MacDon A30-S Unloading And Assembly Instructions Download

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TABLE OF CONTENTS

169078

Revision E

INTRODUCTION ........................................................................................................................................................ 2

GENERAL SAFETY .................................................................................................................................................. 2

RECOMMENDED TORQUES ................................................................................................................................... 4

GENERAL ..................................................................................................................................... 4

SAE BOLTS .................................................................................................................................. 4

METRIC BOLTS ........................................................................................................................... 4

HYDRAULIC FITTINGS ................................................................................................................ 5

CONVERSION CHART ............................................................................................................................................. 7

DEFINITIONS ............................................................................................................................................................ 7

STEP 1.

UNLOAD HEADER ............................................................................................................................. 8

STEP 2.

REMOVE UNDERSIDE SHIPPING STAND ....................................................................................... 9

STEP 3.

INSTALL ADDITIONAL SKID SHOES ............................................................................................... 9

STEP 4.

INSTALL GAUGE ROLLERS ........................................................................................................... 10

STEP 5.

LOWER HEADER ............................................................................................................................. 11

STEP 6.

REMOVE SHIPPING STANDS ......................................................................................................... 12

STEP 7.

INSTALL TALL CROP DIVIDER ...................................................................................................... 13

STEP 8.

ADJUST LEAN BAR ........................................................................................................................ 14

STEP 9.

ADJUST PAN EXTENSIONS: GRASS SEED SPECIAL ................................................................ 14

STEP 10.

ADJUST LIGHTS .............................................................................................................................. 14

STEP 11.

ASSEMBLE FORMING SHIELD ...................................................................................................... 15

STEP 12.

INSTALL FORMING SHIELD ........................................................................................................... 16

STEP 13.

ATTACH HEADER TO WINDROWER ............................................................................................. 18

STEP 14.

MODIFY HYDRAULICS .................................................................................................................... 23

A30-S .......................................................................................................................................... 23

A40-D .......................................................................................................................................... 23

STEP 15.

CONFIGURE REVERSER VALVE JUMPER HOSE ....................................................................... 29

STEP 16.

ATTACH HYDRAULICS ................................................................................................................... 31

A30-S .......................................................................................................................................... 31

A40-D .......................................................................................................................................... 33

STEP 17.

CONFIGURE HOSE ROUTING: A-40D ONLY ................................................................................ 36

STEP 18.

RE-POSITION SICKLE DRIVE BOX BREATHER ........................................................................... 36

STEP 19.

LUBRICATE HEADER ..................................................................................................................... 37

STEP 20.

PERFORM PRE-DELIVERY CHECKS ............................................................................................ 44

DRIVE BELTS AND DRIVE CHAINS ......................................................................................... 45

AUGER STRIPPER BAR CLEARANCE .................................................................................... 46

REEL TINE TO HEADER PAN CLEARANCE ............................................................................ 46

HEADER FLOTATION ................................................................................................................ 47

HEADER LEVELLING ................................................................................................................ 48

CONDITIONER ROLLS .............................................................................................................. 49

SKID SHOES/GAUGE ROLLERS .............................................................................................. 50

LIGHTS ....................................................................................................................................... 50

RUN-UP THE HEADER .............................................................................................................. 51

KNIFE ......................................................................................................................................... 51

MANUALS ................................................................................................................................... 52

Summary of Contents for A30-S

Page 1: ...169078 Revision E A30 S and A40 D Auger Self Propelled Windrower Header Unloading and Assembly Instructions Published August 2012 ...

Page 2: ...delivery requirements for the MacDon Model A30 S and A40 D Auger Headers including a Grass Seed version Use the Table of Contents to guide you to specific areas CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD ASSEMBLE OR USE THE MACHINE MACDON A40 D SELF PROPELLED AUGER HEADER ...

Page 3: ... 10 ADJUST LIGHTS 14 STEP 11 ASSEMBLE FORMING SHIELD 15 STEP 12 INSTALL FORMING SHIELD 16 STEP 13 ATTACH HEADER TO WINDROWER 18 STEP 14 MODIFY HYDRAULICS 23 A A30 S 23 B A40 D 23 STEP 15 CONFIGURE REVERSER VALVE JUMPER HOSE 29 STEP 16 ATTACH HYDRAULICS 31 A A30 S 31 B A40 D 33 STEP 17 CONFIGURE HOSE ROUTING A 40D ONLY 36 STEP 18 RE POSITION SICKLE DRIVE BOX BREATHER 36 STEP 19 LUBRICATE HEADER 37 ...

Page 4: ...aid kit for use in case of emergencies Keep a fire extinguisher on the machine Be sure the extinguisher is properly maintained and be familiar with its proper use Keep young children away from machinery at all times Be aware that accidents often happen when the Operator is tired or in a hurry to get finished Take the time to consider the safest way Never ignore warning signs of fatigue Wear close ...

Page 5: ... oily floors are slippery Wet spots can be dangerous when working with electrical equipment Be sure all electrical outlets and tools are properly grounded Use adequate light for the job at hand Keep machinery clean Do not allow oil or grease to accumulate on service platforms ladders or controls Clean machines before storage Never use gasoline naphtha or any volatile material for cleaning purposes...

Page 6: ...orque values by 5 B 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 8 150 203 200 271 3 4 265 359 365 495 7 8 420 569 600 813 1 640 867 890 1205 Torque categories for bolts and capscrews are identified by their head markings C METRIC BOLTS BOLT DIA A STD COARSE BOLT T...

Page 7: ...O RING TYPE 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 fitting c Hand tighten fitting until back up washer A or washer face if straight fitting bottoms on part face C and O ring is seated d Position angle fittings by unscrewing no more than one turn e Tighten straight fittings to torque shown f Ti...

Page 8: ... 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 value in the table shown in the opposite column NOTE If available always hold the hex on the fitting body to prevent unwanted rotation of fitting body and hose when tightening the fitting nut e When assembling unions or two hos...

Page 9: ...ters per second m s miles per hour mph x 1 6063 kilometers per hour km h Volume US gallons US gal x 3 7854 liters L ounces oz x 29 5735 milliliters ml cubic inches in 3 x 16 3871 cubic centimeters cm 3 or cc Weight pounds lb x 0 4536 kilograms kg DEFINITIONS TERM DEFINITION API American Petroleum Institute APT Articulating Power Tongue ASTM American Society Of Testing And Materials Header The remo...

Page 10: ... WARNING Be sure forks are secure before moving away from load Stand clear when lifting IMPORTANT Do not unload using lean bar for lifting Chain hook slots in lean bar are only for laying the machine over into working position after it is on the ground NOTE Take care not to bend parts on back tube a Approach header from either its topside or underside and slide forks A in underneath lifting framew...

Page 11: ... prior to laying the header down a Unpack skid shoe bundle b Remove two clevis pins C from each skid shoe c Remove nuts bolts and clips D from skid shoe d Insert tabs on skid shoe into slots E on cutterbar at inboard mounting locations on frame and secure with clevis pin C e Attach clips D with bolts and nuts removed at step c to secure skid shoe to cutterbar NOTE Use a socket and ratchet wrench t...

Page 12: ...abs on roller assembly into slots C on cutterbar at outboard mounting locations on frame and secure to support bracket with locking pin A at lowest position e Attach clips B with bolts and nuts removed at step c to secure roller assembly to cutterbar f Tighten nuts NOTE Use a socket and ratchet wrench to access the nuts g Remove locking pin A and adjust rollers to desired height Re install both lo...

Page 13: ...eet 1 2 m vertical chain height Chain Type Overhead Lifting Quality 1 2 Inch Minimum Working Load 5000 lb 2270 kg CAUTION Stand clear when lowering as machine may swing NOTE Do not lift at lean bar when unloading from trailer This procedure is only for laying the machine over into working position d Raise forks until lift chains are fully tensioned e Back up SLOWLY while simultaneously lowering ma...

Page 14: ...in C Secure clevis pin C with lynch pin NOTE In soft conditions use a wooden block under the stand k Lower header onto stand D STEP 6 REMOVE SHIPPING STANDS a Remove two bolts E from shipping stand F b Remove hairpin from pin G c Hold shipping stand F remove pin G and remove stand Discard stand and hardware d Repeat above steps for opposite shipping stand e Remove four bolts H and remove angle J D...

Page 15: ...emove lean bar b Attach extensions C to lean bar with four bolts D and nuts provided c Re attach lean bar to header with existing hardware at desired location Tighten bolts d Attach LH divider assembly E to LH end of lean bar with two bolts F and nuts provided The divider may be positioned as shown or using the optional mounting hole G e Install U bolt H and tighten all bolts f Repeat for RH divid...

Page 16: ... loosen bolt B b Slide pan extensions C and swath forming rods inboard to desired position and align holes c Re install two bolts A Tighten bolts A and B d Repeat for opposite pan extension STEP 10 ADJUST LIGHTS a Position amber light supports perpendicular to header b Check that pivot bolt is tight enough to hold light support in upright position yet still allow light to pivot out of the way of o...

Page 17: ...ver A with bolts B jam nut D washer E and nut F from previous step e Tighten flange nut F enough to hold deflectors C in position but still allow deflectors to move f Tighten jam nut D against cover while holding bolt B g Remove lynch pin G from adjuster rod H and locate rod in hole in side deflector C Secure with lynch pin G h Repeat for other deflector i Invert forming shield to installation pos...

Page 18: ...er hole Hardware is supplied with forming shield kit c Remove two clevis pins C from forward end of forming shield d Position forming shield under windrower frame e Locate forming shield onto bolts A in windrower legs and secure with clevis pins C and lynch pin f Lift aft end of the forming shield and attach straps D to pins E on windrower frame Install washer and hairpin to secure strap Use the m...

Page 19: ... on both sides Position deflectors at the narrowest setting for a narrow windrow silage for example Position deflectors at the widest position for a wide window NOTE Refer to the Operator s Manual or Quick Card for additional information on adjusting the forming shield h Adjust fluffer shield G to middle position Loosen handles H if required BOTH SIDES G H F ...

Page 20: ...the area b Start windrower engine and activate HEADER DOWN button on the GSL to fully retract header lift cylinders IMPORTANT If the center link is too low it may contact the header as the windrower approaches the header for hook up c If necessary adjust position of the hydraulic center link E so that the hook F is above the attachment pin on the header by using one of the following methods 1 If t...

Page 21: ...t position of the center link cylinder E with the REEL UP and REEL DOWN switches and HEADER TILT switches on the GSL to position the hook above the header attachment pin IMPORTANT Hook release J must be down to enable self locking mechanism If the release is open up manually push it down after hook engages header pin 2 Lower the center link onto the header with REEL DOWN switch until it locks into...

Page 22: ...a pet could engage an idling machine 1 Stop engine and remove key 2 Loosen nut F and rotate barrel G to adjust length so that other end lines up with header bracket 3 Install pin H and secure with cotter pins 4 Adjust link to required length for proper header angle by rotating barrel G Tighten nut F against barrel A slight tap with a hammer is sufficient f If engine is not running start engine and...

Page 23: ...r 3 Repeat for opposite lift cylinder h Install pin N through each boot and foot and secure with hairpin IMPORTANT Ensure pin N is fully inserted and hairpin is installed behind bracket i Remove lynch pin from pin O in stand P j Hold stand P and remove pin O k Re position stand to storage position by inverting stand and re locating on bracket as shown l Re insert pin O and secure with lynch pin m ...

Page 24: ...078 22 Revision E CAUTION Check to be sure all bystanders have cleared the area p Start engine and activate HEADER DOWN switch on GSL to lower header fully HEADER UP HEADER TILT UP HEADER TILT DOWN REEL UP REEL DOWN HEADER DOWN ...

Page 25: ...LVE JUMPER HOSE M205 hydraulics need to be modified to accept an A Series header and kits B5491 B5492 and B5497 should have been supplied with your header Install the kits in accordance with instructions that were supplied with the kits Then proceed to STEP 16 ATTACH HYDRAULICS B A40 D I M100 M105 a Open LH maintenance platform and modify valve block as follows 1 At valve D remove the cap E from p...

Page 26: ...l with the coupler O If O ring is missing re use O ring from fitting N 5 Remove and discard cap P and adapter fitting Q from the small coupler assembly R 6 Install the small coupler subassembly R onto the tee S on valve block D NOTE Adjacent hoses may require slight re positioning to allow access for new hoses b Proceed to STEP 16 ATTACH HYDRAULICS O D SMALL COUPLER ASSEMBLY G Q P R R D S ...

Page 27: ...e coupler assemblies C and D from hoses in bundle E from header and remove caps 3 Install smaller coupler assembly C in R2 port in valve block A and the larger coupler assembly D in R2 port in valve block B b Proceed to STEP 15 CONFIGURE REVERSER VALVE JUMPER HOSE WITHOUT REVERSER VALVE R2 WITH REVERSER VALVE A R2 R2 B M150 WITHOUT REVERSER VALVE A R2 B R2 WITH REVERSER VALVE C D A B WITHOUT REVER...

Page 28: ...for proper plumbing for each header type a Remove the plugs from ports R2 on valve blocks A and B Ports may not be identified b Remove female coupler assemblies C and D from hoses in bundle E from header and remove caps c Install smaller coupler assembly C in R2 port in valve block A and the larger coupler assembly D in R2 port in valve block B NOTE Adjacent hoses may require slight re positioning...

Page 29: ...p F and adapter fitting G with O ring from the large coupler H d Install larger coupler H onto fitting at port R2 on valve block B e Remove cap from smaller coupler assembly C and install assembly in port R2 on valve A IMPORTANT Make sure O ring is on JIC threads in port R1 to ensure a proper seal with the coupler H If O ring is missing re use O ring from fitting G f Proceed to STEP 16 ATTACH HYDR...

Page 30: ...to accept an A Series auger header and kits B5491 B5492 and B5497 should have been supplied with your header b Install kits in accordance with the instructions that were supplied with the kits to achieve the configuration shown above c Proceed to STEP 16 ATTACH HYDRAULICS AUGER HEADER HYDRAULICS ...

Page 31: ... Check the routing of the jumper hose as follows and change as required b Move LH windrower platform to open position to expose hydraulic valve blocks c To route hose B from A40 D position to A30 S position 1 Disconnect jumper hose B from port C2 fitting on header drive valve block C 2 Rotate 90 fitting D under reverser valve block A so that it points aft 3 Remove cap from 90 fitting in port R4 on...

Page 32: ...er reverser valve block A so that hose can be routed to port C2 on header drive valve block C 3 Remove cap from fitting in header drive valve block port C2 and connect jumper hose B to port C2 fitting 4 Install cap removed in step 3 and install it on 90 fitting in port R4 on reverser valve block A e Move LH maintenance platform to normal operating position B R4 A D C2 B D A C ...

Page 33: ... bundle E to header e Rotate lever D clockwise and engage in bracket to store IMPORTANT If the hose bundle contains four hoses draper header operation only three are required to power the A30 header Ensure loose hose is properly secured to avoid contact with the drivelines f Route hoses E from windrower through support F and access hole G in header frame g Remove cover on header electrical recepta...

Page 34: ...tors onto mating receptacles as shown until collars on receptacles snap into lock position k Activate header tilt cylinder switches to extend and retract center link Check for sufficient clearance between hoses and electrical harness RETURN CASE DRAIN HEADER DRIVE ...

Page 35: ... fully up position to release hose bundle E d Move hose bundle E to header e Rotate lever D clockwise and engage in bracket to store f Route hoses E from windrower through support F and access hole G in header frame alongside hose bundle H Hose bundle H will be attached later in the procedure g Remove cover on header electrical receptacle J h Push connector onto receptacle and turn collar on conne...

Page 36: ... 1 2 inch carriage bolt M and locking nut Install bolt from under bracket 4 Repeat above steps at the two other brackets on hose support m Route reel auger return and auger pressure hose bundle H from header to windrower and locate bundle above existing hose support N as shown n Secure with three straps K and lower lever D continued next page H N K D GRASS SEED HEADER AUGER and REEL PRESSURE KNIFE...

Page 37: ...ment I M100 M105 II M150 M155 III M200 IV M205 M200 WITHOUT REVERSER VALVE REEL AUGER RETURN AUGER PRESSURE AUGER PRESSURE REEL AUGER RETURN M200 WITH REVERSER VALVE AUGER PRESSURE REEL AUGER RETURN REEL AUGER RETURN AUGER REEL PRESSURE AUGER REEL PRESSURE REEL AUGER RETURN M150 M155 WITHOUT REVERSER VALVE AUGER PRESSURE REEL AUGER RETURN M150 M155 WITH REVERSER VALVE REEL AUGER RETURN AUGER PRESS...

Page 38: ...ee 2 Disconnect hose D at reel motor 3 Disconnect tee E at motor lower port d Re connect hoses as follows 1 Relocate tee E to upper port 2 Connect hose D to tee 3 Connect hose C to motor lower port e Close drive shield before engaging header STEP 18 RE POSITION SICKLE DRIVE BOX BREATHER a Move breather dipstick B to back port and install plug A in forward port at sickle drive box es b Check oil le...

Page 39: ...e excess grease on fitting to keep out dirt d Replace any loose or broken fittings immediately e If fitting will not take grease remove and clean thoroughly Also clean lubricant passageway Replace fitting if necessary f Refer to illustrations on following pages for lubrication points High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base AUGER ...

Page 40: ...sive wear caused by sickle pressing on guards 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 REEL SHAFT BEARING 1 PLC High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base A30 S HEADER LH SIDE SICKLE HEAD BEARING 1 PLC ...

Page 41: ... than 6 to 8 pumps of the 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 SIDES IF INSTALLED High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base A40 D HEADER LH SIDE TINE BAR BEARING 4 PLCS EACH TINE BAR ...

Page 42: ...event binding and or excessive wear caused by sickle pressing on guards 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 SICKLE HEAD BEARING 1 PLC High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base A40 D HEADER RH SIDE ...

Page 43: ...ision E LUBRICATE HEADER cont d HAY CONDITIONER ROLL SHAFT BEARINGS 2 PLCS ROLL SHAFT BEARINGS 2 PLCS ROLL PIVOT 1 PLC BOTH SIDES High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base ...

Page 44: ...ERSALS 2 PLCS DRIVELINE UNIVERSALS 2 PLCS DRIVELINE SHAFTS 1 PLC DRIVELINE UNIVERSALS 2 PLCS DRIVELINE SHAFTS 2 PLCS A40 D 10 MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINTS ONLY 10 MOLY GREASE IS RECOMMENDED FOR DRIVELINE SHAFT SLIP JOINTS ONLY High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base ...

Page 45: ...ling chains apply oil to upper edge of lower spans SAE 30 REEL DRIVE CHAIN 1 PLC OIL KNIFE DAILY EXCEPT IN SANDY SOIL AUGER DRIVE CHAIN 1 PLC SICKLE DRIVE BOX A30 S 1 PLC A30 D A40 D 2 PLCS CHECK OIL LEVEL WITH TOP OF SICKLE DRIVE BOX HORIZONTAL CHECK ROLL GEARBOX 1 PLC OILING ...

Page 46: ...ng machine IMPORTANT To avoid machine damage check that no shipping dunnage has fallen down between auger and pans a Perform the final checks and adjustments as listed on the Pre Delivery Checklist yellow sheet to ensure the machine is field ready Refer to the following pages for detailed instructions as indicated on the Checklist b The completed Checklist should be retained either by the Operator...

Page 47: ... inch 6 mm when a load of 20 lbf 80 N is applied at mid span g Auger drive chain D deflection at mid span should be 1 4 inch 6 mm h Auger drive belts E belt should deflect 3 16 in 4 mm when a load of 8 12 lbf 35 40 N is applied to each belt at mid span i Close shield j Proceed to STEP 20B AUGER STRIPPER BAR CLEARANCE II A40 D DOUBLE KNIFE a Open shield on header RH side b Sickle drive timing belt ...

Page 48: ...the guards but not the knife sections or the auger pan a Rotate reel slowly by hand and check tine clearance at knife and pan Flex tines to simulate crop loaded position to ensure tine clearances to knife sections and auger pan are adequate for working conditions b Check that reel rotates freely NOTE If there are a few reel tine that are touching the pan while the rest are at the correct height tr...

Page 49: ...e lean bar and lifting The force to lift should be 75 85 lbf 335 380 N and should be approximately the same at both ends b If necessary perform the following steps to adjust the float 1 Raise header fully shut down engine and remove key 2 Turn drawbolt A clockwise to increase float makes header lighter or counterclockwise to decrease float makes header heavier 3 Re check the float A ...

Page 50: ...e e Place float pins A in locked out position CAUTION Check to be sure all bystanders have cleared the area f Start engine and set header approximately six inches 150 mm off ground Check that member B is against link C g Note high and low end of header h Place wooden blocks under header cutterbar and legs i Lower header onto blocks so that members B lift off of links C j Shut down engine and remov...

Page 51: ...er roll to achieve consistent intermesh across the rolls d Loosen bolt D and rotate cover E to expose access port F e Check roll timing by examining distance X at each end of the rolls F Each steel bar on one roll should be centered between two bars of the other roll so that distance X is 0 5 inches 12 mm f If required adjust the roll timing as follows 1 Loosen four bolts G in slots of yoke plate ...

Page 52: ... shoes or for any reason a Raise header and engage lift cylinder lockouts b Check that pins are installed in the same position in all skid shoes gauge rollers H LIGHTS Hazard lights which are mounted on both ends of the header are activated by switches in the M Series windrower cab Check for operation during run up a Check that pivot bolt is tight enough to hold light support in upright position y...

Page 53: ...Delivery Checklist yellow sheet attached to this instruction to ensure the machine is field ready c Check actual speed of sickle drive box pulley using a hand held optical tachometer during run up Speed should be 775 rpm for A30 S and 950 rpm for A40 D with the engine at maximum operating rpm d If speed is incorrect check the header ID in the windrower display module or the header drive pump may r...

Page 54: ...case in the windrower cab A Series Auger Header Quick Card MD Part 169407 Operator s Manual MD Part 169000 169040 Parts Catalog MD Part 169002 b This instructional manual should be kept for future reference c The yellow Checklist should be retained by either the Dealer or the Operator ...

Page 55: ...NOTES 169078 53 Revision E ...

Page 56: ... Ltd A C N 079 393 721 P O Box 243 Suite 3 143 Main Street Greensborough Victoria Australia 3088 t 03 9432 9982 f 03 9432 9972 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Centre t 7 495 775 6971 direct line f 7 495 967 7600 CUSTOMERS www macdon com DEALERS www macdonDealers com Trademarks of products are the marks of their respective ...

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