SPECIFICATIONS 5 SPECIFICATIONS 5.1 PULL-TYPE HEADERS HEADER SIZE 14 FT 16 FT 18 FT HEADER MODEL A30-S A30-D A30-S A30-D A30-D FRAME and STRUCTURE 16 ft-3 in. 19 ft-3 in. Width 17 ft-9 in. (5410 mm) (4953 mm)
  • Page 24 SECTION 5 SPECIFICATIONS PULL-TYPE HEADERS (Cont’d) HEADER SIZE 14 FT 16 FT 18 FT HEADER MODEL A30-S A30-D A30-S A30-D A30-D AUGER Drive Mechanical 2 Belts To Chain Tube 10 in. (254 mm) O.D Size Flighting 20 in. (508 mm) O.D., 0.25 in. (6 mm) thick.

  • Page 25: Self-Propelled Headers

    17 ft-9 in. (5410 mm) 19 ft-3 in. (5867 mm) 5680 5850 6020 Weight [lb (kg)] (2579) (2656) (2733) Carrier MacDon M Series Self-Propelled Windrowers Lighting Two Amber Transport Lights Frame Frame Spare Knife Storage Lean Bar Lean Bar Lean Bar Tube...
  • Page 26 SECTION 5 SPECIFICATIONS SELF-PROPELLED HEADERS (Cont’d) HEADER SIZE 14 FT 16 FT 18 FT HEADER MODEL A30-S A30-D A40-D A30-S A30-D A40-D A30-D A40-D REEL 14.2 in 14.2 in 14.2 in Hydraulic Direct (232 cc) (232 cc) (232 cc) Mounted Motor...

  • Page 27: Operation

    SECTION 6 OPERATION  Never attempt to start tractor/windrower engine or operate the machine, except 6 OPERATION from the Operator’s seat.  Check the operation of all controls in a 6.1 OWNER/OPERATOR safe clear area before starting work. RESPONSIBILITIES  Do not allow riders on tractor/windrower or mower conditioner.

  • Page 28: Tractor Setup: Pull-Type

    SECTION 6 OPERATION 6.3.2 Drawbar Adjustment 6.3 TRACTOR SETUP: PULL-TYPE CAUTION 6.3.1 Tractor Requirements MINIMUM Shut off tractor, engage parking brake, and MINIMUM MINIMUM DRAWBAR HEADER remove key before working around hitch. POWER HYDRAULICS WIDTH CAPACITY HP (KW) psi (MPA) LBF (N) 1400 14 FT...

  • Page 29: Drawbar Hitch Set-Up

    SECTION 6 OPERATION 6.3.3 Drawbar Hitch Set-Up a. Secure tractor drawbar so the hitch-pin hole is directly below the driveline. g. Assemble PTO driveline male half (G) onto PTO b. Loosen bolts (B) on extension assembly (A), and shaft (H) on APT. Push male half so that PTO slide onto drawbar.

  • Page 30: Point Hitch (Cat. Ii, Iii Or Iiin) Set-Up

    SECTION 6 OPERATION 3. Flip outer plate (F) and inner plate (G) on each arm. 6.3.4 3 Point Hitch (Cat. II, III or IIIN) Set-Up IMPORTANT The inner plate (G) has a smaller joggle than the outer plate (F). Always maintain the proper locations.

  • Page 31: Mower Conditioner / Tractor Hookup: Pull-Type

    SECTION 6 OPERATION e. Attach driveline (E) to tractor PTO shaft as 6.4 MOWER CONDITIONER / TRACTOR follows: HOOKUP: PULL-TYPE CAUTION Shut off tractor, engage parking brake, and remove key before working around hitch. CAUTION Never attach mower conditioner to tractor rear axle or three-point hitch arms.

  • Page 32: Point Hitch (Cat. Ii, Iii, Or Iiin) Hook-Up

    SECTION 6 OPERATION measurement must exceed 6.4.2 3 Point Hitch (Cat. II, III, or IIIN) Hook- dimensions listed below. ‘X’ DRIVELINE SHAFT SIZE DISTANCE CAUTION 1.375 in. (34 mm) 27 in. (685 mm) Shut off tractor, engage parking brake, and 1.75 in.

  • Page 33: Hydraulic Connections

    SECTION 6 OPERATION b. Connect two steering cylinder hoses (A) as 6.4.3 Hydraulic Connections follows: CONTROL MOWER- WARNING CYLINDER LEVER CONDITIONER MOVEMENT POSITION DIRECTION remote hydraulic system Forward Extend Right pressures over 3000 psi (20684 kPa). Check Backward Retract Left your tractor Operator’s Manual for remote system pressure.

  • Page 34: Mower Conditioner / Tractor Unhook: Pull-Type

    SECTION 6 OPERATION 6.5 MOWER CONDITIONER / TRACTOR UNHOOK: PULL-TYPE CAUTION To prevent accidental movement of tractor, shut off engine, engage parking brake, and remove key. To maintain stability, always lower the machine completely. Block mower conditioner wheels before detaching from tractor.
  • Page 35 SECTION 6 OPERATION Remove chain lock (F), and unhook safety chain from tractor. Wrap chain around APT for storage. k. Lower jack to raise APT clear of drawbar. Slowly drive tractor away from mower conditioner. m. Replace hitch pin (A), and secure with hairpin. Form 169000 / 169040 Revision D...

  • Page 36: 3-Point Hitch Unhook

    SECTION 6 OPERATION 6.5.2 3-Point Hitch Unhook a. Park machine on flat level surface. b. Lower header onto blocks, or leave header raised. If leaving in raised position, engage lift cylinder lock-out valves. CAUTION To prevent accidental movement of tractor, shut off engine, engage parking brake, and remove key.

  • Page 37: Header Attachment: Self-Propelled

    A30-S, A30-D 6.6.1.1 M100, M105, M150, M155 b. Remove the cap (C) from electrical connector, The M100, M105, M150, and M155 Windrowers and remove connector from support bracket. are factory-equipped with A30-S and A30-D header hydraulics electrical harness. Proceed as follows:...
  • Page 38 Check to ensure that hoses and electrical If necessary, obtain the following kits from your harness clear tire. MacDon Dealer, and install them in accordance with the instructions supplied with the kit. n. Proceed to Section 6.6.3 Configure Reverser Valve Jumper Hose.

  • Page 39: A40-D

    SECTION 6 OPERATION 6.6.2 A40-D CAUTION prevent accidental movement windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. 6.6.2.1 M100, M105 b. Remove the cap (C) from electrical connector, and remove connector from support bracket.
  • Page 40 KNIFE and CONDITIONER PRESSURE STANDARD HEADER m. If valve blocks are not configured (as shown), AUGER and REEL KNIFE RETURN PRESSURE install required fittings as described in “A30-S, (MALE FITTING AT HEADER) A30-D A40-D Auger Self-Propelled Windrower Header Unloading and Assembly Instructions - Form 169078”...
  • Page 41 SECTION 6 OPERATION o. Open header LH driveshield. p. Check hose routing at the reel motor. The hose routing depends on which windrower model the header is being attached to. The header is factory-assembled for M150, M155, and M200 windrowers. FACTORY CONFIGURATION q.
  • Page 42 SECTION 6 OPERATION 6.6.2.2 M150, M155 CAUTION prevent accidental movement windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. b. Remove the cap (C) from electrical connector, and remove connector from support bracket. c.
  • Page 43 M150 - WITH REVERSER VALVE m. If valve blocks are not configured as shown above, install required fittings as described in “A30-S, A30-D and A40-D Auger Self-Propelled Windrower Header Unloading and Assembly Instructions - Form 169078” that was supplied with your A40-D header.
  • Page 44 SECTION 6 OPERATION 6.6.2.3 M200 CAUTION prevent accidental movement windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. b. Remove the cap (C) from electrical connector, and remove connector from support bracket. c.
  • Page 45 M200 - WITHOUT REVERSER VALVE m. If valve blocks are not configured as shown above, install required fittings as described in “A30-S, A30-D and A40-D Auger Self-Propelled Windrower Header Unloading and Assembly Instructions - Form 169078” that was supplied with your A40-D header.
  • Page 46 If necessary, obtain the following kits from your b. Remove the cap (C) from electrical connector, MacDon Dealer, and install them in accordance and remove connector from support bracket. with the instructions supplied with the kit.
  • Page 47 SECTION 6 OPERATION Push hose connectors onto mating receptacles (as shown) until collars on receptacles snap into “lock” position. e. Route bundle (E) from windrower through support (F) and access hole (G) in header frame alongside existing hose bundle (H) from header. k.

  • Page 48: Configure Reverser Valve Jumper Hose

    4. Connect jumper hose (B) onto 90° fitting in port R4. 5. Install cap removed in step 3. onto port C2 fitting. (continued next page) HOSE (B) POSITION - A30-S, A30-D M150 SHOWN - M155, M200 SIMILAR Form 169000 / 169040 Revision D...
  • Page 49 SECTION 6 OPERATION c. To route hose (B) from A30-S, A30-D position to A40-D position: 1. Disconnect jumper hose (B) at 90° fitting in port R4. 2. Rotate 90° fitting (C) under reverser valve block (A) so that hose can be routed to port C2 on header drive valve block.

  • Page 50: Header Detachment: Self-Propelled

    6.7.1 A30-S, A30-D Detachment 1. Line-up slot (C) in collar with pin (D) on connector. 2. Push collar toward pin, and pull connector to disengage. 3. Install caps on connectors and hose ends (if equipped).

  • Page 51: A40-D Detachment

    SECTION 6 OPERATION b. Disconnect the two hydraulic hoses (A) and (B) 6.7.2 A40-D Detachment or (C) and (D) from windrower valve(s). CAUTION prevent accidental movement windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key.
  • Page 52 SECTION 6 OPERATION h. Move hose bundle (H) from header, and locate on windrower LH side with hose ends in support (J) and under lever (E). Rotate lever (E) clockwise, and push to engage bracket. Locate electrical harness through support (J), and attach cap to electrical connector.

  • Page 53: Transporting Mower Conditioner

    SECTION 6 OPERATION 6.8 TRANSPORTING MOWER DIRECTION OF TRAVEL CONDITIONER 6.8.1 Self-Propelled Refer your Self-Propelled Windrower Operator’s Manual for transporting headers when attached to the Windrower. AMBER 6.8.1.1 Amber Lights The two hazard light fixtures are fitted with reversible amber and red reflector assemblies to accommodate cab-forward and engine-forward operation (M150, M155, M200, and M205).
  • Page 54 SECTION 6 OPERATION NOTE The hydraulic hoses do not need to be attached to the tractor for towing. Ensure they are securely stored on the APT. d. Position towing adapter (C) on APT, and secure with pins (D). e. Attach mower conditioner to truck. Remove jack from “working”...
  • Page 55 SECTION 6 OPERATION e. If steering cylinder is not fully charged, install 6.8.2.3 Preparing Mower Conditioner for temporary transport lock follows: Transport Otherwise, proceed to step f. below. a. Charge the steering circuit as follows: 1. Connect two APT steering cylinder hoses to a tractor hydraulic circuit.

  • Page 56: Pull-Type: Flatbed

    SECTION 6 OPERATION Remove complete forming shield group as 6.8.3 Pull-Type: Flatbed follows: To transport the mower conditioner on a flatbed trailer, proceed as follows: CAUTION following procedure when transporting the mower conditioner on a flatbed trailer. 6.8.3.1 Loading: Pull-Type 1.
  • Page 57 SECTION 6 OPERATION IMPORTANT The APT must not widen the shipping package. g. Remove pin at rod end of APT steering cylinder, and move cylinder away from frame. Re-insert pin in clevis. Secure frame hook prevent movement. Use cardboard or suitable material under the tie to protect paint.
  • Page 58 SECTION 6 OPERATION p. Lower mower conditioner onto flatbed, so that its weight rests on the frame and sloped edge of header end panels, or cutterbar as shown. Attach a chain to each frame hook (K) and a chain to each end of the lean bar at (L). Chain must pass through hole at end of lean bar.
  • Page 59 SECTION 6 OPERATION 6.8.3.2 Unloading: Pull-Type a. Remove tie downs. b. Install lean bar onto mower conditioner with four bolts (N) (shown on previous page) e. Lower mower conditioner, and install wheel/axle assemblies onto mower conditioner. Secure axle to frame with bolt (C), and tighten to required torque..
  • Page 60 SECTION 6 OPERATION Swing APT to “working” position. Attach steering cylinder rod end to frame. k. Install rear forming shields using reverse order of step f. in Section 6.8.3.1 Loading: Pull-Type. Move lift cylinder lock out valve handles to “vertical” position. Form 169000 / 169040 Revision D...

  • Page 61: Break-In Period

    Adjust tension on drive belts. Refer to Sections loud noises. 7.8 SICKLE AND SICKLE DRIVE, 7.9 REEL (continued next page) AND REEL DRIVE: A30-S, A30-D, and 7.11 AUGER AND AUGER DRIVE: A30-S, A30-D. b. Lubricate chains and adjust tensions. Refer to Sections 7.6.2 Lubrication Points, 7.9.1 Reel Drive Chain: A30-S, A30-D, 7.11 AUGER AND...

  • Page 62: Shutdown Procedure

    SECTION 6 OPERATION 6.14 LIFT CYLINDER LOCK-OUTS Do the following each day before start-up: a. Check the machine for leaks or any parts that WARNING are missing, broken, or not working correctly. NOTE To avoid bodily injury or death from fall of Use proper procedure when searching raised machine, always lock-out lift cylinders for pressurized fluid leaks.

  • Page 63: Steering: Pull-Type

    SECTION 6 OPERATION 6.15.1 Right Side Operation: Pull-Type 6.15 STEERING: PULL-TYPE Steering the mower conditioner is controlled by the tractor’s remote hydraulic system. This steering system allows the mower conditioner to follow directly behind the tractor, make a full cut to either side, or any position in-between.

  • Page 64: Left Side Operation: Pull-Type

    SECTION 6 OPERATION 6.15.2 Left Side Operation: Pull-Type 6.15.3 Avoiding Obstacles Move steering lever backward to achieve Move steering lever as required to avoid desired position of mower conditioner on LH obstacles. side of tractor. 6.15.4 Square Corners To adjust tracking of mower conditioner during LH side operation, the steering cylinder stroke The following procedure is intended only as a control can be re-positioned:...

  • Page 65: Degree Turn

    SECTION 6 OPERATION 6.15.5 180 Degree Turn c. At position (B), start turning tractor back towards the uncut crop. NOTE IMPORTANT When cutting back and forth on one side When turning, take care that inside tractor of the field, approximately 50 ft. (15 m) tire does not contact APT of mower is required at each end of the field to conditioner.

  • Page 66: Unplugging The Header / Mower Conditioner

    Stop forward movement of the tractor, and stop the PTO. 6.16.2 Unplugging Conditioner: Self- b. Raise the machine, and slowly engage the PTO. Propelled - A30-S and A30-D NOTE Reverse the header drive. Refer to your Self- Raising mower conditioner Propelled Windrower Operator’s Manual for...

  • Page 67: Header Operation

    SECTION 6 OPERATION 6.17 HEADER OPERATION 6.17.1 Lean Bar Position Satisfactory function of the windrower in all IMPORTANT situations requires making proper adjustments to To prevent structural damage to the suit various crops and conditions. header, do not operate with lean bar removed.

  • Page 68: Auger Speed

    6.17.2.1 Auger Speed: A30-S and A30-D The A30 auger speed is fixed to the engine rpm, and an optional 19 tooth drive sprocket provides lower auger speeds. A30-S...

  • Page 69: Reel Speed

    Remove reel drive belt (A) and reel drive chain (B) from drive sprocket. Refer to Sections 7.9.1 Reel Drive Chain: A30-S, A30-D and 7.9.2 Reel Drive Belts: A30-S, A30-D. b. Remove snap-ring (C) from pulley (D), and remove pulley.

  • Page 70: Auger Position

    SECTION 6 OPERATION 6.17.4 Auger Position 6.17.4.1 Auger Fore-Aft Adjustment: A30-S a. Open LH endshield. CAUTION b. Loosen auger drive chain (A) as follows: To avoid personal injury, before servicing header/mower conditioner or opening drive covers, follow procedures in Section 7.1 PREPARATION FOR SERVICING.
  • Page 71 SECTION 6 OPERATION Open RH endshield. o. Check reel drive chain tension. Total chain slack at (N) should be 1/4 in. (6 mm). Loosen reel drive belts as follows: If necessary, adjust as follows: 1. Loosen bolt (O) on sprocket, and jam-nut on adjuster bolt (P).
  • Page 72 SECTION 6 OPERATION g. Check auger drive V-belt (F) tension. Each belt 6.17.4.2 Auger Vertical Adjustment: A30-S should deflect 3/16 in. (4 mm) at mid-span when a load of 8 - 12 lbf (35 - 40 N) is applied to each CAUTION belt.
  • Page 73 SECTION 6 OPERATION n. Check reel drive chain tension. Total chain slack at (N) should be 1/4 in. (6 mm). If necessary, adjust as follows: 1. Loosen bolt (O) on sprocket, and jam-nut on adjuster bolt (P). 2. Turn adjuster bolt (P) to move idler sprocket “downward”...
  • Page 74 SECTION 6 OPERATION Open RH endshield. 6.17.4.3 Auger Fore-Aft Adjustment: A30-D h. Loosen reel drive belts (F) as follows: CAUTION prevent accidental movement windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. a.
  • Page 75 SECTION 6 OPERATION Check reel drive chain tension. Total chain slack at (K) should be 1/4 in. (6 mm). If necessary, adjust as follows: 1. Loosen bolt (L) on sprocket and jam-nut on adjuster bolt (M). 2. Turn adjuster bolt (M) to move idler sprocket “downward”...
  • Page 76 SECTION 6 OPERATION g. Open RH endshield. 6.17.4.4 Auger Vertical Adjustment: A30-D h. Loosen reel drive belts (E) as follows: CAUTION prevent accidental movement windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. a.
  • Page 77 SECTION 6 OPERATION Check reel drive chain tension. Total chain slack at (K) should be 1/4 in. (6 mm). If necessary, adjust as follows: 1. Loosen bolt (L) on sprocket and jam-nut on adjuster bolt (M). 2. Turn adjuster bolt (M) to move idler sprocket “downward”...
  • Page 78 SECTION 6 OPERATION 6.17.4.5 Auger Fore-Aft Adjustment: A40-D 6.17.4.6 Auger Vertical Adjustment: A40-D a. Open LH endshield. CAUTION prevent accidental movement windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. a.

  • Page 79: Reel Position

    Thick Stemmed Or Up And Forward Heavy Standing To make adjustments to reel position, refer to the following Sections 6.17.5.1 to 6.17.5.4. 6.17.5.1 Reel Fore-Aft Position: A30-S, A30-D NOTE The reel must be adjusted equally on both sides. CAUTION g. Loosen four nuts (F).
  • Page 80 SECTION 6 OPERATION e. Open RH endshield. 6.17.5.2 Reel Vertical Position: A30-S, A30-D Loosen reel drive chain (C) as follows: CAUTION prevent accidental movement windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key.
  • Page 81 SECTION 6 OPERATION Tighten reel drive chain (C) as follows: 6.17.5.3 Reel Fore-Aft Position: A40-D NOTE The reel must be adjusted equally on both sides. CAUTION prevent accidental movement windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key.
  • Page 82 SECTION 6 OPERATION 6.17.5.4 Reel Vertical Position: A40-D Open RH endshield. a. Open LH endshield. g. Loosen four nuts (G). b. Loosen four nuts (E). h. Loosen jam-nuts on adjuster bolts (H), and turn bolts (H) to adjust reel “vertical” position. Tighten jam-nut.

  • Page 83: Tine Aggressiveness Adjustment

    Tighten nuts (A), and jam-nuts on bolts (B). e. Check that chain and/or belt have not become “over-tight”. Adjust to recommended tension if required. Refer to Sections 7.9.1 Reel Drive Chain: A30-S, A30-D, and 7.9.2 Reel Drive Belts: A30-S, A30-D. A40-D TINES b.

  • Page 84: Cutting Height

    SECTION 6 OPERATION e. Check that skid shoes or gauge rollers are 6.17.7 Cutting Height adjusted to the “same position”. Check header float, and adjust if required. Refer Cutting height is controlled with a combination of to Section 6.17.9 Header Flotation. skid shoes or gauge rollers, and header angle adjustment - not with the header lift cylinders.

  • Page 85: Header Angle

    SECTION 6 OPERATION e. “Snug up” nut (B), but do not over-tighten. A 6.17.8 Header Angle slight tap with a small hammer is sufficient. Header (or guard) angle can be varied from 8° to Check cutting height, and adjust if required. 16°...

  • Page 86: Header Flotation

    SECTION 6 OPERATION 6.17.9 Header Flotation Header flotation springs are normally set so 70 lbf (311 N) is required to lift either end of the header just off the ground. In rough or stony conditions, it may be desirable to change setting to 35 - 50 lbf (156 - 222 N) to protect cutting components.

  • Page 87: Feed Pan / Rock-Drop Tine Position

    SECTION 6 OPERATION 6.17.10 Feed Pan / Rock-Drop Tine Position The rear of the feed pan is adjustable “up” and “down” to raise or lower the feed pan and rock drop tines.  Lowering the feed-pan helps prevent plugging in heavy crop. ...

  • Page 88: Hay Conditioner

    SECTION 6 OPERATION 6.17.11 Hay Conditioner Steel rolls "condition" the crop by crimping and crushing the stem in several places to allow moisture release for quicker drying. The degree to which crop is conditioned as it passes through the rolls is controlled by roll gap (factory-set at 1/4 in.
  • Page 89 SECTION 6 OPERATION NOTE 6.17.11.2 Roll Timing and Alignment If the distance ‘X’ varies more than 1/16 in. (1.6 mm) from one end to the For proper conditioning, the rolls must be other, the rolls should be re-aligned. properly timed and aligned with each steel bar Refer to next Section 6.17.11.2.2 Roll on one roll centered between two bars of the Alignment.
  • Page 90 SECTION 6 OPERATION NOTE 6.17.11.2.2 Roll Alignment The rolls are aligned if the distance ‘X’ varies less than 1/16 in. (1.6 mm) from The rolls can be aligned in the fore and aft one end to the other. direction by shimming the pivot assembly link at the RH end of the upper roll.

  • Page 91: Roll Tension

    SECTION 6 OPERATION 6.17.12 Roll Tension The roll tension (the force holding the rolls together) is factory-set, and is adjustable. There is a spring (A) for each end of the roll. See illustration below. CAUTION prevent accidental movement windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key.

  • Page 92: Forming Shields

    SECTION 6 OPERATION a. Set forming shield side deflectors to desired width by re-positioning adjuster bars as follows: 6.17.13 Forming Shields WARNING Keep hands and feet away from discharge opening. Keep everyone several hundred feet away from your operation. Never direct the discharge toward anyone.
  • Page 93 SECTION 6 OPERATION 6.17.13.2 Rear Deflector (Fluffer Shield) The rear deflector (D) slows the crop exiting the conditioner rolls, directs the flow downward, and "fluffs" the material. CAUTION prevent accidental movement windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key.

  • Page 94: Tall Crop Dividers

    SECTION 6 OPERATION 6.17.14 Tall Crop Dividers The tall crop dividers attach to the ends of the header for clean crop dividing, and reel entry in tall crops. They can be easily adjusted to suit the crop, or removed when not required. d.

  • Page 95: Ground Speed

    SECTION 6 OPERATION 6.17.15 Ground Speed b. Choose a ground speed that allows the sickle to cut the crop smoothly and evenly. CAUTION c. The chart below indicates the relationship between ground speed and area cut for three Reduce speed when turning, crossing...

  • Page 96: Grass Seed Windrowing

    SECTION 6 OPERATION 6.17.16.4 Auger Pan Extensions 6.17.16 Grass Seed Windrowing The grass seed header is equipped with The grass seed auger header has several adjustable auger pan extensions that allow features to adapt it to this special application. adjustment of delivery opening to vary the These features include: windrow characteristics.
  • Page 97 SECTION 6 OPERATION 6.17.16.5 Windrow Forming Rods Forming rods are provided to assist in forming narrow windrows preferred this application. a. Bend rods to modify the windrow shape. Use forming rods in conjunction with auger pan extensions to achieve the width and shape of windrows you desire.

  • Page 98: Haying Tips

    SECTION 6 OPERATION 6.18.4 Windrow Characteristics 6.18 HAYING TIPS It is recommended that a windrow with the 6.18.1 Curing following characteristics be produced. Refer to a. A quick cure will maintain top quality because: Section 6.17 HEADER OPERATION instructions on adjusting the header/mower ...

  • Page 99: Storage

    SECTION 6 OPERATION 6.19 STORAGE Do the following at the end of each operating season: a. Clean the header/mower conditioner thoroughly. CAUTION Never use gasoline, naphtha or any volatile material cleaning purposes. These materials may be toxic and/or flammable. CAUTION Cover cutterbar and sickle guards to prevent injury from accidental contact.

  • Page 100: Maintenance And Servicing

    SECTION 7 MAINTENANCE AND SERVICING 7 MAINTENANCE AND SERVICING The following instructions are provided to assist the Operator in the use of the header/mower conditioner. Detailed maintenance, service, and parts information are contained in the Service Instruction Manual and Parts Catalog that are ...

  • Page 101: Maintenance Specifications

    SECTION 7 MAINTENANCE AND SERVICING 7.3 MAINTENANCE SPECIFICATIONS 7.3.1.2 Metric Bolts 7.3.1 Recommended Torques STD COARSE BOLT TORQUE*  BOLT Tighten all bolts to the torques specified in 10.9 DIA. chart (unless otherwise noted throughout "A" lbf·ft N·m lbf·ft N·m this manual).
  • Page 102 SECTION 7 MAINTENANCE AND SERVICING 7.3.1.3 Flare Type Hydraulic Fittings 7.3.1.4 O-ring Type Hydraulic Fittings FLARE FITTING LOCKNUT WASHER O-RING GROOVE BODY FLARESEAT SEAT a. Check flare and flare seat for defects that might cause leakage. b. Align tube with fitting before tightening. c.
  • Page 103 SECTION 7 MAINTENANCE AND SERVICING a. Check components to ensure that the sealing 7.3.1.5 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.

  • Page 104: Recommended Fluids And Lubricants

    SECTION 7 MAINTENANCE AND SERVICING 7.3.2 Recommended Fluids and Lubricants Your machine can operate at top efficiency only if clean lubricants are used.  clean containers handle lubricants.  Store in an area protected from dust, moisture, and other contaminants. LUBRICANT SPEC DESCRIPTION...

  • Page 105: Conversion Chart

    SECTION 7 MAINTENANCE AND SERVICING 7.3.3 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 =...

  • Page 106: Driveshields

    SECTION 7 MAINTENANCE AND SERVICING 7.4 DRIVESHIELDS 7.5 LIFT CYLINDER LOCK-OUTS 7.5.1 Self-Propelled Refer to your Windrower Operator’s Manual. 7.5.2 Pull-Type DANGER To avoid bodily injury or death from unexpected start-up fall raised machine; stop engine, remove key and engage lift cylinder lock-out valves before going under machine for any reason.

  • Page 107: Lubrication

    Refer to the specified pages to identify header/mower conditioner or opening drive lubrication points for your specific model: covers, follow procedures in Section 7.1 PREPARATION FOR SERVICING. A30-S HEADER Pages 106 - 107 Refer to Section 7.3.2 Recommended Fluids A30-D HEADER Pages 108 - 109 and Lubricants for recommended greases.
  • Page 108 SECTION 7 MAINTENANCE AND SERVICING A30-S Headers 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 109 SECTION 7 MAINTENANCE AND SERVICING A30-S Headers (Cont’d) A30-S HEADER RH SIDE High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base. AUGER SHAFT BEARING (1 PLC) REEL SHAFT BEARING (1 PLC) Form 169000 / 169040...
  • Page 110 SECTION 7 MAINTENANCE AND SERVICING A30-D Headers A30-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 HEAD BEARING (1 PLC) NOTE prevent binding and/or excessive wear caused by sickle pressing on guards, do not over-...
  • Page 111 SECTION 7 MAINTENANCE AND SERVICING A30-D Headers (Cont’d) A30-D HEADER LH SIDE High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base. CROSS SHAFT BEARING (1 PLC) REEL SHAFT BEARING (1 PLC) SICKLE HEAD BEARING (1 PLC) NOTE prevent binding...
  • Page 112 SECTION 7 MAINTENANCE AND SERVICING III. A40-D HEADERS 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 prevent...
  • Page 113 SECTION 7 MAINTENANCE AND SERVICING A40-D Headers (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 114 SECTION 7 MAINTENANCE AND SERVICING IV. 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) Form 169000 / 169040 Revision D...
  • Page 115 SECTION 7 MAINTENANCE AND SERVICING DRIVELINES High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base. A30-S DRIVELINE UNIVERSALS (2 PLCS) 10% MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINTS ONLY CROSS SHAFT (1 PLC)
  • Page 116 SECTION 7 MAINTENANCE AND SERVICING VI. PULL TYPE CARRIER FRAME TONGUE PIVOT (1 PLC) LIFT LINKAGE (2 PLCS) - BOTH SIDES WHEEL BEARINGS FRAME/HEADER PIVOT LIFT CYLINDER (1 PLC) (1 PLC) - BOTH SIDES (1 PLC) - BOTH SIDES Form 169000 / 169040 Revision D...

  • Page 117: Oiling

    Apply oil to upper edge of lower spans when oiling chains. SAE 30 A30-S HEADER OIL KNIFE DAILY EXCEPT IN SANDY SOIL AUGER DRIVE CHAIN (1 PLC) REEL DRIVE CHAIN (1 PLC) A30-S HEADER LH SIDE Form 169000 / 169040 Revision D...
  • Page 118 A30-D HEADER LH SIDE SAE 30 AUGER DRIVE CHAIN (1 PLC) CHECK ROLL GEARBOX (1 PLC) WOBBLE BOX (A30-S 1 PLC) (A30-D / A40-D 2 PLCS) (CHECK OIL LEVEL WITH TOP OF WOBBLE BOX HORIZONTAL) Form 169000 / 169040 Revision D...

  • Page 119: Sealed Bearing Installation

    SECTION 7 MAINTENANCE AND SERVICING 7.6.4 Sealed Bearing Installation a. Clean shaft, and coat with rust preventative. b. Install flangette (A), bearing (B), second flangette (C), and lock collar (D). NOTE The locking cam is only on one side of the bearing.

  • Page 120: Hydraulics

    SECTION 7 MAINTENANCE AND SERVICING 7.7.2.3 Adding Hydraulic Oil 7.7 HYDRAULICS 7.7.1 Hydraulics: Self-Propelled Refer your Self-Propelled Windrower Operator’s Manual hydraulic system maintenance procedures self-propelled windrowers. 7.7.2 Hydraulics: Pull-Type The pull-type mower conditioner is hydraulically powered using the following systems: a.

  • Page 121: Hoses And Lines

    SECTION 7 MAINTENANCE AND SERVICING 7.7.2.5 Changing Hydraulic Oil Filter 7.7.3 Hoses and Lines NOTE Check hydraulic hoses and lines daily for signs Change hydraulic oil filter after the first of leaks. 100 hours operation, and every 250 hours thereafter. WARNING Avoid high-pressure...

  • Page 122: Sickle And Sickle Drive

    SECTION 7 MAINTENANCE AND SERVICING 7.8.2 Sickle Removal 7.8 SICKLE AND SICKLE DRIVE WARNING CAUTION Stand to rear of sickle during removal to To avoid personal injury, before servicing reduce risk of injury from cutting edges. header/mower conditioner or opening drive Wear heavy gloves when handling sickle.

  • Page 123: Sickle Installation

    SECTION 7 MAINTENANCE AND SERVICING 7.8.4 Sickle Head Bearing Removal 7.8.3 Sickle Installation a. Remove the sickle. See Section 7.8.2 Sickle Removal. WARNING Stand to rear of sickle during installation to reduce risk of injury from cutting edges. Wear heavy gloves when handling sickle. IMPORTANT Align guards, and re-set sickle hold-downs while replacing sickle.

  • Page 124: Spare Sickle

    SECTION 7 MAINTENANCE AND SERVICING 7.8.7 Sickle Guards 7.8.6 Spare Sickle Check daily that guards are aligned to obtain a. A spare sickle complete with knife head on proper shear cut between sickle section and single knife headers may be stored in the guard.
  • Page 125 SECTION 7 MAINTENANCE AND SERVICING TIP: If trouble is encountered cutting tangled, or fine-stemmed material, replace guards with stub guards. If material is tough to cut, install stub guards with top guard and adjuster plate. A stub guard conversion kit for the header/mower conditioner DRIVE SIDE is available from your Dealer.
  • Page 126 SECTION 7 MAINTENANCE AND SERVICING 7.8.7.2.2 Pointed Guard Replacement: Double Knife Refer to previous section for standard guard replacement. The guard near the center of the double knife header, where the two sickles overlap, requires a slightly different replacement procedure. IMPORTANT Replace adjacent guards when replacing center guard.
  • Page 127 SECTION 7 MAINTENANCE AND SERVICING 7.8.7.2.3 Stub Guard Replacement: Single Knife Stub guards, complete with top guides and adjuster plates are designed to cut tough crops. CAUTION Stop engine, and remove key from ignition before leaving Operator's seat for any reason.
  • Page 128 SECTION 7 MAINTENANCE AND SERVICING 7.8.7.2.4 Stub Guard Replacement: Double Knife Refer to previous section for typical guard replacement. The guard near the center of the double knife header, where the two sickles overlap, requires a slightly different replacement procedure. IMPORTANT Replace adjacent guards when replacing center guard.

  • Page 129: Sickle Hold-Downs

    SECTION 7 MAINTENANCE AND SERVICING 7.8.8.1 Sickle Hold-Down Adjustment: Pointed 7.8.8 Sickle Hold-Downs Guards Check daily that sickle hold-downs are set to Single Knife prevent sickle sections from lifting off guards, but still permit sickle to slide without binding. NOTE Guards should be aligned prior to adjusting hold-downs.
  • Page 130 SECTION 7 MAINTENANCE AND SERVICING 7.8.8.2 Sickle Hold-Down Adjustment: Stub Guards Single Knife 0.004 - 0.040 in. 0.004 - 0.016 in. (0.1 - 1.0 mm) (0.1 - 0.4 mm) a. Torque nuts (E) to 35 ft·lbf (46 N·m). b. Turn adjuster bolts (F). Using a feeler gauge, clearance from hold-down to sickle section should be 0.004 - 0.016 in.

  • Page 131: Sickle Drive Belt: A30-S

    SECTION 7 MAINTENANCE AND SERVICING 7.8.9.2 Removal: Sickle Drive Belt - A30-S 7.8.9 Sickle Drive Belt: A30-S a. Open LH endshield. CAUTION 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 132 SECTION 7 MAINTENANCE AND SERVICING 7.8.9.3 Installation: A30-S Sickle Drive Belt g. Install bolt-in plate in LH endsheet at wobble box, and close endshield. h. Re-adjust tension of a new belt after a short run-in period, (about 5 hours). a. Route sickle drive belt (A) through opening in endsheet onto wobble box pulley and sickle drive pulley (E) as shown.

  • Page 133: Sickle Drive Belts: A30-D

    SECTION 7 MAINTENANCE AND SERVICING 7.8.10.2 Removal: LH Sickle Drive Belts: A30-D 7.8.10 Sickle Drive Belts: A30-D a. Open LH endshield. 7.8.10.1 Tension Adjustment: LH Sickle Drive Timing Belt - A30-D IMPORTANT To prolong belt and drive life, do not over- tighten belts.
  • Page 134 SECTION 7 MAINTENANCE AND SERVICING Loosen three nuts (B). g. Loosen jam-nut on adjuster bolt (C), and turn adjuster bolt (C) so that sickle drive belt (A) can be slipped off pulley (D). h. Remove bolt-in plate in LH endsheet at wobble box.
  • Page 135 SECTION 7 MAINTENANCE AND SERVICING 7.8.10.3 Installation: LH Sickle Drive Belts: A30-D CAUTION 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. Re-position V-belts (K) on pulley (D) e.
  • Page 136 SECTION 7 MAINTENANCE AND SERVICING 7.8.10.4 Tension Adjustment: RH Sickle Drive 7.8.10.5 Removal: RH Sickle Drive Timing Belt: Timing Belt - A30-D A30-D IMPORTANT a. Open shield on header RH side. To prolong belt and drive life, do not over- tighten belts.
  • Page 137 SECTION 7 MAINTENANCE AND SERVICING 7.8.10.6 Installation: RH Sickle Drive Timing Belt - A30-D CAUTION 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. e.

  • Page 138: Sickle Drive Belts: A40-D

    SECTION 7 MAINTENANCE AND SERVICING Double V-Belts 7.8.11 Sickle Drive Belts: A40-D 7.8.11.1 Tension Adjustment: LH Sickle Drive Belts - A40-D IMPORTANT To prolong belt and drive life, do not over- tighten belts. Timing Belt CAUTION Stop engine, and remove key from ignition before leaving Operator's seat for any reason.
  • Page 139 SECTION 7 MAINTENANCE AND SERVICING 7.8.11.3 Installation: LH Sickle Drive Timing Timing Belt Belts - A40-D a. Remove double V-belts as per previous page. CAUTION 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 140 SECTION 7 MAINTENANCE AND SERVICING Double V-Belts 7.8.11.4 Tension Adjustment: RH Sickle Drive Belt - A40-D IMPORTANT Belts are a matched set. Replace both IMPORTANT drive belts even if only one needs To prolong belt and drive life, do not over- replacing.
  • Page 141 SECTION 7 MAINTENANCE AND SERVICING 7.8.11.5 Removal: RH Sickle Drive Belt - A40-D 7.8.11.6 Installation: RH Sickle Drive Belt - A40-D CAUTION 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 142: Sickle Drive Timing Adjustment

    SECTION 7 MAINTENANCE AND SERVICING 7.8.12 Sickle Drive Timing Adjustment Double knife A30-D and A40-D Auger Headers require that the sickles are properly timed to move in opposite directions. CAUTION Stop engine, and remove key from ignition before leaving Operator's seat for any reason.
  • Page 143 SECTION 7 MAINTENANCE AND SERVICING g. If timing is “off”, proceed as follows: 1. Loosen right side timing belt sufficiently to allow skipping the belt one or more teeth as required. Refer to Section 7.8.10.4 Tension Adjustment: RH Sickle Drive Timing Belt - A30-D, or 7.8.11.4 Tension Adjustment: RH Sickle Drive Belt - A40-D.

  • Page 144: Wobble Box

    Loosen sickle drive belt (B), and slip off wobble shaft. box pulley. Refer to one of the following sections, depending on your equipment:  Section 7.8.9.1 Tension Adjustment: Sickle Drive Belt - A30-S  Section 7.8.10.1 Tension Adjustment: LH Sickle Drive Timing Belt - A30-D ...
  • Page 145 Refer to one of the following sections, depending on your equipment: c. Slide pitman arm (C) onto wobble box output  Section 7.8.9.1 Tension Adjustment: Sickle shaft. Drive Belt - A30-S d. Rotate wobble box pulley to ensure pitman arm  Section 7.8.10.1 Tension Adjustment: “just”...
  • Page 146 SECTION 7 MAINTENANCE AND SERVICING 7.8.13.4 Pulley Removal 7.8.13.6 Changing Wobble Box Oil a. Remove wobble box. See previous page. NOTE Change wobble box lubricant after the first 50 hours operation, and every 1000 hours (or 3 years) thereafter. a. Raise header to allow a suitable container to be placed under wobble box drain to collect oil.

  • Page 147: Reel And Reel Drive: A30-S, A30-D

    Remove reel drive belt (D) from pulley (E). Adjust reel drive chain (A) tension as follows: Refer to Section 7.9.2 Reel Drive Belts: A30-S, A30-D. a. Open shield on header RH side. c. Loosen nut (B) on idler sprocket.

  • Page 148: Reel Drive Belts: A30-S, A30-D

    SECTION 7 MAINTENANCE AND SERVICING 7.9.2.2 Removal 7.9.2 Reel Drive Belts: A30-S, A30-D Remove reel drive belts (A) as follows: 7.9.2.1 Tension Adjustment a. Open shield on header RH side. IMPORTANT To prolong drive life, do not over-tighten belts. Belt slippage is used to protect the reel in an overload situation.

  • Page 149: Reel Tines And Tine Bar Bearings: A30-S, A30-D

    SECTION 7 MAINTENANCE AND SERVICING 7.9.3.2 Installation: Tines and Bearings - Cam 7.9.3 Reel Tines and Tine Bar Bearings: A30-S, A30-D CAUTION IMPORTANT Keep reel tines good condition. Straighten or replace as required. Stop engine, and remove key from ignition before leaving Operator's seat for any 7.9.3.1...
  • Page 150 SECTION 7 MAINTENANCE AND SERVICING c. Remove bolt (N) securing bearing halves to tine bar. d. Position end of tine bar clear of cam disc, and slide tines off bar. e. Slide bearing support (M) off tine bar, and remove bearing halves (Q). Remove nut, bolt, and keeper on each tine to be removed, and slide tine off the bar.

  • Page 151: Reel And Reel Drive: A40-D

    SECTION 7 MAINTENANCE AND SERVICING 7.10 REEL AND REEL DRIVE: A40-D CAUTION To avoid personal injury, before servicing header/mower conditioner or opening drive covers, follow procedures in Section 7.1 PREPARATION FOR SERVICING. 7.10.1 Reel Drive: A40-D The reel drive gearbox and hydraulic motor are a factory-assembled unit.
  • Page 152 SECTION 7 MAINTENANCE AND SERVICING h. Replace tine as follows: Position end of tine bar clear of cam disc, and install cam arm assembly (D), complete with bearing on tine bar. Engage cam arm into cam track as shown. k. Attach bearing flangettes at discs #1 and #2 with bolts (G).
  • Page 153 SECTION 7 MAINTENANCE AND SERVICING e. Replace tine as follows: 7.10.2.2 Tine and Bearing Replacement: Center Section X DISC #2 DISC #3 DISC #4 DISC #3 1. Remove bolt (D) and keeper (E) on tine to be replaced. 2. Remove bolts and keepers on tines as required facilitate replacement...
  • Page 154 SECTION 7 MAINTENANCE AND SERVICING e. Replace tine as follows: 7.10.2.3 Tine and Bearing Replacement: Opposite Cam - Section Y DISC #3 DISC #4 DISC #4 1. Remove bolt (D) and keeper (E) on tine to be replaced. 2. Remove bolts and keepers on tines as required facilitate replacement...
  • Page 155 SECTION 7 MAINTENANCE AND SERVICING 7.10.2.4 Tine Replacement: Tine Bar Extension - Section Z DISC #3 DISC #4 DISC #4 a. Remove bolt (F) and keepers (G) on tine to be replaced, and slide tines off tine bar. b. Install tines on tine bar, and secure with bolt (F) and two keepers (G).

  • Page 156: Auger And Auger Drive: A30-S, A30-D

    SECTION 7 MAINTENANCE AND SERVICING 7.11.1.2 Removal 7.11 AUGER AND AUGER DRIVE: A30-S, A30-D Remove chain (A) as follows: a. Open LH endshield. CAUTION To avoid personal injury, before servicing header/mower conditioner or opening drive covers, follow procedures in Section 7.1 PREPARATION FOR SERVICING.

  • Page 157: Auger Drive Chain: A30-D

    SECTION 7 MAINTENANCE AND SERVICING 7.11.2 Auger Drive Chain: A30-D 7.11.2.1 Tension CAUTION 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. Open LH endshield. b.

  • Page 158: Auger Drive Belt: A30-S

    SECTION 7 MAINTENANCE AND SERVICING 7.11.3.2 Removal 7.11.3 Auger Drive Belt: A30-S a. Open LH endshield. 7.11.3.1 Tension IMPORTANT To prolong drive life, do not over-tighten belts. Belt slippage is used to protect the auger in an overload situation. NOTE Minor belt tension adjustments may be made without affecting chain tension.

  • Page 159: Auger Drive Belts: A30-D

    SECTION 7 MAINTENANCE AND SERVICING 7.11.4.2 Removal 7.11.4 Auger Drive Belts: A30-D a. Open LH endshield. 7.11.4.1 Tension b. Remove auger drive chain (D) as follows: IMPORTANT To prolong drive life, do not over-tighten belt. Belt slippage is used to protect the auger in an overload situation.

  • Page 160: Auger Pans

    7.11.5 Auger Pans 7.11.7 Stripper Bars The high density polyethylene auger pans are repairable and replaceable. Refer to the Technical Service Manual, MacDon Form AUGER 169048 for details on replacing the pans. 1 - 4 mm IMPORTANT (1/32 - 5/32”) CLEARANCE...

  • Page 161: Auger And Auger Drive: A40-D

    SECTION 7 MAINTENANCE AND SERVICING a. Raise header, and engage lift cylinder stops. 7.11.7.2 Stripper Bar Replacement WARNING To avoid bodily injury or death from unexpected start-up fall raised machine, stop engine, remove key, and engage lift cylinder stops before going under machine.

  • Page 162: Conditioner

    SECTION 7 MAINTENANCE AND SERVICING Replace drain plug (C), and add oil at (A) to 7.13 CONDITIONER required level. Use Gear Lubricant, SAE 85W-140, API Service Class GL-5, 1.5 quarts CAUTION (1.4 liters). g. Oil is at required level when it runs out of check To avoid personal injury, before servicing plug (B).

  • Page 163: Disassemble Forming Shield

    SECTION 7 MAINTENANCE AND SERVICING e. Disassemble fluffer shield (J) from forming 7.13.3 Disassemble Forming Shield shield cover. a. Invert forming shield onto top. Remove bolts (K) to remove deflector fins (L) from cover. b. Remove lynch pin (A) from adjuster rods (B), 7.13.4 Assemble Forming Shield and disassemble rods from side deflectors (C).

  • Page 164: Hydraulic Drive Motor Removal: All Models

    SECTION 7 MAINTENANCE AND SERVICING 7.13.6 Hydraulic Drive Motor Removal: All Models a. Open shield covering conditioner drive. b. On pull-type machines, disconnect hydraulic hoses from the motor, and install caps on hose ends and motor ports. c. On self-propelled machines, disconnect hoses at couplers on motor.

  • Page 165: Gearbox Removal: A30-S

    SECTION 7 MAINTENANCE AND SERVICING Remove the auger drive pulley (F) as follows: 7.13.8 Gearbox Removal: A30-S a. Remove hydraulic drive motor. Refer to Section 7.13.6 Hydraulic Drive Motor Removal: All Models. NOTE It is not necessary to disconnect the motor hoses for this operation.

  • Page 166: Gearbox Installation: A30-S

    SECTION 7 MAINTENANCE AND SERVICING e. Install auger drive pulley (F) as follows: 7.13.9 Gearbox Installation: A30-S 1. Slide pulley (F) onto shaft with key. 2. Install tapered bushing (G) onto shaft, a. Position gearbox (A) as shown, picking up the ensuring holes are aligned with holes in three holes (B) in the endsheet.
  • Page 167 SECTION 7 MAINTENANCE AND SERVICING g. Slide upper roll driveline onto gearbox as shown. Install and tighten two bolts and nuts (O). Torque to 75 ft·lbf (102 N·m). h. Attach lower roll driveline flange onto gearbox flange using four bolts and nuts (P). Adjust roll timing.

  • Page 168: Gearbox Removal: A30-D

    SECTION 7 MAINTENANCE AND SERVICING Remove auger drive chain (D) from small 7.13.10 Gearbox Removal: A30-D sprocket as follows: a. Open shield covering conditioner drive. 1. Loosen nut (E) on idler sprocket support. 2. Turn adjuster bolt (F) to loosen chain (D). 3.
  • Page 169 SECTION 7 MAINTENANCE AND SERVICING h. Remove auger drive pulley (K) as follows: Remove two bolts (O), and nut and bolt (P) attaching channel (Q) to endsheet, and remove 1. Remove three bolts (L) from hub (M), and channel (Q). remove hub and sprocket.

  • Page 170: Gearbox Installation: A30-D

    SECTION 7 MAINTENANCE AND SERVICING Install drive pulley (F) as follows: 7.13.11 Gearbox Installation: A30-D 1. Slide pulley (F) onto shaft with key. a. Position gearbox (A) as shown, picking up the three holes in the endsheet. 2. Install tapered bushing (G) onto shaft, ensuring holes are aligned with holes in b.
  • Page 171 SECTION 7 MAINTENANCE AND SERVICING n. Slide upper roll driveline onto gearbox as shown. Install and tighten two bolts and nuts (S). h. Position auger drive belts (M) as shown above. Torque to 75 ft·lbf (102 N·m). Turn adjuster bolt (N) so that belts (M) deflect o.

  • Page 172: Gearbox Removal: A40-D

    SECTION 7 MAINTENANCE AND SERVICING e. Open endshield on the LH side of the header. 7.13.12 Gearbox Removal: A40-D a. Open shield covering conditioner drive. Loosen three nuts (D) and jam-nut on adjuster bolt (E). g. Turn adjuster bolt (E) so that drive belts (F) can be slipped off pulley (G).

  • Page 173: Gearbox Installation: A40-D

    SECTION 7 MAINTENANCE AND SERVICING Install drive pulley (G) as follows: Remove three flanged lock nuts (M) that secure gearbox (N) to header endsheet, and remove gearbox. 1. Slide pulley (G) onto shaft with key. 7.13.13 Gearbox Installation: A40-D 2. Install tapered bushing (H) onto the shaft, ensuring holes are aligned with holes in a.
  • Page 174 SECTION 7 MAINTENANCE AND SERVICING Adjust roll timing. Refer to Section 6.17.11.2 Roll Timing and Alignment. m. Clean off excess sealant from motor flange and gearbox face. n. Apply light coat of silicone to motor flange, and position motor on gearbox as shown until mounting holes are aligned, and pinion engages gear in gearbox.

  • Page 175: Wheels, Tires, And Hitch: Pull-Type

    SECTION 7 MAINTENANCE AND SERVICING 7.14 WHEELS, TIRES, AND HITCH: 7.14.3 Wheel Installation PULL-TYPE CAUTION CAUTION When installing wheel be sure to use the To avoid personal injury, before servicing holes that are countersunk to match bolt head profile. header/mower conditioner or opening drive covers, follow procedures in Section 7.1 The “uncountersunk”...

  • Page 176: Tire Inflation

    SECTION 7 MAINTENANCE AND SERVICING 7.14.4 Tire Inflation Check tire pressure daily. Maintain 30 psi (207 kPa). WARNING  Service tires safely.  A tire can explode during inflation and cause serious injury or death.  Do not stand over tire. Use a clip-on chuck and extension hose.

  • Page 177: Skid Shoe Wear Plate Replacement

    SECTION 7 MAINTENANCE AND SERVICING e. Position replacement wear plate (D) as shown. 7.15 SKID SHOE WEAR PLATE (The same wear plate can be re-installed, but in the reverse position). REPLACEMENT Secure wear plate with bolts and nuts (C). Skid shoes are equipped with replaceable wear IMPORTANT plates that can be reversed for increase service If bolt heads are worn down, replace with...

  • Page 178: Gauge Rollers

    SECTION 7 MAINTENANCE AND SERVICING NOTE 7.16 GAUGE ROLLERS Use a socket and ratchet wrench to access the nuts. Gauge rollers can be removed for replacement c. Tighten nuts. or repair. Proceed as follows to remove gauge rollers: d. Remove pins (B), and adjust rollers to desired height.

  • Page 179: Maintenance Schedule

    SECTION 7 MAINTENANCE AND SERVICING IMPORTANT 7.18 MAINTENANCE SCHEDULE Recommended intervals are for average conditions. Service the machine more following maintenance schedules list often if operated under adverse conditions periodic maintenance procedures, and are (severe dust, extra heavy loads, etc.). organized service intervals.
  • Page 180 SECTION 7 MAINTENANCE AND SERVICING 7.18.1.3 Maintenance Record: Self-Propelled Self-Propelled Windrower Header  - Check  - Lubricate  - Change ACTION: Hour Meter Reading Date Serviced By BREAK-IN Refer To Section 7.18.1.1 Break-In Inspection: Self-Propelled 100 HOURS OR ANNUALLY ...

  • Page 181: Pull-Type Mower Conditioner

    SECTION 7 MAINTENANCE AND SERVICING 7.18.2 Pull-Type Mower Conditioner 7.18.2.1 Break-In Inspection: Pull-Type HOURS ITEM CHECK REFERENCE Wheel Bolts 120 ft·lbf (160 N·m) Section 7.14.1 Torque Steering Cylinder Clevis and 52 ft·lbf (72 N·m) Stroke Control Auger Drive Belt Sections 7.11.3 and 7.11.4 5, 25, 50 Reel Drive Belt Tension...
  • Page 182 SECTION 7 MAINTENANCE AND SERVICING 7.18.2.3 Maintenance Record: Pull-Type Pull-Type Mower Conditoner  - Change  - Check  - Lubricate ACTION: Hour Meter Reading Date Serviced By FIRST USE Refer To Section 7.18.2.1 Break-In Inspection: Pull-Type 100 HOURS OR ANNUALLY ...

  • Page 183: Troubleshooting

    SECTION 8 TROUBLESHOOTING 8 TROUBLESHOOTING 8.1 WINDROWER PERFORMANCE SYMPTOM PROBLEM SOLUTION SECTION Carryover of Crop On Reduce reel speed Reel speed too fast. 6.17.3 Reel. (sprocket size). Reduce auger speed Auger speed too fast. 6.17.2 (sprocket size). Material Build-Up On Header Frame.
  • Page 184 SECTION 8 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION SECTION Pulling Material By The Ground speed too slow. Increase ground speed. Roots Or Tall Material Leaning Into Machine. Reel position incorrect. Move reel forward and down. 6.17.5 Bent or misaligned guards Align guards for proper 7.8.7 causing poor shearing action.
  • Page 185 SECTION 8 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION SECTION Wet undergrowth. Cut when undergrowth is dry. Move reel back and down Reel position incorrect. 6.17.5 (close to guards). 7.8.9 to Sickle drive belt too loose. Adjust belt tension. Sickle Plugging (cont’d). 7.8.11 Sickle hold-downs improperly Adjust hold-downs so sickle 7.8.8...

  • Page 186: Mechanical

    SECTION 8 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION SECTION Plugging At Delivery Move pan extensions to widest Opening In Heavy Grass Opening too narrow. position. Seed. 6.17.16 Grass Seed Windrow Too Pan extensions not adjusted Adjust pan extensions. Wide or Too Narrow. properly.
  • Page 187 SECTION 8 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION SECTION Worn needle bearing in sickle 7.8.4 head. Replace. Knocking In Sickle Drive. Worn sickle head pin. 7.8.3 Replace with special end Incorrect end guards. 7.8.7 guards. Header Turns While Reduce ground speed until Unloaded But Slows Or Cold oil in system.

  • Page 188: Options And Attachments

    SECTION 9 OPTIONS AND ATTACHMENTS 9.4 REPLACEMENT REEL BAT KITS: 9 OPTIONS AND ATTACHMENTS A30-S, A30-D 9.1 HYDRAULIC HEADER ANGLE KITS: PULL-TYPE Consists of one complete bat assembly for ease of replacement. 9.5 STUB GUARD CONVERSION KIT This kit allows the header angle to be adjusted hydraulically with a cylinder that replaces the standard mechanical link.

  • Page 189: Unloading And Assembly

    Header-specific instructional manual for unloading, assembly and set-up procedures are included with your shipment. HEADER DESCRIPTION USED ON INSTRUCTION PART NUMBER A30-S, A30-D Pull-Type Mower Conditioner Form 169001 A30-S, A30-D, A40-D Self-Propelled Windrower Form 169078 Form 169000 / 169040 Revision D...

  • Page 190: Index

    ..............160 Auger Drive oil change ............160 A30-D belt tension ..........157 Grass Seed Windrowing ......... 94 A30-S belt tension ..........156 Greasing ............... 105 A30-S, A30-D ........... 154 A30-D header ........... 108, 109 A40-D ..............159 A30-S header ..........106, 107 sprockets ............
  • Page 191 Side Deflectors ............90 drive chain A30-S, A30-D ......... 145 Skid Plates position ............... 77 additional ............186 tines and bearings A30-S, A30-D ..... 147 Skid Shoes tines and bearings A40-D ......... 149 adustment ............82 Reel Bat Kit ............186 removal/installation ...........
  • Page 192 Vertical Adjust Towing ..............51 A30-D auger ............74 Tracking, Pull-Type ..........61 A30-S auger ............70 Tractor A30-S, A30-D reel ..........78 drawbar ............... 26 A40 auger ............76 set-Up ..............26 A40 reel............... 80 Transport Lock ..........53, 55 Wear Plates ............

This manual is also suitable for:

A30-dA40-d

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