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SECTION 7 MAINTENANCE AND SERVICING

Form 169000 / 169040

115

Revision D

7.6.3 Oiling

Refer to the following illustration to identify the
various locations that require lubrication. See

Section

7.3.2

Recommended Fluids and

Lubricants

for proper oil.

Apply oil to upper edge of lower spans when
oiling chains.

SAE 30

OIL KNIFE DAILY EXCEPT IN SANDY SOIL

REEL DRIVE CHAIN (1 PLC)

A30-S HEADER

A30-S HEADER LH SIDE

AUGER DRIVE CHAIN (1 PLC)

Summary of Contents for 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 15...

Page 2: ...MACDON A40 D SELF PROPELLED AUGER HEADER MACDON A30 D PULL TYPE MOWER CONDITIONER...

Page 3: ...NG TO UNLOAD ASSEMBLE OR USE THE MACHINE Use this manual as your first source of information about the machine If you follow the instructions given here your Header Mower Conditioner will work well fo...

Page 4: ...Requirements 26 6 3 2 Drawbar Adjustment 26 6 3 3 Drawbar Hitch Set Up 27 6 3 4 3 Point Hitch Cat II III or IIIN Set Up 28 6 4 MOWER CONDITIONER TRACTOR HOOKUP PULL TYPE 29 6 4 1 Drawbar Hook Up 29 6...

Page 5: ...Height 82 6 17 8 Header Angle 83 6 17 9 Header Flotation 84 6 17 10 Feed Pan Rock Drop Tine Position 85 6 17 11 Hay Conditioner 86 6 17 12 Roll Tension 89 6 17 13 Forming Shields 90 6 17 14 Tall Crop...

Page 6: ...A30 D 147 7 10 REEL AND REEL DRIVE A40 D 149 7 10 1 Reel Drive A40 D 149 7 10 2 Reel Tines and Tine Bar Bearings A40 D 149 7 11 AUGER AND AUGER DRIVE A30 S A30 D 154 7 11 1 Auger Drive Chain A30 S 154...

Page 7: ...Propelled Mower Conditioner 177 7 18 2 Pull Type Mower Conditioner 179 8 TROUBLESHOOTING 181 8 1 WINDROWER PERFORMANCE 181 8 2 MECHANICAL 184 9 OPTIONS AND ATTACHMENTS 186 9 1 HYDRAULIC HEADER ANGLE K...

Page 8: ...h 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 It is also used as...

Page 9: ...SECTION 2 SAFETY Form 169000 169040 7 Revision D 2 3 2 3 Panel Safety Sign Locations Pull Type 140311 BOTH SIDES 36651 DRIVELINES 142909 BOTH ENDS 170281...

Page 10: ...SECTION 2 SAFETY Form 169000 169040 8 Revision D 3 Panel Safety Sign Locations Pull Type cont d 109843 44944 115100 BOTH SIDES 171029 30316...

Page 11: ...SECTION 2 SAFETY Form 169000 169040 9 Revision D 3 Panel Safety Sign Locations Pull Type cont d 32738 BOTH ENDS 115148 28403 BOTH ENDS 44944 142912 142908 BACK SIDE...

Page 12: ...SECTION 2 SAFETY Form 169000 169040 10 Revision D 2 3 3 3 Panel Safety Sign Locations Self Propelled 142909 BOTH ENDS 170281 134070 109843 36651 DRIVELINES...

Page 13: ...SECTION 2 SAFETY Form 169000 169040 11 Revision D 3 Panel Safety Sign Locations Self Propelled cont d 28403 32738...

Page 14: ...SECTION 2 SAFETY Form 169000 169040 12 Revision D 2 3 4 2 Panel Safety Sign Locations Self Propelled 184372 194521 DRIVELINES 184385 174474 194464...

Page 15: ...SECTION 2 SAFETY Form 169000 169040 13 Revision D 2 Panel Safety Sign Locations Self Propelled cont d 174632 184371 BOTH ENDS 184371...

Page 16: ...as ear muffs A or ear plugs B protects against objectionable or loud noises Provide a first aid kit for use in case of emergencies Keep a fire extinguisher on the machine Be sure the extinguisher is...

Page 17: ...gage an idling machine Keep the area used for servicing machinery clean and dry Wet or oily floors are slippery Wet spots can be dangerous when working with electrical equipment Be sure all electrical...

Page 18: ...on with the Operator and engine facing in the direction of travel Header or Auger Header A machine that cuts and conditions hay and is attached to a windrower Mower Conditioner A machine that cuts and...

Page 19: ...NT IDENTIFICATION 4 1 PULL TYPE ARTICULATING POWER TONGUE APT HEADER STEERING CYLINDER CENTER LINK CARRIER FRAME LEAN BAR MANUAL CASE LIFT CYLINDER LOCK VALVE WOBBLE BOX SIDE DEFLECTOR FLUFFER DRIVESH...

Page 20: ...SECTION 4 COMPONENTS Form 169000 169040 18 Revision D PULL TYPE cont d HEADER DRIVE FLOAT SPRING HAZARD LIGHT TAIL LIGHT DRIVESHIELD FORMING SHIELD ADJUSTER BOLTS...

Page 21: ...Form 169000 169040 19 Revision D PULL TYPE cont d ARTICULATING POWER TONGUE STEERING CYLINDER LOCKOUT VALVE CONTROL HOSES PUMP 1000 RPM PTO DRIVELINE SAFETY CHAIN JACK DRAWBAR HITCH TOWING ADAPTER 3...

Page 22: ...20 Revision D 4 2 SELF PROPELLED SKID SHOE GAUGE ROLLER CONDITIONER HAZARD LIGHT REEL BAT REEL CAM DRIVESHIELD WOBBLE BOX DOUBLE KNIFE AUGER HAZARD LIGHT HYDRAULIC DRIVE FORMING SHIELD WINDROWER HEAD...

Page 23: ...nside LH Endsheet Manual Storage Frame Mounted Case WHEELS Tires 31 x 13 5 15 NHS 8 Ply Terra Rib Tread Width 150 in 3810 mm Pressure 30 psi 207 kPa CUTTERBAR Effective Cutting Width 14 ft 9 in 4496 m...

Page 24: ...Replaceable Polyethylene Radius to tine tip 22 in 540 mm Speed rpm 20T Sprocket 20T Auger No Load 71 74 71 74 Load 69 71 69 71 19T Auger No Load 68 70 68 70 Load 65 68 65 68 19T Sprocket 20T Auger No...

Page 25: ...Adjustment 7 17 5 HEADER DRIVE A30 Hydraulic From Windrower Pump to One Piston Motor A40 Hydraulic From Windrower Pump to One Piston Motor and Two Gear Motors SICKLE Belt Driven Heavy Duty MD Wobble...

Page 26: ...lace able Poly ethylene Greasable Ball Radius to tine tip 22 in 540 mm Max Speed rpm 22T Sprocket 22T Auger 77 15 85 77 15 85 73 15 85 19T Auger 67 67 69 19T Sprocket 22T Auger 67 69 19T Auger 58 58 6...

Page 27: ...AFETY CAUTION Follow all safety and operational instructions given in your Operator s Manual If you do not have a tractor windrower manual get one from your Dealer and read it thoroughly Never attempt...

Page 28: ...to supply power to the mower conditioner s warning lights 6 3 2 Drawbar Adjustment CAUTION Shut off tractor engage parking brake and remove key before working around hitch Adjust tractor drawbar to me...

Page 29: ...c Install pin C through drawbar and extension from underside and secure with hairpin d Gradually tighten four bolts to 265 ft lbf 359 N m e Attach the swivel APT member D with pin E onto the APT f Sec...

Page 30: ...y III tractor hitch arms 1 Remove pins D 2 Remove bolts E 3 per side 3 Flip outer plate F and inner plate G on each arm IMPORTANT The inner plate G has a smaller joggle than the outer plate F Always m...

Page 31: ...hairpin IMPORTANT If the tractor has a three point hitch lower the lower links as low as possible to prevent damage to the APT e Attach driveline E to tractor PTO shaft as follows 1 Position driveline...

Page 32: ...or Operator s Manual e Check distance X between tractor PTO shaft D and implement input shaft E without the front half of the driveline attached f The measurement must not exceed the dimensions listed...

Page 33: ...d Retract Left c Connect one lift cylinder hose B as follows CONTROL LEVER POSITION CYLINDER MOVEMENT HEADER MOVEMENT Forward Retract Lower Backward Extend Raise d Connect two header tilt cylinder hos...

Page 34: ...ocks or leave header raised If leaving in raised position engage lift cylinder lock out valves c Move remote cylinder control valve lever back and forth to relieve stored hydraulic pressure d Disconne...

Page 35: ...ision D j 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 l Slowly drive tractor away from mower conditioner m Rep...

Page 36: ...ontrol valve lever back and forth to relieve stored hydraulic pressure e Disconnect hydraulic hoses and electrical harness Store hose ends in holes at front of APT as shown f Pull pin A securing jack...

Page 37: ...d with A30 S and A30 D header hydraulics and electrical harness Proceed as follows DANGER Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet c...

Page 38: ...6 6 3 Configure Reverser Valve Jumper Hose 6 6 1 2 M200 The M200 requires four hoses to run an A30 D header If required configure the M200 by installing Kit B4651 The Kit which is available through yo...

Page 39: ...remove connector from support bracket c Disengage and rotate lever D counter clockwise to fully up position to release the hose bundle E d Move hose electrical bundle E to header e Route bundle E from...

Page 40: ...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 n Push auger reel pressure...

Page 41: ...e header is factory assembled for M150 M155 and M200 windrowers q Change hoses as follows if header is being mounted on a M100 M105 or M205 windrower 1 Disconnect hose C at tee E 2 Disconnect hose D a...

Page 42: ...ector from support bracket c Disengage and rotate lever D counter clockwise to fully up position to release the hose bundle E d Move hose electrical bundle E to header e Route bundle E from windrower...

Page 43: ...Header Unloading and Assembly Instructions Form 169078 that was supplied with your A40 D header n Push auger pressure A and auger reel return B hose couplers onto mating receptacles on valve block unt...

Page 44: ...pen driveline shield B b Remove the cap C from electrical connector and remove connector from support bracket c Disengage and rotate lever D counter clockwise to fully up position to release the hose...

Page 45: ...Header Unloading and Assembly Instructions Form 169078 that was supplied with your A40 D header n Push auger pressure A and auger reel return B hose couplers onto mating receptacles on valve block unt...

Page 46: ...the following kits from your MacDon Dealer and install them in accordance with the instructions supplied with the kit KIT DESCRIPTION KIT NUMBER Base Kit B5491 Completion B5492 Coupler B5497 a Diseng...

Page 47: ...cles snap into lock position k Route auger return and reel pressure hose bundle H from header to windrower and locate bundle above existing hose support K as shown l Secure with three straps L and low...

Page 48: ...f a reverser valve block A has been installed the jumper hose B must be routed as shown opposite Do not operate the headers unless hose is routed as shown b To route hose B from A40 D position to A30...

Page 49: ...nder reverser valve block A so that hose can be routed to port C2 on header drive valve block 3 Remove cap from port C2 fitting on header drive valve block 4 Connect jumper hose B to port C2 fitting o...

Page 50: ...toward pin and pull connector to disengage 3 Install caps on connectors and hose ends if equipped d Move hose bundle E from header and locate on windrower LH side with hose ends in support F and under...

Page 51: ...nd D from windrower valve s c Raise lever E and undo Velcro straps F d Move hose bundle G to store on header walkway e Install caps on connectors and hose ends if equipped f At the header disconnect e...

Page 52: ...ge bracket j Locate electrical harness through support J and attach cap to electrical connector k Close driveline shield and move windrower platform to closed position l Check to ensure hoses and elec...

Page 53: ...ansported on public roads by towing with a tractor or a truck Proceed to Section 6 8 2 1 Transporting With A Tractor or 6 8 2 2 Transporting With A Truck CAUTION Be aware of roadside obstructions onco...

Page 54: ...k CAUTION Do not tow with a vehicle weighing less than 7500 lb 3400 kg Ensure that the capacity of the towing vehicle is sufficient to maintain control If the mower conditioner is in Transport mode pr...

Page 55: ...ylinder is not fully charged loss of control can result in injury or death Use the temporary transport lock pin if machine must be towed without a fully charged steering cylinder e If steering cylinde...

Page 56: ...Refer to Section 6 5 MOWER CONDITIONER TRACTOR UNHOOK PULL TYPE d Tie hoses to APT e Remove tall crop dividers if equipped as follows 1 Remove U bolt A and bolts B securing crop divider C to lean bar...

Page 57: ...e j Secure APT to frame hook to prevent movement Use cardboard or suitable material under the tie to protect paint k Secure the steering cylinder to the frame with wire Wrap tie around clevis and use...

Page 58: ...ing bolt M and pulling wheel axle assembly from frame o Lift mower conditioner and back the flatbed trailer under the unit The mower conditioner can be positioned with the APT towards the front or rea...

Page 59: ...le tipping or machine damage Lifting Vehicle Minimum Lifting Capacity 8500 lb 3865 kg Minimum Lifting Height 15 ft 4 5 m Chain Type Overhead Lifting Quality 1 2 in Minimum Working Load 5000 lb 2270 kg...

Page 60: ...sion D i Swing APT to working position j 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 l Move lift cylinde...

Page 61: ...the following at the beginning of each operating season a Adjust tension on drive belts Refer to Sections 7 8 SICKLE AND SICKLE DRIVE 7 9 REEL AND REEL DRIVE A30 S A30 D and 7 11 AUGER AND AUGER DRIVE...

Page 62: ...O PULL TYPE DANGER Be sure all bystanders are clear of the machine before engaging the PTO Never leave tractor seat with the PTO engaged a Engage PTO slowly just before the mower conditioner is moved...

Page 63: ...or The control is operated momentarily for steering and must be returned to OFF or NEUTRAL position as soon as the mower conditioner reaches the desired path of travel 6 15 1 Right Side Operation Pull...

Page 64: ...r LH side operation 6 15 3 Avoiding Obstacles Move steering lever as required to avoid obstacles 6 15 4 Square Corners The following procedure is intended only as a guide to developing a turning proce...

Page 65: ...tion away from the uncut crop NOTE For ease of operation both levers can be activated with one hand and held until steering cylinder completes its stroke c At position B start turning tractor back tow...

Page 66: ...n rolls forward until plug clears h Return wrench to storage location and secure in place with pin WARNING Return unplug wrench to storage location and close LH driveshield before re starting machine...

Page 67: ...6 17 1 Auger Speed 6 17 2 Reel Speed 6 17 3 Auger Position 6 17 4 Reel Position 6 17 5 Tine Aggressiveness Adjustment 6 17 6 Cutting Height 6 17 7 Header Angle 6 17 8 Header Flotation 6 17 9 Feed Pan...

Page 68: ...ckets as follows 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 Remove auger drive chain A Refer...

Page 69: ...ng Operator s seat for any reason A child or even a pet could engage an idling machine a Remove reel drive belt A and reel drive chain B from drive sprocket Refer to Sections 7 9 1 Reel Drive Chain A3...

Page 70: ...by approximately 1 32 5 32 in 1 4 mm Shimming the stripper bars may be required Refer to Section 7 11 7 Stripper Bars 6 17 4 1 Auger Fore Aft Adjustment A30 S a Open LH endshield b Loosen auger drive...

Page 71: ...lects 3 16 in 4 mm when a load of 8 12 lbf 35 40 N is applied to each belt at mid span 2 Tighten jam nut on adjuster bolt H and nuts J o Check reel drive chain tension Total chain slack at N should be...

Page 72: ...drive V belt F tension Each belt should deflect 3 16 in 4 mm at mid span when a load of 8 12 lbf 35 40 N is applied to each belt If necessary adjust as follows 1 Loosen jam nut on adjuster bolt G 2 T...

Page 73: ...olt O on sprocket and jam nut on adjuster bolt P 2 Turn adjuster bolt P to move idler sprocket downward until chain slack is achieved as above 3 Rotate auger and check chain for slack at tightest poin...

Page 74: ...auger fore aft position e Tighten jam nut and four nuts D f Tighten auger drive chain A as follows 1 Turn adjuster bolt C to achieve 1 4 in 6 mm slack at mid span of chain A 2 Tighten nut B on idler...

Page 75: ...olt L on sprocket and jam nut on adjuster bolt M 2 Turn adjuster bolt M to move idler sprocket downward until chain slack is achieved as above 3 Rotate auger and check chain for slack at tightest poin...

Page 76: ...ger vertical position e Tighten jam nut and four nuts C f Tighten auger drive chain A as follows 1 Turn adjuster bolt C to achieve 1 4 in 6 mm slack at mid span of chain A 2 Tighten nut B on idler spr...

Page 77: ...olt L on sprocket and jam nut on adjuster bolt M 2 Turn adjuster bolt M to move idler sprocket downward until chain slack is achieved as above 3 Rotate auger and check chain for slack at tightest poin...

Page 78: ...H endshield g Loosen four nuts C h Loosen jam nut on adjuster bolt D and turn bolt D to adjust auger fore aft position i Tighten jam nut j Tighten nuts C k Close shields before engaging header 6 17 4...

Page 79: ...eel Fore Aft Position A30 S A30 D NOTE The reel must be adjusted equally on both sides CAUTION To prevent accidental movement of windrower place all controls in NEUTRAL or in PARK engage park brake if...

Page 80: ...eel NOTE Adjustment at forward adjuster bolt should be 0 47 in 12 mm lower than at rear adjuster bolt d Tighten jam nuts and nuts A e Open RH endshield f Loosen reel drive chain C as follows 1 Loosen...

Page 81: ...ove any sharp edges or burrs from tine m Check that reel is evenly adjusted 6 17 5 3 Reel Fore Aft Position A40 D NOTE The reel must be adjusted equally on both sides CAUTION To prevent accidental mov...

Page 82: ...nuts E f Open RH endshield g Loosen four nuts G h Loosen jam nuts on adjuster bolts H and turn bolts H to adjust reel vertical position i Tighten jam nut j Tighten nuts G k Close shields before engagi...

Page 83: ...t side rotate cam clockwise to obtain more aggressive tine action d 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 re...

Page 84: ...dry faster WARNING To avoid bodily injury or death from unexpected start up or fall of raised machine stop engine remove key and engage lift cylinder lockout valves before going under machine to adjus...

Page 85: ...decrease flatten header angle rotate the turnbuckle sleeve C so that the turnbuckle decreases in length d To increase steepen header angle rotate the turnbuckle sleeve C so that the turnbuckle increas...

Page 86: ...Because header weight transfers to outside tire whenever header is swung from one side to the other tires must be fully inflated 30 psi 207 kPa to minimize effects on header float CAUTION To prevent a...

Page 87: ...To avoid bodily injury or death from unexpected start up or fall of raised machine stop engine remove key and engage header lift cylinder stops before going under machine a Raise header fully and enga...

Page 88: ...r header fully b Stop engine and remove key 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 rol...

Page 89: ...r B to expose access port C at each end of conditioner b Examine roll timing distance X at each end of the rolls with header fully lowered Each steel bar on one roll should be centered between two bar...

Page 90: ...it rests on the ground b Loosen bolt A and rotate cover B to expose access port C c Examine roll timing distance X at each end of the rolls NOTE The rolls are aligned if the distance X varies less tha...

Page 91: ...of windrower place all controls in NEUTRAL or in PARK engage park brake if applicable shut off engine and remove key a Lower header fully b Stop engine and remove key c To increase the roll tension l...

Page 92: ...d for ease of pick up 6 17 13 1 Side Deflectors The position of the side forming shields controls the width and placement of the windrow CAUTION To prevent accidental movement of windrower place all c...

Page 93: ...ARK engage park brake if applicable shut off engine and remove key a For more crop control in light material lower the deflector G by pushing down on one side of the deflector and then on the other si...

Page 94: ...B and re position divider C to align with alternate hole location D c Re install bolts B and tighten d Tighten U bolt A Proceed as follows to remove tall crop dividers a Remove U bolt A and bolts B a...

Page 95: ...ound satisfactory b Choose a ground speed that allows the sickle to cut the crop smoothly and evenly c The chart below indicates the relationship between ground speed and area cut for three header siz...

Page 96: ...beaters and beater supports have been removed to reduce auger wrapping 6 17 16 3 Seven Bat Reel A seventh bat is added to the reel body for smoother reel action and better crop feed into the header 6...

Page 97: ...row Forming Rods Forming rods are provided to assist in forming the narrow windrows preferred for this application a Bend rods to modify the windrow shape Use forming rods in conjunction with auger pa...

Page 98: ...g or tedding will expose the hay to fresher less saturated air e Cut hay perpendicular to the direction of the prevailing winds is also recommended 6 18 4 Windrow Characteristics It is recommended tha...

Page 99: ...nder lock outs d If possible block up the header to take weight off tires e Re paint all worn or chipped painted surfaces to prevent rust f Loosen drive belts g Lubricate header mower conditioner thor...

Page 100: ...ling items such as scarves or bracelets Use adequate light for the job at hand Replace all shields removed or opened for service Use only service and repair parts made or approved by the equipment man...

Page 101: ...y 5 7 3 1 1 SAE Bolts BOLT DIA A in NC BOLT TORQUE SAE 5 SAE 8 lbf ft N m lbf ft N m 1 4 9 12 11 15 5 16 18 24 25 34 3 8 32 43 41 56 7 16 50 68 70 95 1 2 75 102 105 142 9 16 110 149 149 202 5 8 150 20...

Page 102: ...assembly 7 3 1 4 O ring Type Hydraulic Fittings a Inspect O ring and seat for dirt or obvious defects b On angle fittings back off the lock nut until washer A bottoms out at top of groove B in fittin...

Page 103: ...Thread tube or hose nut until hand tight The nut should turn freely until it is bottomed out Torque fitting further to the specified number of F F F T Flats From Finger Tight or to a given torque val...

Page 104: ...High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base As Required Unless Otherwise Specified High Temperature Extreme Pressure EP Performance Wi...

Page 105: ...re pounds per square inch psi x 6 8948 kilopascals kPa x 00689 megapascals MPa Torque pound feet or foot pounds lbf ft or ft lbf x 1 3558 newton meters N m pound inches or inch pounds lbf in or in lbf...

Page 106: ...from fully closed position Shield will self latch c To open driveline shield disengage rubber latch C and open shield D d To close lower shield D and engage rubber latch C 7 5 LIFT CYLINDER LOCK OUTS...

Page 107: ...CE SCHEDULE 7 6 1 Greasing Procedure a Wipe grease fitting with a clean cloth before greasing to avoid injecting dirt and grit b Inject grease through fitting with grease gun until grease overflows fi...

Page 108: ...s do not over grease If more than 6 to 8 pumps of the grease gun are required to fill the cavity replace the seal in the sickle head High Temperature Extreme Pressure EP2 Performance With 1 Max Molybd...

Page 109: ...Form 169000 169040 107 Revision D A30 S Headers Cont d AUGER SHAFT BEARING 1 PLC REEL SHAFT BEARING 1 PLC A30 S HEADER RH SIDE High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum D...

Page 110: ...e EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base SICKLE DRIVE BEARING 1 PLC AUGER SHAFT BEARING 1 PLC NOTE To prevent binding and or excessive wear caused by sickle pressin...

Page 111: ...sed by sickle 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 sickle head AUGER SHAFT BEARING 1 PLC REEL SHAFT BEA...

Page 112: ...A40 D HEADER RH SIDE NOTE To prevent binding and or excessive wear caused by sickle pressing on guards do not over grease If more than 6 to 8 pumps of grease gun are required to fill the cavity repla...

Page 113: ...ease If more than 6 to 8 pumps of grease gun are required to fill the cavity replace the seal in the sickle head SICKLE HEAD BEARING 1 PLC SICKLE DRIVE BEARING 1 PLC GAUGE ROLLER BEARINGS 2 PLCS BOTH...

Page 114: ...169000 169040 112 Revision D IV HAY CONDITIONER ROLL SHAFT BEARINGS 2 PLCS ROLL PIVOT 1 PLC BOTH SIDES ROLL SHAFT BEARINGS 2 PLCS High Temperature Extreme Pressure EP2 Performance With 1 Max Molybden...

Page 115: ...LS 2 PLCS DRIVELINE UNIVERSALS 2 PLCS DRIVELINE SHAFTS 1 PLC DRIVELINE UNIVERSALS 2 PLCS DRIVELINE SHAFTS 2 PLCS A30 D and A40 D 10 MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINTS ONLY 10 M...

Page 116: ...ANCE AND SERVICING Form 169000 169040 114 Revision D VI PULL TYPE CARRIER FRAME WHEEL BEARINGS 1 PLC BOTH SIDES TONGUE PIVOT 1 PLC FRAME HEADER PIVOT 1 PLC BOTH SIDES LIFT LINKAGE 2 PLCS BOTH SIDES LI...

Page 117: ...tion to identify the various locations that require lubrication See Section 7 3 2 Recommended Fluids and Lubricants for proper oil Apply oil to upper edge of lower spans when oiling chains SAE 30 OIL...

Page 118: ...SERVICING Form 169000 169040 116 Revision D Oiling Cont d A30 D HEADER LH SIDE 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 SAE...

Page 119: ...TE The locking cam is only on one side of the bearing c Install but do not tighten flangette bolts E d When shaft is correctly located lock the lock collar with a punch NOTE The collar should be locke...

Page 120: ...ine for the hydraulic oil reservoir 7 7 2 2 Oil Level Check oil level daily before start up at the sight gauge on the left side of the APT Oil level should be at or near FULL mark on the gauge when to...

Page 121: ...ry set at 4000 psi 27 6 MPa See your Dealer for adjustment or service A pressure gauge can be installed at the gauge port F as shown above 7 7 3 Hoses and Lines Check hydraulic hoses and lines daily f...

Page 122: ...sickle from cutterbar a Stroke sickle as required to expose sickle sections b Remove lock nuts A and lift section B off of bolts IMPORTANT Do not mix heavy and light sickle sections on same sickle c...

Page 123: ...bearing if it has been replaced 7 8 4 Sickle Head Bearing Removal a Remove the sickle See Section 7 8 2 Sickle Removal b Using a flat ended tool G with approximately the same diameter as the plug H t...

Page 124: ...g Operator s seat for any reason A child or even a pet could engage an idling machine 1 Remove bolts A from lean bar end cap 2 Pull out end cap and plastic storage tube assembly B with the sickle insi...

Page 125: ...ted Guard Replacement Single Knife 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 Stroke the sick...

Page 126: ...has offset cutting surfaces See illustrations NOTE Top guide C must accommodate the two overlapping knifes at center guard B location on double knife header Ensure replacement is correct part IMPORTAN...

Page 127: ...ard B and top guide C to cutterbar b Remove guard top guide and adjuster bar D c Position replacement guard B adjuster bar D top guide C and install bolts and nuts A Do not tighten IMPORTANT Note posi...

Page 128: ...s offset cutting surfaces See illustration NOTE Top guide C which is an inverted stub guard must accommodate the two overlapping knifes at center guard location on double knife header Ensure replaceme...

Page 129: ...ge clearance from hold down to sickle section should be 0 004 0 024 in 0 1 0 6 mm NOTE For larger adjustments it may be necessary to loosen bolts B turn adjuster bolt A and then re tighten nuts B Doub...

Page 130: ...N m Double Knife a Torque nuts G to 35 ft lbf 46 N m b Turn adjuster bolts H Using a feeler gauge clearance from hold down to sickle section should be 0 004 0 016 in 0 1 0 4 mm at the guide tip and 0...

Page 131: ...of 20 lbf 80 N deflects belt A 1 4 in 6 mm at mid span e Tighten jam nut at C and nut B on idler pulley f Close shield g Re adjust tension of a new belt after a short run in period about 5 hours 7 8...

Page 132: ...then tension belt b Turn adjuster bolt C to move idler until a force of 20 lbf 80 N deflects belt A 1 4 in 6 mm at mid span c Tighten idler bolt B d Position belts F on pulley G as shown e Turn adjust...

Page 133: ...nut on adjuster bolt C d Turn adjuster bolt C to move pulley D until a force of 5 6 5 lbf 22 30 N deflects belt A 0 55 in 14 mm at mid span e Tighten jam nut at C and three nuts B f Close endshield g...

Page 134: ...osen 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 i Slip belt o...

Page 135: ...e pulley D until a force of 5 6 5 lbf 22 30 N deflects belt A 0 55 in 14 mm at mid span c Tighten jam nut at C and three nuts B d Re position V belts K on pulley D e Turn adjuster bolt J to move drive...

Page 136: ...2 30 N applied at mid span deflects belt A 0 55 in 14 mm d Tighten jam nut at C and three nuts B e Close endshield f Re adjust tension of a new belt after a short run in period about 5 hours 7 8 10 5...

Page 137: ...pulley Be sure adjusting screw is fully loosened then tension belt b Turn adjuster bolt C to move pulley D until a force of 5 6 5 lbf 22 30 N applied at mid span deflects belt A 0 55 in 14 mm c Tight...

Page 138: ...an deflects belt A 0 55 in 14 mm d Tighten jam nut at C and three nuts B e Re adjust tension of a new belt after a short run in period about 5 hours Double V Belts a Loosen three nuts F and jam nut on...

Page 139: ...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 Timing Belt a Route sickle drive belt A through op...

Page 140: ...0 16 in 4 mm c Tighten jam nut at G and three nuts F d Re adjust tension of a new belt after a short run in period about 5 hours 7 8 11 4 Tension Adjustment RH Sickle Drive Belt A40 D IMPORTANT To pr...

Page 141: ...rough this hole to remove it 7 8 11 6 Installation RH Sickle Drive Belt A40 D a Route sickle drive belt A through opening in endsheet onto wobble box pulley and sickle drive pulley J as shown NOTE Whe...

Page 142: ...le sections are centered between guard points as shown c Rotate right side wobble box pulley C counter clockwise until right side sickle D is at the center of the inboard stroke d Install right side w...

Page 143: ...Adjustment RH Sickle Drive Timing Belt A30 D or 7 8 11 4 Tension Adjustment RH Sickle Drive Belt A40 D 2 If RIGHT SICKLE leads LEFT SICKLE rotate RIGHT HAND driven pulley C clockwise 3 If RIGHT SICKL...

Page 144: ...ections 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 Section 7 8 10 4 Tension Adjustment...

Page 145: ...p g Install bolt E and nut and torque to 160 ft lbf 217 N m h Align sickle head D with pitman arm C i Install sickle head pin F in pitman arm C and tap it down into the sickle head ensuring pin is bot...

Page 146: ...ure with bolt F and nut Torque bolts to 160 ft lbf 217 N m d Install wobble box See previous page 7 8 13 6 Changing Wobble Box Oil NOTE Change wobble box lubricant after the first 50 hours operation a...

Page 147: ...C and nut B and re check tension f Close shield before engaging header 7 9 1 2 Removal Remove reel drive chain A as follows a Open shield on header RH side b Remove reel drive belt D from pulley E Ref...

Page 148: ...drive chain tension and adjust if necessary See Section 7 9 1 Reel Drive Chain A30 S A30 D f Close shield before engaging header 7 9 2 2 Removal Remove reel drive belts A as follows a Open shield on h...

Page 149: ...sembly D g Slide bearing support J off tine bar and remove bearing halves K h Remove nut bolt and keeper on each tine to be removed and slide tine off the bar 7 9 3 2 Installation Tines and Bearings C...

Page 150: ...off bar e Slide bearing support M off tine bar and remove bearing halves Q f Remove nut bolt and keeper on each tine to be removed and slide tine off the bar 7 9 3 4 Installation Tines and Bearings O...

Page 151: ...l 7 10 2 1 Tine and Bearing Replacement Cam End Disc 1 a Loosen bolt on cover A and slide cover to expose hole in cam disc Rotate reel and align bearing with hole b Remove cam follower bearing bolt B...

Page 152: ...tall bolts in end tines at this time i Position end of tine bar clear of cam disc and install cam arm assembly D complete with bearing on tine bar j Engage cam arm into cam track as shown k Attach bea...

Page 153: ...bolt D and keeper E on tine to be replaced 2 Remove bolts and keepers on tines as required to facilitate replacement of damaged or worn tine 3 Slide tines off tine bar 4 Install tines on tine bar and...

Page 154: ...lace tine as follows 1 Remove bolt D and keeper E on tine to be replaced 2 Remove bolts and keepers on tines as required to facilitate replacement of damaged or worn tine 3 Slide tines off tine bar 4...

Page 155: ...Extension Section Z 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 Tine H must be clamped betwe...

Page 156: ...d 7 11 1 2 Removal Remove chain A as follows a Open LH endshield b Loosen three bolts B c Loosen jam nut on adjuster bolt C d Turn adjuster bolt C to loosen chain A e Remove chain 7 11 1 3 Installatio...

Page 157: ...eck chain for slack at tightest point Re adjust position of idler sprocket to achieve required slack e Close endshield 7 11 2 2 Removal a Open LH endshield b Loosen nut A on idler sprocket support c T...

Page 158: ...B f Tighten jam nut at C g Close shield before engaging header 7 11 3 2 Removal a Open LH endshield b Remove chain D from small sprocket as follows 1 Loosen three bolts B 2 Loosen jam nut on adjuster...

Page 159: ...after about 5 hours of operation f Close shield before engaging header 7 11 4 2 Removal a Open LH endshield b Remove auger drive chain D as follows 1 Loosen nut E on idler sprocket support 2 Turn adj...

Page 160: ...locally remove the poly Use a plastic welder to rejoin the material Replacement pans are also available from your Dealer 7 11 6 Rubber Fingers Rubber fingers should be replaced if missing or damaged...

Page 161: ...ion if required for certain crop conditions or especially in tall crops that cause material to bunch up at the ends of the conditioner rolls Stripper bar extensions will allow the auger to carry the c...

Page 162: ...d Remove breather A check plug B and drain plug C e Allow oil to drain f Replace drain plug C and add oil at A to required level Use Gear Lubricant SAE 85W 140 API Service Class GL 5 1 5 quarts 1 4 li...

Page 163: ...ff forming shield Repeat for other deflector d Disassemble locking handles H and remove bolts e Disassemble fluffer shield J from forming shield cover f Remove bolts K to remove deflector fins L from...

Page 164: ...c 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 prop...

Page 165: ...the auger drive belts E from the drive pulley as follows 1 Loosen three bolts F 2 Loosen jam nut on adjuster bolt G 3 Turn adjuster bolt G to loosen chain H 4 Loosen jam nut on adjuster bolt J 5 Turn...

Page 166: ...ensuring holes are aligned with holes in pulley 3 Align pulley F and countershaft pulley H faces to within 06 in 1 5 mm 4 Install three bolts in tapered bushing G and tighten to 18 ft lbf 25 N m 5 Tap...

Page 167: ...four bolts and nuts P i Adjust roll timing Refer to Section 6 17 11 2 Roll Timing and Alignment j Clean off excess sealant from motor flange and gearbox face k Apply light coat of silicone to motor fl...

Page 168: ...eline clear of gearbox d Remove two nuts and bolts C from upper roll shaft at gearbox and pull driveline clear of gearbox e Open LH endshield f Remove auger drive chain D from small sprocket as follow...

Page 169: ...t 2 Remove three bolts N from the tapered bushing 3 Install bolts in two threaded holes in bushing and tighten to release bushing 4 Remove pulley K bushing and key i Remove two bolts O and nut and bol...

Page 170: ...r hole and tighten Install bolt E from backside e Tighten hardware f Install drive pulley F as follows 1 Slide pulley F onto shaft with key 2 Install tapered bushing G onto shaft ensuring holes are al...

Page 171: ...on of idler sprocket to achieve required slack n Slide upper roll driveline onto gearbox as shown Install and tighten two bolts and nuts S Torque to 75 ft lbf 102 N m o Attach lower roll driveline fla...

Page 172: ...s C from the upper roll shaft at the gearbox and pull driveline clear of gearbox e Open endshield on the LH side of the header f Loosen three nuts D and jam nut on adjuster bolt E g Turn adjuster bolt...

Page 173: ...Install tapered bushing H onto the shaft ensuring holes are aligned with holes in pulley 3 Align faces of pulley G and countershaft pulley O to within 06 in 1 5 mm 4 Install three bolts in tapered bu...

Page 174: ...lean 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 gea...

Page 175: ...jack 5000 lb capacity from storage position on APT c Position jack on mount provided on frame leg as shown and raise tire just off the ground Place block under frame leg d Remove wheel bolts e Remove...

Page 176: ...er weld a wheel rim Never use force on an inflated or partially inflated tire Make sure the tire is correctly seated before inflating to operating pressure If the tire is not in correct position on th...

Page 177: ...ench to access the nuts c Remove clevis pins B and disengage tabs on skid shoe from slots in cutterbar d Remove eight bolts C and remove wear plates D e Position replacement wear plate D as shown The...

Page 178: ...allation a Position gauge roller assembly below cutterbar and insert tabs on roller assembly into slots C in frame Secure with two pins B at lowest position b Attach clips A with bolts and nuts to sec...

Page 179: ...el Drive Belt Section 7 9 2 Sickle Drive Belt Sections 7 8 9 7 8 10 and 7 8 11 10 Auger Drive Chain Tension Lubrication Sections 7 11 1 and 7 11 2 Reel Drive Chain Section 7 9 1 Wobble Box Mounting Bo...

Page 180: ...MAINTENANCE IS NOT NORMALLY REQUIRED BUT IS AT THE OWNER OPERATOR S DISCRETION Auger Drive Chain except A40 D Hydraulic Hoses and Lines Hydraulic Oil Level Reel Drive Chain except A40 D Sections Guard...

Page 181: ...First 100 Hours Only Every 250 Hours Thereafter END OF SEASON Refer To Section 6 19 STORAGE 10 HOURS OR DAILY 1 Check Hydraulic Oil Level 2 Check Hydraulic Hoses And Lines For Leaks 3 Oil Sickle Exce...

Page 182: ...F DAILY MAINTENANCE IS NOT NORMALLY REQUIRED BUT IS AT THE OWNER OPERATOR S DISCRETION Auger Drive Chain Hydraulic Hoses and Lines Hydraulic Oil Level Reel Drive Chain Sections Guards and Hold Downs S...

Page 183: ...is spread too narrow Adjust forming shields for wider swath 6 17 13 Crop is bunched in windrow Adjust forming shields baffle Excessive Drying Or Bleaching Of Crop Excessive crimping Increase roll gap...

Page 184: ...PTO Check for proper match of pump and gear drive at PTO 5 1 Reel drive chain too loose except A40 D Increase chain tension 7 9 1 Reel position incorrect Move reel forward and down 6 17 5 Relief valve...

Page 185: ...ground speed Roll gap too large Adjust roll gap 6 17 11 Conditioner running too slow Maintain rated knife conditioner speed 5 1 5 2 Uneven crop flow across auger Remove front stripper bar or stripper...

Page 186: ...tting 6 17 9 Sickle speed too slow Maintain proper RPM on PTO Check for proper match of pump and gear drive at PTO 5 1 Guards sickle and hold downs misaligned Straighten guards align hold downs 7 8 7...

Page 187: ...l sickle Replace 7 8 4 Worn sickle head pin 7 8 3 Bent or broken guard Straighten or replace 7 8 7 Incorrect end guards at sickle head Replace with correct number of special guards Windrower Side Drif...

Page 188: ...be added for extra control of cutting height and protection of cutting components 9 3 GAUGE ROLLER KIT The gauge roller kit replaces the outer skid shoes and consists of rollers in place of skid shoes...

Page 189: ...D 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 Mo...

Page 190: ...ng 176 Feed Pan Position 85 Fluffer 91 Fore Aft Adjust A30 D auger 72 A30 S auger 68 A30 S A30 D reel 77 A40 auger 76 A40 reel 79 Forming Rods 95 Forming Shields 90 Gauge Roller Kit 186 Gauge Rollers...

Page 191: ...eed A30 S A30 D 67 A40 D 67 Relief Valve 119 Reservoir hydraulic 118 oil level 118 Reverser Valve 46 Rock Drop Position 85 Rolls alignment 87 gap 86 tension 89 timing 87 unplugging 64 Rubber Fingers 1...

Page 192: ...2 flatbed 54 Troubleshooting mechanical 184 windrower performance 181 Turning 180 degrees 63 square corners 62 Unhook Pull Type 32 Unloading 57 187 Unplugging rolls 64 sickle 64 Valve Blocks 49 Vertic...

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MacDon A30-S, Operator'S Manual

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