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.
MACDON A40-D SELF-PROPELLED AUGER HEADER MACDON A30-D PULL-TYPE MOWER CONDITIONER
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.
TABLE OF CONTENTS Section/Title 1 2 3 4 5 6 ____ __Page INTRODUCTION ............................................................................................................................................... 1 SAFETY ............................................................................................................................................................ 6 2.1 SAFETY ALERT SYMBOL ............................................................................................
TABLE OF CONTENTS Section/Title __Page 6.14 LIFT CYLINDER LOCK-OUTS .......................................................................................................... 58 6.14.1 Self-Propelled ............................................................................................................................ 58 6.14.2 Pull-Type ................................................................................................................................... 58 6.
TABLE OF CONTENTS Section/Title ____ __Page 7.6 LUBRICATION ................................................................................................................................ 104 7.6.1 Greasing Procedure ................................................................................................................ 104 7.6.2 Lubrication Points .................................................................................................................... 104 7.6.3 Oiling .......
TABLE OF CONTENTS Section/Title __Page 7.14 WHEELS, TIRES, AND HITCH: PULL-TYPE ................................................................................. 172 7.14.1 Wheel Bolts ............................................................................................................................. 172 7.14.2 Wheel Removal ....................................................................................................................... 172 7.14.3 Wheel Installation ...................
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. It is also used as a reminder of good safety practices. This safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. 2.
SECTION 2 SAFETY 2.3.
SECTION 2 SAFETY 2-Panel Safety Sign Locations: Pull-Type (cont’d) B and F #184422 - Both sides A #174632 - Both sides C #184372 D #194462 E #171279 - Both sides 169000 / 169040 8 Revision E
SECTION 2 SAFETY 2-Panel Safety Sign Locations: Pull-Type (cont’d) A #194464 B #174436 C #171281 - Both sides D #171280 169000 / 169040 9 Revision E
SECTION 2 SAFETY 2.3.
SECTION 2 SAFETY 2-Panel Safety Sign Locations: Self-Propelled (cont’d) A #174632 - Both sides 169000 / 169040 B and C #184422 - Both sides 11 Revision E
SECTION 2 SAFETY 2.4 GENERAL SAFETY CAUTION The following are general farm safety precautions that should be part of your operating procedure for all types of machinery. Protect yourself. When assembling, operating and servicing machinery, wear all the protective clothing and personal safety devices that COULD be necessary for the job at hand. Don't take chances. You may need: o o o o o o Provide a first-aid kit for use in case of emergencies. Keep a fire extinguisher on the machine.
SECTION 2 SAFETY Use only service and repair parts made or approved by the equipment manufacturer. Substituted parts may not meet strength, design, or safety requirements. Do not modify the machine. Unauthorized modifications may impair the function and/or safety and affect machine life. Stop engine, and remove key from ignition before leaving Operator's seat for any reason. A child or even a pet could engage an idling machine. Keep the area used for servicing machinery clean and dry.
SECTION 3 DEFINITIONS 3 DEFINITIONS The following terms may be used in this manual: TERM DEFINITION API American Petroleum Institute APT Articulating Power Tongue ASTM American Society Of Testing And Materials Cab-Forward Windrower operation with the Operator and cab facing in the direction of travel. Center-link A hydraulic cylinder or turnbuckle type link between header and the machine that tilts the header.
SECTION 4 COMPONENTS 4 COMPONENT IDENTIFICATION 4.
SECTION 4 COMPONENTS PULL-TYPE (cont’d) HEADER DRIVE HAZARD LIGHT TAIL LIGHT FORMING SHIELD ADJUSTER BOLTS FLOAT SPRING DRIVESHIELD 169000 / 169040 16 Revision E
SECTION 4 COMPONENTS PULL-TYPE (cont’d) ARTICULATING POWER TONGUE CONTROL HOSES STEERING CYLINDER LOCKOUT VALVE PUMP - 1000 RPM PTO JACK SAFETY CHAIN 3-POINT HITCH ADAPTER 169000 / 169040 DRIVELINE DRAWBAR HITCH TOWING ADAPTER 17 Revision E
SECTION 4 COMPONENTS 4.
SECTION 5 SPECIFICATIONS 5 SPECIFICATIONS 5.1 PULL-TYPE HEADERS HEADER SIZE HEADER MODEL 14 FT 16 FT A30-S A30-D 16 ft-3 in. (4953 mm) n/a A30-S 18 FT A30-D A30-D FRAME and STRUCTURE Width Transport 19 ft-3 in. (5867 mm) 17 ft-9 in. (5410 mm) 26 ft-7 in. (8130 mm) Length Field 26 ft-7 in. (8130 mm) Transport 86 in. (2184 mm) Field 86 in.
SECTION 5 SPECIFICATIONS PULL-TYPE HEADERS (cont’d) HEADER SIZE HEADER MODEL 14 FT A30-S 16 FT A30-D A30-S 18 FT A30-D A30-D AUGER Drive Mechanical 2 Belts To Chain Tube Size 10 in. (254 mm) O.D Flighting 20 in. (508 mm) O.D., 0.25 in. (6 mm) thick. Type Undershot, Center Feed. Rubber Finger Feed. Stripper Bars 3 Per Side 20T Sprocket Speed (rpm) 19T Sprocket No Load 265 275 265 275 Load 256 265 256 265 No Load 252 261 252 261 Load 243 252 243 252 Delivery Opening 95.
SECTION 5 SPECIFICATIONS 5.2 SELF-PROPELLED HEADERS HEADER SIZE HEADER MODEL 14 FT A30-S 16 FT A40-D A30-S 18 FT A40-D A40-D FRAME and STRUCTURE Width 16 ft-3 in. (4953 mm) Weight (lb [kg]) n/a 17 ft-9 in. (5410 mm) 5680 (2579) n/a 19 ft-3 in.
SECTION 5 SPECIFICATIONS SELF-PROPELLED HEADERS (cont’d) HEADER SIZE HEADER MODEL 14 FT 16 FT A30-S A40-D --- 18 FT A30-S A40-D A30-D A40-D 14.2 in (232 cc) /rev --- 14.2 in (232 cc) /rev --- 14.
SECTION 6 OPERATION Never attempt to start tractor/windrower engine or operate the machine, except from the Operator’s seat. Check the operation of all controls in a safe clear area before starting work. Do not allow riders on tractor/windrower or mower conditioner. Never start or move the machine until you are sure all bystanders have cleared the area. Avoid travelling over loose fill, rocks, ditches or holes. Drive slowly doorways. If cutting ditch banks, use extreme caution.
SECTION 6 OPERATION 6.3.2 6.3 TRACTOR SETUP: PULL-TYPE 6.3.1 Drawbar Adjustment CAUTION Tractor Requirements HEADER WIDTH 14 FT 16 FT 18 FT MINIMUM POWER HP (KW) MINIMUM DRAWBAR CAPACITY LBF (N) 90 (68) 110 (83) 1400 (6227) 1450 (6449) 130 (98) 1500 (6672) Shut off tractor, engage parking brake, and remove key before working around hitch. MINIMUM HYDRAULICS psi (MPA) PTO 2000 (13.
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 J A B H C g. Assemble PTO driveline male half (G) onto PTO shaft (H) on APT. Push male half so that PTO shaft is at its fully compressed length. h. Locate PTO shaft in hook (J). b. Loosen bolts (B) on extension assembly (A), and slide onto drawbar. c. Install pin (C) through drawbar and extension from underside, and secure with hairpin. d.
SECTION 6 OPERATION 6.3.4 3. Flip outer plate (F) and inner plate (G) on each arm. 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. 4. Re-install bolts (E). 5. Replace pins (D). C H B A a. Attach the 3 point hitch adapter (A) to the APT with pin (B). The installation is similar to that described in the previous section. b. Secure pin (B) with clevis pin (C), washers, and cotter pin. c.
SECTION 6 OPERATION e. Attach driveline (E) to tractor PTO shaft as follows: 6.4 MOWER CONDITIONER / TRACTOR HOOKUP: PULL-TYPE E CAUTION F 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. 6.4.1 G Drawbar Hook-Up f. A H 1. Position driveline onto tractor PTO shaft (F). 2. Pull back collar on driveshaft, and push driveshaft until it locks. Release collar.
SECTION 6 OPERATION f. 6.4.2 3 Point Hitch (Cat. II, III, or IIIN) HookUp CAUTION Shut off tractor, engage parking brake, and remove key before working around hitch. The measurement must dimensions listed below. not exceed DRIVELINE SHAFT SIZE DISTANCE ‘X’ 1.375 in. (34 mm) 27 in. (685 mm) 1.75 in. (43 mm) 31 in. (790 mm) the CAT. II and IIIN CONFIGURATION G A C F B g. Position driveshaft (F) onto tractor PTO shaft. Driveline should be approximately level. a.
SECTION 6 OPERATION 6.4.3 b. Connect two steering cylinder hoses (A) as follows: Hydraulic Connections WARNING Do not use remote hydraulic system pressures over 3000 psi (20684 kPa). Check your tractor Operator’s Manual for remote system pressure. B c.
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. C To maintain stability, always lower the machine completely. Block mower conditioner wheels before detaching from tractor. 6.5.1 Drawbar Hitch Unhook f. Rotate hook (C) to the lower position. g. Pull back collar on driveline (B), slide coupler off tractor PTO shaft, and position driveline in hook. a.
SECTION 6 OPERATION F j. k. l. Remove chain lock (F), and unhook safety chain from tractor. Wrap chain around APT for storage. Lower jack to raise APT clear of drawbar. Slowly drive tractor away from mower conditioner. A m. Replace hitch pin (A), and secure with hairpin.
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. A CAUTION To prevent accidental movement of tractor, shut off engine, engage parking brake, and remove key. B To maintain stability, always lower the machine completely. Block mower conditioner wheels before detaching from tractor. g. Install at working position at front of APT.
SECTION 6 OPERATION 6.6 HEADER ATTACHMENT: SELFPROPELLED Refer to your Self-Propelled Windrower Operator’s Manual for procedures for mechanically attaching the auger header to the self-propelled windrower, and for modifications if required to the windrower hydraulic connections. 6.6.1 6.6.1.1 C E Refer to the following procedures for electrical and hydraulic connections. Header drive hydraulic hoses and electrical harness are located on the LH cab-forward side of the windrower.
SECTION 6 OPERATION 6.6.1.2 E M205 F H G f. Route hoses (E) from windrower through support (F) and access hole (G) in header frame. g. Remove cover on header electrical receptacle (H). h. Push connector onto receptacle, and turn collar on connector to lock it in place. Try to rotate collar to ensure it is locked. i. Attach cover to mating cover on windrower wiring harness. j. Remove caps (if installed) from hydraulic couplers, and clean if necessary.
SECTION 6 OPERATION 6.6.2 A40-D CAUTION To prevent accidental movement of windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. For windrowers with Reverser Kit #B4656 to prevent draper header reel damage and improper operation: If switching between A40 Auger Header and Draper header, hose plumbing to reverser valve must be changed to suit the header type. See Instruction MD Part #169213 for proper plumbing for each header type. 6.6.2.
SECTION 6 OPERATION REEL and AUGER PRESSURE KNIFE and CONDITIONER RETURN CASE DRAIN KNIFE and CONDITIONER PRESSURE STANDARD HEADER m. If valve blocks are not configured (as shown), install required fittings as described in A30-S and A40-D Auger Self-Propelled Windrower Header Unloading and Assembly Instructions – MD Part #169078 that was supplied with your A40-D header.
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-configured for M150, M155, and M200 windrowers. D C E FACTORY CONFIGURATION M150, M155 AND M200 q. Change hoses as follows if header is being mounted on a M100, M105, or M205 windrower: D E C M100, M105, M205 CONFIGURATION 1. Disconnect hose (C) at tee (E). 2. Disconnect hose (D) at reel motor. 3.
SECTION 6 OPERATION 6.6.2.2 M150, M155 CAUTION To prevent accidental movement of windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. C E D b. Remove the cap (C) from electrical connector, and remove connector from support bracket. c. Disengage and rotate lever (D) counterclockwise to fully up position to release the hose bundle (E). The M150 is factory-equipped with four hoses. E F J G B H A d.
SECTION 6 OPERATION REEL and AUGER PRESSURE KNIFE and CONDITIONER RETURN A B CASE DRAIN KNIFE and CONDITIONER PRESSURE AUGER/REEL RETURN STANDARD HEADER AUGER PRESSURE B A AUGER and REEL PRESSURE KNIFE RETURN (MALE FITTING AT HEADER) M150 - WITHOUT REVERSER VALVE AUGER/REEL RETURN KNIFE PRESSURE (FEMALE FITTING AT HEADER) CASE DRAIN AUGER PRESSURE GRASS SEED HEADER j. D K l. A Push hose connectors onto mating receptacles (as shown) until collars on receptacles snap into lock position.
SECTION 6 OPERATION 6.6.2.3 M200 CAUTION To prevent accidental movement of windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. C E D b. Remove the cap (C) from electrical connector, and remove connector from support bracket. c. Disengage and rotate lever (D) counterclockwise to fully up position to release the hose bundle (E). The Windrower requires four hoses to run an A40-D header.
SECTION 6 OPERATION REEL and AUGER PRESSURE KNIFE and CONDITIONER RETURN B A CASE DRAIN AUGER/REEL RETURN KNIFE and CONDITIONER PRESSURE AUGER PRESSURE STANDARD HEADER B AUGER and REEL PRESSURE KNIFE RETURN (MALE FITTING AT HEADER) A M200 - WITH REVERSER VALVE KNIFE PRESSURE (FEMALE FITTING AT HEADER) CASE DRAIN AUGER PRESSURE AUGER/REEL RETURN B GRASS SEED HEADER j. D H M200 - WITHOUT REVERSER VALVE K k. l.
SECTION 6 OPERATION 6.6.2.4 M205 CAUTION To prevent accidental movement of the windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. B A a. Disengage rubber latch (A), and open driveline shield (B). C E D AUGER HEADER HYDRAULICS FOR M205 The M205 must be equipped with an auger drive basic kit and a completion kit as shown above.
SECTION 6 OPERATION j. E F G J Push hose connectors onto mating receptacles (as shown) until collars on receptacles snap into lock position. D H H K e. Route bundle (E) from windrower through support (F) and access hole (G) in header frame alongside existing hose bundle (H) from header. f. Remove cover on header electrical receptacle (J). g. Push connector onto receptacle, and turn collar on connector to lock it in place. h. Attach cover to mating cover on windrower wiring harness.
SECTION 6 OPERATION 6.6.3 Configure Reverser Valve Jumper Hose A An optional reverser valve block to reverse the header drive in the event of plugging, may have been installed on M150, M155, and M200 windrowers. A jumper hose on this valve block has a specific routing for each model of auger header. Check routing of the jumper hose as follows, and change as required: C2 C a. Move LH windrower platform to open position to expose hydraulic valve blocks.
SECTION 6 OPERATION c. To route hose (B) from A30-S position to A40-D position: R4 A B C 1. Disconnect jumper hose (B) at 90° fitting in port R4. A C2 B 2. Rotate 90° fitting (C) under 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 on header drive valve block. 5. Install cap removed in step 3.
SECTION 6 OPERATION c. 6.7 HEADER DETACHMENT: SELFPROPELLED Disconnect hoses from hydraulic motor as follows: CAUTION D C To prevent accidental movement of windrower, shut off engine, engage parking brake, and remove key. 6.7.1 A30-S 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). B A G a.
SECTION 6 OPERATION 6.7.2 b. Disconnect the two hydraulic hoses (A) and (B) or (C) and (D) from windrower valve(s). A40-D Detachment CAUTION E G To prevent accidental movement of windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. a. Move LH cab-forward platform to rear of windrower. F c. Raise lever (E), and undo Velcro straps (F). d. Move hose bundle (G) to store on header walkway.
SECTION 6 OPERATION E H J h. Move hose bundle (H) from header, and locate on windrower LH side with hose ends in support (J) and under lever (E). i. Rotate lever (E) clockwise, and push to engage 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 electrical harness clear tire. m. Detach header from windrower.
SECTION 6 OPERATION 6.8 TRANSPORTING MOWER CONDITIONER 6.8.1 DIRECTION OF TRAVEL Self-Propelled B Refer to your Self-Propelled Windrower Operator’s Manual for transporting headers when attached to the Windrower. 6.8.1.1 AMBER 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). d. Secure with bolts (A), spacers, and nuts. e. Repeat above steps for other light.
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. B C A d. Position towing adapter (C) on APT, and secure with pins (D). e. Attach mower conditioner to truck. f. Remove jack from working position, and store on APT. Secure with pin. NOTE The PTO does not need to be attached for towing purposes. If not attached, lower hook (A), store driveline on hook, and remove forward half (B) of driveline.
SECTION 6 OPERATION e. If steering cylinder is not fully charged, install temporary transport lock pin as follows: Otherwise, proceed to step f. below. 6.8.2.3 Preparing Mower Conditioner for Transport a. Charge the steering circuit as follows: 1. Connect two APT steering cylinder hoses to a tractor hydraulic circuit. 2. Steer header completely to the left, then right. Repeat three or four times. b. Steer mower conditioner so that it is centered behind the towing vehicle. 1.
SECTION 6 OPERATION f. 6.8.3 Pull-Type: Flatbed Remove complete forming shield group as follows: To transport the mower conditioner on a flatbed trailer, proceed as follows: CAUTION Use the following procedure when transporting the mower conditioner on a flatbed trailer. 6.8.3.1 C A B Loading: Pull-Type 1. Remove pins (A). 2. Disassemble adjuster bars (B) from side deflectors (C). Note orientation of hardware. D E 3. Remove nuts (D), and drop side deflectors from frame (E). a.
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. h. Ensure temporary transport lock pin is in storage location. WARNING To avoid tipping over, the header must be resting on the ground prior to swinging the APT. j. Secure APT to frame hook to prevent movement. Use cardboard or suitable material under the tie to protect paint. k.
SECTION 6 OPERATION K 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. L l. 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. m. Position forklift from either front or back of mower conditioner, and lift slightly off the ground. N q. Remove four bolts (N), and remove the lean bar to minimize load width.
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) A C e. Lower mower conditioner, and install wheel/axle assemblies onto mower conditioner. Secure axle to frame with bolt (C), and tighten to required torque.. f. Lower mower conditioner to ground, and remove lifting chains. B c. Attach a chain to each frame hook (A), and a chain to each end of the lean bar at (B).
SECTION 6 OPERATION i. Swing APT to working position. j. k. Attach steering cylinder rod end to frame. Install rear forming shields using reverse order of step f. in Section 6.8.3.1 Loading: Pull-Type. l. Move lift cylinder lock-out valve handles to vertical position.
SECTION 6 OPERATION c. Check tire pressure, and adjust as required. See Section 7.14.4 Tire Inflation. d. Perform all annual maintenance. See Section 7.18 MAINTENANCE SCHEDULE. 6.9 BREAK-IN PERIOD a. After attaching header/mower conditioner to windrower/tractor for the first time, operate the machine slowly for 5 minutes, watching and listening FROM THE TRACTOR/WINDROWER SEAT for binding or interfering parts. 6.
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 are missing, broken, or not working correctly. WARNING NOTE To avoid bodily injury or death from fall of raised machine, always lock-out lift cylinders before going under mower conditioner for any reason. Use proper procedure when searching for pressurized fluid leaks. Refer to Section 7.7.3 Hoses and Lines. b.
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. Move steering lever FORWARD to achieve desired position of mower conditioner on RIGHT side of tractor.
SECTION 6 OPERATION 6.15.2 Left Side Operation: Pull-Type 6.15.3 Avoiding Obstacles Move steering lever backward to achieve desired position of mower conditioner on LH side of tractor. Move steering lever as required to avoid obstacles. 6.15.4 Square Corners To adjust tracking of mower conditioner during LH side operation, the steering cylinder stroke control can be re-positioned: The following procedure is intended only as a guide to developing a turning procedure for the tractor being used.
SECTION 6 OPERATION c. 6.15.5 180 Degree Turn NOTE IMPORTANT When cutting back and forth on one side of the field, approximately 50 ft. (15 m) is required at each end of the field to make a 180 degree turn-around. When turning, take care that inside tractor tire does not contact APT of mower conditioner. d. In positions (C) and (D), continue turning towards the uncut crop, (with the mower conditioner steered towards the outside of the turning circle), being aware of APT-to-tire clearance. e.
SECTION 6 OPERATION g. Use wrench on LH end of primary driveshaft to turn rolls forward until plug clears. h. Return wrench to storage location, and secure in place with pin. 6.16 UNPLUGGING THE HEADER / MOWER CONDITIONER 6.16.1 Unplugging Conditioner: Pull-type WARNING WARNING Return unplug wrench to storage location, and close LH driveshield before re-starting machine. Stop tractor engine, and remove key before removing plugged material from mower conditioner.
SECTION 6 OPERATION 6.17 HEADER OPERATION 6.17.1 Lean Bar Position Satisfactory function of the windrower in all situations requires making proper adjustments to suit various crops and conditions. IMPORTANT To prevent structural damage to the header, do not operate with lean bar removed. Correct operation reduces crop loss and allows cutting of more acres. As well, proper adjustments and timely maintenance will increase the length of service you receive from the machine.
SECTION 6 OPERATION 6.17.2 Auger Speed B Auger speed must be high enough to carry crop into the conditioner, and yet not throw it out. A In light crops, a lower throttle setting on the tractor/windrower will slow down the header/mower conditioner operating speed, and help to prevent carryover. 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.
SECTION 6 OPERATION 6.17.3 Reel Speed 6.17.3.2 Reel Speed: A40-D For best feeding of the crop into the header/ mower conditioner, reel speed must be faster than ground speed. This gently sweeps material across the sickle into the auger. The A40-D auger header features a hydraulic direct drive reel with operating speed range of 15 to 85 rpm (M150, M155, M200, M205), 15 to 50 rpm (M100, M105), and is controlled from the Operator’s station on the self-propelled windrower.
SECTION 6 OPERATION 6.17.4.1 Auger Fore-Aft Adjustment: A30-S a. Open LH endshield. b. Loosen auger drive chain (A) as follows: 6.17.4 Auger Position CAUTION To avoid personal injury, before servicing header/mower conditioner or opening drive covers, follow procedures in Section 7.1 PREPARATION FOR SERVICING. G C A F B Auger position has been factory-set, and should not normally require adjustment.
SECTION 6 OPERATION i. j. o. Check reel drive chain tension. Total chain slack at (N) should be 1/4 in. (6 mm). If necessary, adjust as follows: Open RH endshield. Loosen reel drive belts as follows: H J O P K N 1. Loosen bolt (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 point. Re-adjust position of idler sprocket to achieve required slack. 4.
SECTION 6 OPERATION g. Check auger 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. Turn adjuster bolt (G) to achieve tension as per above. 3. Tighten jam nut at (G), and tighten bolts (B). h. Open RH endshield. i. Loosen reel drive belts (K) as follows: 6.17.4.
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: O P N 1. Loosen bolt (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 point. Re-adjust position of idler sprocket to achieve required slack. 4. Tighten jam nut at (P) and nut (O) on sprocket. Re-check tension. o.
SECTION 6 OPERATION g. Open RH endshield. h. Loosen reel drive belts (F) as follows: 6.17.4.3 Auger Fore-Aft Adjustment: A30-D CAUTION To prevent accidental movement of windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. H a. Open LH endshield. b. Loosen auger drive chain (A) as follows: G A F 1. Loosen nuts (G). 2. Loosen jam nut on adjuster bolt (H), and turn adjuster bolt (H) to loosen reel drive belts. B C 1.
SECTION 6 OPERATION l. Check reel drive chain tension. Total chain slack at (K) should be 1/4 in. (6 mm). If necessary, adjust as follows: L M K 1. Loosen bolt (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 point. Re-adjust position of idler sprocket to achieve required slack. 4. Tighten jam nut at (M) and nut (L) on sprocket. Re-check tension. m.
SECTION 6 OPERATION g. Open RH endshield. h. Loosen reel drive belts (E) as follows: 6.17.4.4 Auger Vertical Adjustment: A30-D CAUTION To prevent accidental movement of windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. H a. Open LH endshield. b. Loosen auger drive chain (A) as follows: G A F 1. Loosen nuts (G). 2. Loosen jam nut on adjuster bolt (H), and turn adjuster bolt (H) to loosen reel drive belts (F). B C 1.
SECTION 6 OPERATION l. Check reel drive chain tension. Total chain slack at (K) should be 1/4 in. (6 mm). If necessary, adjust as follows: M N L 1. Loosen bolt (M) on sprocket and jam nut on adjuster bolt (N). 2. Turn adjuster bolt (N) to move idler sprocket downward until chain slack is achieved as above. 3. Rotate auger, and check chain for slack at tightest point. Re-adjust position of idler sprocket to achieve required slack. 4. Tighten jam nut at (N) and bolt (M) on sprocket. Re-check tension. m.
SECTION 6 OPERATION 6.17.4.6 Auger Vertical Adjustment: A40-D a. Open LH endshield. 6.17.4.5 Auger Fore-Aft Adjustment: A40-D CAUTION E To prevent accidental movement of windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. F A b. Loosen four nuts (E). c. Loosen jam nuts on adjuster bolts (F), and turn bolts (F) to adjust auger vertical position. d. Tighten jam nuts. e. Tighten nuts (E). f. Open RH endshield. B a. Open LH endshield. b.
SECTION 6 OPERATION e. Open RH endshield. f. Loosen the reel drive chain (C) as follows: 6.17.5 Reel Position Reel position has been found to be a critical factor in achieving good results in adverse conditions. Reel position is factory-set for average straight standing crop. It can be adjusted both vertically and horizontally (fore-aft) for different crop conditions.
SECTION 6 OPERATION e. Open RH endshield. f. Loosen reel drive chain (C) as follows: 6.17.5.2 Reel Vertical Position: A30-S, A30-D CAUTION D To prevent accidental movement of windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. a. Open LH endshield. E A C 1. Loosen nut (D) on sprocket. 2. Loosen jam nut on adjuster bolt (E), and turn adjuster bolt (E) to loosen chain. F b. Loosen four nuts (A). B g. Loosen four nuts (F). G c.
SECTION 6 OPERATION j. 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. D CAUTION To prevent accidental movement of windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. E C a. Open LH endshield. k. l. 1. Turn adjuster bolt (E) to tighten chain until total chain slack at (C) is 1/4 in. (6 mm). 2.
SECTION 6 OPERATION 6.17.5.4 Reel Vertical Position: A40-D a. Open LH endshield. f. Open RH endshield. G G E E g. Loosen four nuts (G). b. Loosen four nuts (E). H F c. h. Loosen jam nuts on adjuster bolts (H), and turn bolts (H) to adjust reel vertical position. i. Tighten jam nut. j. Tighten four nuts (G). k. Close shields before engaging header. l. Check that the reel rotates freely. Loosen jam nuts on adjuster bolts (F), and turn bolts (F) to raise or lower reel.
SECTION 6 OPERATION 6.17.6 Tine Aggressiveness Adjustment B CAUTION To prevent accidental movement of windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. a. Open RH endshield. A30-S and A30-D A B A40-D A30-S and A30-D c. A Loosen jam nuts on bolts (B), and turn bolts to rotate cam to desired position. Viewed from right side, rotate cam clockwise to obtain more aggressive tine action. d. Tighten nuts (A), and jam nuts on bolts (B).
SECTION 6 OPERATION WARNING 6.17.7 Reel Tine to Header Pan Clearance 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 adjust skid shoes or for any reason. TINES .08–.39 in (2–10 mm) .08 in (2 mm) 6.17.8.1 Cutting Height Adjustment: CHECK TINE CLEARANCE IMPORTANT The above dimensions are provided as guidelines only.
SECTION 6 OPERATION e. Snug up nut (B), but do not over-tighten. A slight tap with a small hammer is sufficient. f. Check cutting height, and adjust if required. Refer to Section 6.17.8 Cutting Height. g. Check header float, and adjust if required. Refer to Section 6.17.10 Header Flotation. 6.17.9 Header Angle Header (or guard) angle can be varied from 8° to 16° below horizontal. Choose an angle that maximizes performance for your crop and field conditions.
SECTION 6 OPERATION 6.17.10 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. B NOTE When float setting is light, it may be necessary to use a slower ground speed to avoid excessive bouncing, and leaving a ragged cut. A c. Back jam nuts (A) away from spring. d.
SECTION 6 OPERATION 6.17.11 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. Raising the feed-pan helps to form an even windrow in light crop. WARNING 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.
SECTION 6 OPERATION 6.17.12 0 Hay Conditioner 1 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. [6 mm]). See illustration below. A B C 2 B 3 4 A 5 6 7 8 9 C 10 PULL-TYPE SELF-PROPELLED c. Loosen and back-off upper jam nut (A), on both sides of conditioner. d.
SECTION 6 OPERATION NOTE 6.17.12.2 Roll Timing and Alignment If the distance ‘X’ varies more than 1/16 in. (1.6 mm) from one end to the other, the rolls should be re-aligned. Refer to next Section 6.17.12.2.2 Roll Alignment. For proper conditioning, the rolls must be properly timed and aligned, with each steel bar on one roll centered between two bars of the other roll as shown. The factory-setting should be suitable for most crop conditions. c.
SECTION 6 OPERATION NOTE 6.17.12.2.2 Roll Alignment The rolls are aligned if the distance ‘X’ varies less than 1/16 in. (1.6 mm) from one end to the other. The rolls can be aligned in the fore and aft direction by shimming the pivot assembly link at the RH end of the upper roll. Rolls are aligned at the factory, but adjustment is provided in case the rolls become misaligned during operation. If ‘X’ varies more than 1/16 in. (1.
SECTION 6 OPERATION 6.17.13 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 To prevent accidental movement 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. A B C c.
SECTION 6 OPERATION a. Set forming shield side deflectors to desired width by re-positioning adjuster bars as follows: 6.17.14 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. Stones or other foreign objects can be ejected with force. A B Position of forming shields controls the width and placement of the windrow. The decision on forming shield position (settings between 36 in.
SECTION 6 OPERATION 6.17.14.2 Rear Deflector (Fluffer Shield) The rear deflector (G) slows the crop exiting the conditioner rolls, directs the flow downward, and fluffs the material. CAUTION To prevent accidental movement of windrower, place all controls in NEUTRAL or in PARK, engage park brake (if applicable), shut off engine, and remove key. BOTH SIDES H G SELF-PROPELLED H H G PULL-TYPE a.
SECTION 6 OPERATION 6.17.15 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. A H C d. Re-position lean bar on header at desired height, and install existing carriage bolts (H) two per side. Tighten bolts. D B a. Loosen U-bolt (A). b. Remove bolts (B), and re-position divider (C) to align with alternate hole location (D). c.
SECTION 6 OPERATION 6.17.16 Ground Speed 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 sizes. CAUTION Reduce speed when turning, crossing slopes, or when travelling over rough ground. Example: At ground speed of 5 mph (8 km/h) with a 16 FT header, the area cut would be approximately 10 acres (4 hectares) per hour. a.
SECTION 6 OPERATION 6.17.17 6.17.17.4 Auger Pan Extensions Grass Seed Windrowing The grass seed header is equipped with adjustable auger pan extensions that allow adjustment of delivery opening to vary the windrow characteristics. Adjust as follows: The grass seed auger header has several features to adapt it to this special application. These features include: 6.17.17.1 Stub Guards and Hold-Downs WIDE C The cutterbar is equipped with stub guards for effective cutting in tough grass crops.
SECTION 6 OPERATION 6.17.17.5 Windrow 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 pan extensions to achieve the width and shape of windrows you desire.
SECTION 6 OPERATION 6.17.18 Recommended Settings These settings are intended as a starting point. Operators should fine-tune to crop and field conditions. Also refer to the A Series Auger Header Quick Card that was included in your shipment. Crop Field Crop Condition Type TPA (tons Condition Header Header Height Angle Knife Speed Reel RPM 1600–1800 73–77 Float (LBS) Feed Pan Position Roll Gap Lower Slot 5/8 in. Center Slot 1/2 in. Upper Slot 3/8 in. Variable see above Lower Slot 3/8 in.
SECTION 6 OPERATION 6.18.4 Windrow Characteristics 6.18 HAYING TIPS It is recommended that a windrow with the following characteristics be produced. Refer to Section 6.17 HEADER OPERATION for instructions on adjusting the header/mower conditioner. 6.18.1 Curing a. A quick cure will maintain top quality because: 5% of the protein is lost for each day hay lies on the ground, The sooner the cut hay is off, the earlier the start for next growth. b.
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 for cleaning purposes. These materials may be toxic and/or flammable. CAUTION Cover cutterbar and sickle guards to prevent injury from accidental contact. b. Store in a dry, protected place if possible. If stored outside, always cover mower conditioner with a waterproof canvas or other protective material. c.
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 available from your Dealer. Wear protective shoes with slip-resistant soles, a hard hat, protective glasses or goggles and heavy gloves.
SECTION 7 MAINTENANCE AND SERVICING 7.3 MAINTENANCE SPECIFICATIONS 7.3.1.2 7.3.1 Metric Bolts Recommended Torques BOLT DIA. "A" Tighten all bolts to the torques specified in chart (unless otherwise noted throughout this manual). Check tightness of bolts periodically, using bolt torque chart as a guide. Replace hardware with the same strength bolt. Torque figures are valid for non-greased or non-oiled threads and heads unless otherwise specified.
SECTION 7 MAINTENANCE AND SERVICING 7.3.1.3 Flare Type Hydraulic Fittings 7.3.1.4 O-Ring Type Hydraulic Fittings NUT 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. Lubricate connection, and hand-tighten swivel nut until snug. d. To prevent twisting the tube(s), use two wrenches.
SECTION 7 MAINTENANCE AND SERVICING 7.3.1.5 a. Check components to ensure that the sealing surfaces and fitting threads are free of burrs, nicks, and scratches, or any foreign material. b. Apply lubricant (typically Petroleum Jelly) to O-ring and threads. If O-ring is not already installed, install O-ring. Align the tube or hose assembly. c. Ensure that flat face of the mating flange comes in full contact with O-ring. d. Thread tube or hose nut until hand-tight.
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. Use clean containers to handle all lubricants. Store in an area protected from dust, moisture, and other contaminants. LUBRICANT Grease Gear Lubricant Hydraulic Oil 169000 / 169040 SPEC SAE MultiPurpose DESCRIPTION USE High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2). Lithium Base.
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 ha Flow US gallons per minute gpm x 3.7854 = liters per minute L/min Force pounds force lbf x 4.4482 = Newtons N inch in. x 25.4 = millimeters mm foot ft x 0.305 = meters m Power horsepower hp x 0.7457 = kilowatts kW x 6.8948 = kilopascals kPa Pressure pounds per square inch psi x .
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 A B Pull-Type DANGER To avoid bodily injury or death from unexpected start-up or fall of raised machine; stop engine, remove key and engage lift cylinder lock-out valves before going under machine for any reason. a. To open LH and RH driveshields on header, press a screwdriver against latch in opening at (A). a.
SECTION 7 MAINTENANCE AND SERVICING 7.6.2 7.6 LUBRICATION Lubrication Points Lubrication requirements depend on the model of header/mower conditioner that is being serviced. CAUTION To avoid personal injury, before servicing header/mower conditioner or opening drive covers, follow procedures in Section 7.1 PREPARATION FOR SERVICING. Refer to the specified pages to identify lubrication points for your specific model: Refer to Section 7.3.2 Recommended Fluids and Lubricants for recommended greases.
SECTION 7 MAINTENANCE AND SERVICING I. 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) 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 the grease gun are required to fill the cavity, replace the seal in the sickle head.
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.
SECTION 7 MAINTENANCE AND SERVICING II. 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 To prevent binding and/or excessive wear caused by sickle pressing on guards, do not overgrease. If more than 6 to 8 pumps of grease gun are required to fill the cavity, replace the seal in the sickle head.
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 To prevent binding and/or excessive wear caused by sickle pressing on guards, do not overgrease. If more than 6 to 8 pumps of grease gun are required to fill the cavity, replace the seal in the sickle head.
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 To prevent binding and/or excessive wear caused by sickle pressing on guards, do not overgrease.
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) BOTH SIDES - IF INSTALLED NOTE To prevent binding and/or excessive wear caused by sickle pressing on guards, do not over-grease.
SECTION 7 MAINTENANCE AND SERVICING IV. HAY CONDITIONER High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base.
SECTION 7 MAINTENANCE AND SERVICING V. DRIVELINES High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2) Lithium Base.
SECTION 7 MAINTENANCE AND SERVICING VI.
SECTION 7 MAINTENANCE AND SERVICING 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.
SECTION 7 MAINTENANCE AND SERVICING Oiling (Cont’d) A30-D HEADER LH SIDE SAE 30 AUGER DRIVE CHAIN (1 PLC) CHECK ROLL GEARBOX (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) 169000 / 169040 115 Revision E
SECTION 7 MAINTENANCE AND SERVICING 7.6.4 Sealed Bearing Installation a. Clean shaft, and coat with rust preventative. A C B E D b. Install flangette (A), bearing flangette (C), and lock collar (D). (B), second NOTE 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 locked in the same direction the shaft rotates. Tighten the set screw in the collar.
SECTION 7 MAINTENANCE AND SERVICING 7.7.2.3 7.7 HYDRAULICS 7.7.1 Hydraulics: Self-Propelled Adding Hydraulic Oil A Refer to your Self-Propelled Windrower Operator’s Manual for hydraulic system maintenance procedures for self-propelled windrowers. 7.7.2 Hydraulics: Pull-Type The pull-type mower conditioner is hydraulically powered using the following systems: a. Slowly unscrew filler cap (A) from filler tube. b. Add SAE 15W40 oil until level is between ADD and FULL marks on sight gauge. c.
SECTION 7 MAINTENANCE AND SERVICING 7.7.2.5 Changing Hydraulic Oil Filter 7.7.3 NOTE Check hydraulic hoses and lines daily for signs of leaks. Change hydraulic oil filter after the first 100 hours operation, and every 250 hours thereafter. WARNING Avoid high-pressure fluids. Escaping fluid can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. E C Tighten all connections before applying pressure.
SECTION 7 MAINTENANCE AND SERVICING 7.8.2 7.8 SICKLE AND SICKLE DRIVE Sickle Removal WARNING CAUTION Stand to rear of sickle during removal to reduce risk of injury from cutting edges. Wear heavy gloves when handling sickle. To avoid personal injury, before servicing header/mower conditioner or opening drive covers, follow procedures in Section 7.1 PREPARATION FOR SERVICING. a. Stroke sickle to its outer limit. CAUTION Wear heavy gloves when working around or handling sickles. D C WARNING b.
SECTION 7 MAINTENANCE AND SERVICING 7.8.3 7.8.4 Sickle Installation Sickle Head Bearing Removal a. Remove the sickle. Removal. WARNING See Section 7.8.2 Sickle G Stand to rear of sickle during installation to reduce risk of injury from cutting edges. Wear heavy gloves when handling sickle. J K IMPORTANT Align guards, and re-set sickle hold-downs while replacing sickle. H L A C E M D REMOVAL B b.
SECTION 7 MAINTENANCE AND SERVICING 7.8.6 7.8.7 Spare Sickle Sickle Guards Check daily that guards are aligned to obtain proper shear cut between sickle section and guard. Sickle sections should contact shear surface of each guard. a. A spare sickle complete with knife head on single knife headers may be stored in the header frame tube at RH end as shown. Ensure sickle is secured in place. 7.8.7.1 b. Spare sickles with knife head for double knife headers may be stored inside the lean bar.
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 is available from your Dealer. Refer to Section 9.5 STUB GUARD CONVERSION KIT. DRIVE SIDE NORMAL IMPORTANT 7.8.7.2 The second, third, and fourth outboard guards on drive side of the header do not have a support.
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.
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. A child or even a pet could engage an idling machine. A C D B a. Remove two nuts (A) and bolts that attach guard (B) and top guide (C) to cutterbar. b. Remove guard, top guide, and adjuster bar (D). c.
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.
SECTION 7 MAINTENANCE AND SERVICING 7.8.8 7.8.8.1 Sickle Hold-Downs Check daily that sickle hold-downs are set to prevent sickle sections from lifting off guards, but still permit sickle to slide without binding. Sickle Hold-Down Adjustment: Pointed Guards Single Knife NOTE B Guards should be aligned prior to adjusting hold-downs. 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 0.004 - 0.
SECTION 7 MAINTENANCE AND SERVICING 7.8.8.2 Sickle Hold-Down Adjustment: Stub Guards Single Knife E F 0.004–0.040 in. (0.1–1.0 mm) 0.004–0.016 in. (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. (0.1–0.4 mm) at the guard tip, and 0.004–0.040 in. (0.1–1.0 mm) at rear of guide. c. Torque nuts (E) to 53 ft·lbf (72 N·m). Double Knife G H 0.004–0.040 in. (0.1–1.0 mm) 0.004–0.
SECTION 7 MAINTENANCE AND SERVICING 7.8.9 7.8.9.2 Removal: Sickle Drive Belt - A30-S a. Open LH endshield. Sickle Drive Belt: A30-S CAUTION D 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. 7.8.9.1 F E Tension Adjustment: Sickle Drive Belt A30-S IMPORTANT To prolong belt and drive life, do not over-tighten belts. G a. Open LH endshield. b. Loosen jam nut on adjuster bolt (D). c. Loosen three bolts (E).
SECTION 7 MAINTENANCE AND SERVICING 7.8.9.3 Installation: A30-S Sickle Drive Belt B g. Install bolt-in plate in LH endsheet at sickle drive box, and close endshield. h. Re-adjust tension of a new belt after a short run-in period (about 5 hours). C A E a. Route sickle drive belt (A) through opening in endsheet onto sickle drive box pulley and sickle drive pulley (E) as shown. NOTE When installing new belt, never pry belt over pulley. Be sure idler is fully loosened, then tension belt. b.
SECTION 7 MAINTENANCE AND SERVICING 7.8.10.2 Removal: LH Sickle Drive Belts: A30-D a. Open LH endshield. 7.8.10 Sickle Drive Belts: A30-D 7.8.10.1 Tension Adjustment: LH Sickle Drive Timing Belt - A30-D IMPORTANT To prolong belt and drive life, do not overtighten belts. A CAUTION E 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. F G a. Open LH endshield. D C b. Loosen nut (E) on idler sprocket. c.
SECTION 7 MAINTENANCE AND SERVICING D C A B f. 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 sickle drive box. i. Slip belt off sickle drive box pulley, and route belt through this hole to remove it.
SECTION 7 MAINTENANCE AND SERVICING 7.8.10.3 Installation: LH Sickle Drive Belts: A30-D K 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 G J C H A d. Re-position V-belts (K) on pulley (D) e. Turn adjuster bolt (J) to move drive pulley until a force of 8–12 lbf (35–50 N) applied at mid-span on each belt (K) deflects each belt 0.16 in. (4 mm). f. Tighten jam nut at (J), and three nuts (H). g.
SECTION 7 MAINTENANCE AND SERVICING 7.8.10.4 Tension Adjustment: RH Sickle Drive Timing Belt - A30-D 7.8.10.5 Removal: RH Sickle Drive Timing Belt: A30-D a. Open shield on header RH side. IMPORTANT To prolong belt and drive life, do not overtighten belts. CAUTION E 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. F a. Open RH endshield. C A H G B b. Loosen jam nut on adjuster bolt (E), and nuts (F). c.
SECTION 7 MAINTENANCE AND SERVICING 7.8.10.6 Installation: RH Sickle Drive Timing Belt - A30-D F 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. H C G E B e. Turn adjuster bolt (F) to move pulley (G) so that each belt (E) deflects 3/16 in. (4 mm) when a load of 8–12 lbf (35–40 N) is applied to each belt at mid-span. f. Tighten jam nut on adjuster bolt (F), and nuts (H). A D E a.
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 overtighten belts. E Timing Belt F H CAUTION G 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. Loosen three nuts (F), and jam nut on adjuster bolt (G). b.
SECTION 7 MAINTENANCE AND SERVICING 7.8.11.3 Installation: LH Sickle Drive Timing Belts - A40-D Timing Belt a. Remove double V-belts as per previous page. CAUTION D 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. C Timing Belt B D J A C B b. Disconnect hoses from auger drive motor (J). Protect hose ends and motor ports with clean, lint-free cloths or clean plastic bags. c.
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 drive belts even if only one needs replacing. IMPORTANT To prolong belt and drive life, do not overtighten belts. NOTE CAUTION When installing new belt, never pry belt over pulley. Be sure adjusting screw is fully loosened, then tension belt. Stop engine, and remove key from ignition before leaving Operator's seat for any reason.
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 J 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 C J B A C a. Route sickle drive belt (A) through opening in endsheet onto sickle drive box pulley and sickle drive pulley (J) as shown. B NOTE When installing new belt, never pry belt over pulley.
SECTION 7 MAINTENANCE AND SERVICING 7.8.12 Sickle Drive Timing Adjustment C 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. A child or even a pet could engage an idling machine. a. Remove the right side sickle drive belt. Refer to Section 7.8.10.5 Removal: RH Sickle Drive Timing Belt: - A30-D, or Section 7.8.11.
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. C 2. If RIGHT SICKLE leads LEFT SICKLE, rotate RIGHT HAND driven pulley (C) clockwise. 3. If RIGHT SICKLE lags LEFT SICKLE, rotate RIGHT HAND driven pulley (C) counterclockwise. 4.
SECTION 7 MAINTENANCE AND SERVICING 7.8.13 Sickle Drive Box D 7.8.13.1 Mounting Bolts CAUTION E 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. C d. Remove grease zerk (D) from sickle head pin (E). e. Remove nut and bolt (C). f. Insert screwdriver in groove of pin (E), and pry up on pin to free sickle. Pin does not have to be removed from arm.
SECTION 7 MAINTENANCE AND SERVICING f. Slide arm (C) up or down on shaft until it just contacts sickle head (D) (0.010 in. [0.25 mm]) gap. 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 bottomed out in the sickle head. j. Tap underside of the sickle head until the pin is flush with the upper face of the pitman arm (C). k.
SECTION 7 MAINTENANCE AND SERVICING 7.8.13.6 Changing Sickle Drive Box Oil 7.8.13.4 Pulley Removal a. Remove sickle drive box. See previous page. NOTE Change sickle drive box lubricant after the first 50 hours operation, and every 1000 hours (or 3 years) thereafter. A a. Raise header to allow a suitable container to be placed under sickle drive box drain to collect oil. CAUTION Stop engine, and remove key from ignition before leaving Operator's seat for any reason.
SECTION 7 MAINTENANCE AND SERVICING 7.9.1.2 7.9 REEL AND REEL DRIVE: A30-S, A30-D Removal Remove reel drive chain (A) as follows: a. Open shield on header RH side. CAUTION E To avoid personal injury, before servicing header/mower conditioner or opening drive covers, follow procedures in Section 7.1 PREPARATION FOR SERVICING. 7.9.1 7.9.1.1 B Reel Drive Chain: A30-S, A30-D Tension NOTE For major adjustments, such as after repositioning reel or auger, adjust belt tension before chain tension.
SECTION 7 MAINTENANCE AND SERVICING 7.9.2 7.9.2.1 7.9.2.2 Reel Drive Belts: A30-S, A30-D Removal Remove reel drive belts (A) as follows: 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. B Adjust reel drive belts (A) tension as follows: CAUTION C Stop engine, and remove key from ignition before leaving Operator's seat for any reason.
SECTION 7 MAINTENANCE AND SERVICING 7.9.3.2 7.9.3 Reel Tines and Tine Bar Bearings: A30-S, A30-D Installation: Tines and Bearings - Cam End CAUTION IMPORTANT Keep reel tines in good condition. Straighten or replace as required. 7.9.3.1 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.
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). f. Remove nut, bolt, and keeper on each tine to be removed, and slide tine off the bar. E C G K F 7.9.3.4 H B Installation: Tines and Bearings, Opposite Cam End CAUTION g. Attach end tine to tine bar with bolt (F) and keeper (G).
SECTION 7 MAINTENANCE AND SERVICING 7.10 REEL AND REEL DRIVE: A40-D D CAUTION E To avoid personal injury, before servicing header/mower conditioner or opening drive covers, follow procedures in Section 7.1 PREPARATION FOR SERVICING. C 7.10.1 Reel Drive: A40-D G B The reel drive gearbox and hydraulic motor are a factory-assembled unit. The gearbox is sealed, and requires no scheduled maintenance. If service is required for either the gearbox or motor, see your Dealer. b.
SECTION 7 MAINTENANCE AND SERVICING h. Replace tine as follows: 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 bearing flangettes at discs #1 and #2 with bolts (G). Tighten bolts to 23–26 ft·lbf (31–36 N·m). l. Position tines as shown, and install shoulder bolts (E) with keepers (F). m. Install cam follower bearing (C) with bolt (B).
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 D DISC #4 Y X X E DISC #3 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. Install tines on tine bar, and secure with bolts (D) and keepers (E). Install nut with tapered side against tine bar.
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 D Y Z Y E DISC #4 C A Z Y B DISC #4 f. a. Remove shoulder bolts (A) and keeper (B) connecting tine bar extension ‘Z’ to section ‘Y’ at reel disc #4. b. Remove flangette mounting bolts (C) at reel disc #4. c. Lift tine bar away from reel arm, and remove tine bar extension ‘Z’ complete with bearing assembly. d.
SECTION 7 MAINTENANCE AND SERVICING 7.10.2.4 Tine Replacement: Tine Bar Extension Section Z DISC #3 DISC #4 Y Z F Z G DISC #4 a. Remove bolt (F) and keepers (G) on tine to be replaced, and slide tines off tine bar. H F G b. Install tines on tine bar, and secure with bolt (F) and two keepers (G). Tine (H) must be clamped between keepers (G). Install nut with flat side against tine bar extension.
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 E To avoid personal injury, before servicing header/mower conditioner or opening drive covers, follow procedures in Section 7.1 PREPARATION FOR SERVICING. C A D B 7.11.1 Auger Drive Chain: A30-S 7.11.1.1 Tension Adjust chain (A) tension as follows: CAUTION b. c. d. e.
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. A B b. Loosen nut (A) on idler sprocket support. c. Turn adjuster bolt (B) to give 0.2 in. (5 mm) slack at mid-span of chain. Tighten nut (A) on idler sprocket support. d. Rotate auger, and check chain for slack at tightest point.
SECTION 7 MAINTENANCE AND SERVICING 7.11.3.2 Removal a. Open LH endshield. b. Remove chain (D) from small sprocket as follows: 7.11.3 Auger Drive Belt: A30-S 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. C NOTE E D Minor belt tension adjustments may be made without affecting chain tension. For major adjustments, like after repositioning reel or auger, adjust chain tension before belt tension.
SECTION 7 MAINTENANCE AND SERVICING 7.11.4.2 Removal a. Open LH endshield. b. Remove auger drive chain (D) as follows: 7.11.4 Auger Drive Belts: A30-D 7.11.4.1 Tension IMPORTANT To prolong drive life, do not over-tighten belt. Belt slippage is used to protect the auger in an overload situation. D NOTE Minor belt tension adjustments may be made without affecting chain tension. For major adjustments, like after re-positioning reel or auger, adjust chain tension before belt tension.
SECTION 7 MAINTENANCE AND SERVICING 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, MD Part #169048 for details on replacing the pans. AUGER 1/32–5/32 in (1–4 mm) CLEARANCE IMPORTANT To prolong the life of the auger pan, be sure to check that reel tines do not contact the pans when adjusting the reel position or tine pitch.
SECTION 7 MAINTENANCE AND SERVICING a. Raise header, and engage lift cylinder stops. 7.11.7.2 Stripper Bar Replacement WARNING C To avoid bodily injury or death from unexpected start-up or fall of raised machine, stop engine, remove key, and engage lift cylinder stops before going under machine. D A b. Remove nuts and carriage bolts (C) securing the two extensions (D) to underside of header pan support, and retain for re-installation. C B E a.
SECTION 7 MAINTENANCE AND SERVICING f. Replace drain plug (C), and add oil at (A) to required level. Use Gear Lubricant, SAE 85W-140, API Service Class GL-5, 1.06 quarts (1.0 liters). g. Oil is at required level when it runs out of check plug (B). 7.13 CONDITIONER CAUTION To avoid personal injury, before servicing header/mower conditioner or opening drive covers, follow procedures in Section 7.1 PREPARATION FOR SERVICING. 7.13.2 Forming Shield Removal 7.13.
SECTION 7 MAINTENANCE AND SERVICING e. Disassemble fluffer shield (J) from forming shield cover. 7.13.3 Disassemble Forming Shield a. Invert forming shield onto top. C B L A K f. b. Remove lynch pin (A) from adjuster rods (B), and disassemble rods from side deflectors (C). Remove bolts (K) to remove deflector fins (L) from cover. 7.13.4 Assemble Forming Shield Reverse the procedure in Disassemble Forming Shield. Section 7.13.3 7.13.5 Install Forming Shield F E M G a.
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. M N A c. Lift forming shield onto bolts (N) in windrower legs, and secure with clevis pins (M) and hairpin. P O d. Remove two bolts (A) securing motor to gearbox, and remove motor. 7.13.
SECTION 7 MAINTENANCE AND SERVICING f. 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 G It is not necessary to disconnect the motor hoses for this operation. F C 1. Remove three bolts from tapered bushing (G) in pulley (F). 2. Install bolts in the two threaded holes in bushing, and tighten to release the bushing. 3. Remove pulley, bushing, and key. B B b.
SECTION 7 MAINTENANCE AND SERVICING e. Install auger drive pulley (F) as follows: 7.13.9 Gearbox Installation: A30-S J H A B G F a. Position gearbox (A) as shown, picking up the three holes (B) in the endsheet. See above. b. Install three flanged locknuts at (B). Do not tighten. C f. E 1. Slide pulley (F) onto shaft with key. 2. Install tapered bushing (G) onto shaft, ensuring holes are aligned with holes in pulley. 3. Align pulley (F) and countershaft pulley (H) faces to within .06 in. (1.5 mm).
SECTION 7 MAINTENANCE AND SERVICING O P P 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). i. Adjust roll timing. Refer to Section 6.17.12.2 Roll Timing and Alignment. j. Clean off excess sealant from motor flange and gearbox face. k.
SECTION 7 MAINTENANCE AND SERVICING f. 7.13.10 Gearbox Removal: A30-D Remove auger drive chain (D) from small sprocket as follows: a. Open shield covering conditioner drive. D A E F 1. Loosen nut (E) on idler sprocket support. 2. Turn adjuster bolt (F) to loosen chain (D). 3. Remove chain from small sprocket. g. Remove V-belts from drive pulley as follows: J b. Remove two bolts (A) securing motor to gearbox, and remove motor.
SECTION 7 MAINTENANCE AND SERVICING h. Remove auger drive pulley (K) as follows: Q L P M O K i. 1. Remove three bolts (L) from hub (M), and remove hub and sprocket. Remove two bolts (O), and nut and bolt (P) attaching channel (Q) to endsheet, and remove channel (Q). S K R N j. 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.
SECTION 7 MAINTENANCE AND SERVICING f. 7.13.11 Install drive pulley (F) as follows: Gearbox Installation: A30-D A F B J H G 1. Slide pulley (F) onto shaft with key. 2. Install tapered bushing (G) onto shaft, 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 (J) in tapered bushing (G), and tighten to 18 ft·lbf (25 N·m). 5. Tap bushing and re-torque.
SECTION 7 MAINTENANCE AND SERVICING M S T O T N 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 flange onto gearbox flange using four bolts and nuts (T). p. Adjust roll timing. Refer to Section 6.17.12.2 Roll Timing and Alignment. q. Clean off excess sealant from motor flange and gearbox face. r.
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. F D A H E G f. 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). h. Remove sickle drive pulley (G) as follows: 1. Remove three bolts from the tapered bushing (H) in pulley (D). 2. Install bolts in two threaded holes in bushing, and tighten to release bushing. 3.
SECTION 7 MAINTENANCE AND SERVICING f. Install drive pulley (G) as follows: N M F O D H E j. j. G Remove three flanged lock nuts (M) that secure gearbox (N) to header endsheet, and remove gearbox. 7.13.13 1. Slide pulley (G) onto shaft with key. 2. 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.
SECTION 7 MAINTENANCE AND SERVICING l. m. n. o. p. q. Adjust roll timing. Refer to Section 6.17.12.2 Roll Timing and Alignment. Clean off excess sealant from motor flange and gearbox face. 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. Install bolts removed in step b. (A) and washers, and torque to 75 ft·lbf (102 N·m). Re-connect hoses to motor. Close all shields before operating machine.
SECTION 7 MAINTENANCE AND SERVICING 7.14 WHEELS, TIRES, AND HITCH: PULL-TYPE 7.14.3 Wheel Installation CAUTION CAUTION When installing wheel be sure to use the holes that are countersunk to match bolt head profile. To avoid personal injury, before servicing header/mower conditioner or opening drive covers, follow procedures in Section 7.1 PREPARATION FOR SERVICING. The uncountersunk holes do not seat the bolts correctly. 7.14.
SECTION 7 MAINTENANCE AND SERVICING 7.14.4 Tire Inflation Check tire pressure daily. (207 kPa). Maintain 30 psi 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. Never increase air pressure beyond 35 psi (241 kPa) to seat the bead on the rim. Replace the tire if it has a defect. Replace a wheel rim, which has cracks, wear or severe rust. Never weld a wheel rim.
SECTION 7 MAINTENANCE AND SERVICING e. Position replacement wear plate (D) as shown. (The same wear plate can be re-installed, but in the reverse position). f. Secure wear plate with bolts and nuts (C). 7.15 SKID SHOE WEAR PLATE REPLACEMENT Skid shoes are equipped with replaceable wear plates that can be reversed for increase service life. It is recommended that wear plates be replaced when the skid shoe weldment becomes exposed. IMPORTANT If bolt heads are worn down, replace with new 1/2 in.
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 or repair. Proceed as follows to remove gauge rollers: c. Removal: Tighten nuts. D E a. Raise header, and engage lift cylinder stops. 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. B d. Remove pins (B), and adjust rollers to desired height.
SECTION 7 MAINTENANCE AND SERVICING IMPORTANT 7.18 MAINTENANCE SCHEDULE Recommended intervals are for average conditions. Service the machine more often if operated under adverse conditions (severe dust, extra heavy loads, etc.). The following maintenance schedules list periodic maintenance procedures, and are organized by service intervals. Regular maintenance is the best insurance against early wear and untimely breakdowns. Following this schedule will increase machine life.
SECTION 7 MAINTENANCE AND SERVICING 7.18.1.3 Maintenance Record: Self-Propelled Self-Propelled Windrower Header - Check MAINTENANCE RECORD ACTION: - Lubricate - Change Hour Meter Reading Date Serviced By BREAK-IN Refer To Section 7.18.1.1 Break-In Inspection: Self-Propelled 100 HOURS OR ANNUALLY Conditioner Drive Gearbox Lube Level Wheel Hub Bearings Sickle Drive Box Bolt Torque Sickle Drive Box Lubricant Level END OF SEASON Refer To Section 6.
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 1 120 ft·lbf (160 N·m) Section 7.14.1 Torque Steering Cylinder Clevis and Stroke Control 52 ft·lbf (72 N·m) Auger Drive Belt 5, 25, 50 Sections 7.11.3 and 7.11.4 Reel Drive Belt Section 7.9.2 Tension Sickle Drive Belt 5 10 Sections 7.8.9 and 7.8.10 Hardware Torque Section 7.3.1 Auger Drive Chain Sections 7.11.1 and 7.11.
SECTION 7 MAINTENANCE AND SERVICING 7.18.2.3 Maintenance Record: Pull-Type Pull-Type Mower Conditoner - Check MAINTENANCE RECORD ACTION: Date Serviced By Refer To Section 7.18.2.
SECTION 8 TROUBLESHOOTING 8 TROUBLESHOOTING 8.1 WINDROWER PERFORMANCE SYMPTOM PROBLEM SOLUTION Carryover of Crop On Reel. Reel speed too fast. Reduce reel speed (sprocket size). 6.17.3 Auger speed too fast. Reduce auger speed (sprocket size). 6.17.2 Very light crop. Reduce tractor/windrower rpm. Roll gap too large. Decrease roll gap. 6.17.12.1 Reel speed too fast. Reduce reel speed. 6.17.3 Material Build-Up On Header Frame. Insufficient Conditioning Of Stems.
SECTION 8 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION Pulling Material By The Roots Or Tall Material Leaning Into Machine. Ground speed too slow. Increase ground speed. Reel position incorrect. Move reel forward and down. 6.17.5 Bent or misaligned guards causing poor shearing action. Align guards for proper shearing action. 7.8.7 Bent sickle causing binding. Straighten bent sickle. Check alignment, and if necessary, replace. 7.8.2 Ground speed too fast. Slow down.
SECTION 8 TROUBLESHOOTING SYMPTOM Sickle Plugging (cont’d). PROBLEM SOLUTION SECTION Wet undergrowth. Cut when undergrowth is dry. Reel position incorrect. Move reel back and down (close to guards). 6.17.5 Sickle drive belt too loose. Adjust belt tension. 7.8.9 to 7.8.11 Sickle hold-downs improperly adjusted. Adjust hold-downs so sickle works freely. Sickle sections or guards are worn or broken. Replace worn or broken parts. 7.8.1 & 7.8.7 Auger to stripper clearance too wide.
SECTION 8 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION Plugging At Delivery Opening In Heavy Grass Seed. Opening too narrow. Move pan extensions to widest position. Grass Seed Windrow Too Wide or Too Narrow. Pan extensions not adjusted properly. Adjust pan extensions. PROBLEM SOLUTION SECTION 6.17.17 8.2 MECHANICAL SYMPTOM Auger and/or Conditioner Feed pan doesn't allow stones to Rolls Damaged By Stones. fall through. Lower rock-drop tines. 6.17.11 Ground speed too high in stony conditions.
SECTION 8 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION Worn needle bearing in sickle head. Knocking In Sickle Drive. Header Turns While Unloaded But Slows Or Stops When Starting To Cut. SECTION 7.8.4 Replace. Worn sickle head pin. 7.8.3 Incorrect end guards. Replace with special end guards. Cold oil in system. Reduce ground speed until oil reaches operating temperature. Dull sickle. 7.8.7 --7.8.4 Replace. Worn sickle head pin. Sickle Back Breakage. Bent or broken guard. Straighten or replace.
SECTION 9 OPTIONS AND ATTACHMENTS 9.4 REPLACEMENT REEL BAT KITS: A30-S, A30-D 9 OPTIONS AND ATTACHMENTS 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.
UNLOADING AND ASSEMBLY 10 UNLOADING AND ASSEMBLY Header-specific instructional manual for unloading, assembly and set-up procedures are included with your shipment.
INDEX Forming Rods ......................................................... 93 Forming Shields ..................................................... 88 Gauge Roller Kit ................................................... 185 Gauge Rollers adjustment .......................................................... 80 removal/installation ........................................... 175 Gearbox A30-D ........................................................ 165, 167 A30-S ...........................................
INDEX tension ................................................................ 87 timing .................................................................. 85 unplugging .......................................................... 62 Rubber Fingers ..................................................... 157 Safety general ................................................................ 12 owner .................................................................. 23 procedures .....................................
INDEX windrower performance .................................... 180 Turning 180 degrees ........................................................ 61 square corners .................................................... 60 Unhook Pull-Type ................................................... 30 Unloading ....................................................... 55, 186 Unplugging rolls ..................................................................... 62 sickle .................................................
NOTES 169000 / 169040 190 Revision E
