A30-S and A30-D Pull-Type Mower Conditioners A30-S, A30-D and A40-D Self-Propelled Auger Headers OPERATOR’S MANUAL Revision C Part #169000 $15
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, and the double knife feature that is available 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 6.13 ENGAGING THE PTO: PULL-TYPE................................................................................................. 61 6.14 LIFT CYLINDER LOCK-OUTS .......................................................................................................... 61 6.14.1 Self-Propelled ............................................................................................................................ 61 6.14.2 Pull-Type .......................................................
TABLE OF CONTENTS 7.6.2 7.6.3 7.6.4 Lubrication Points .................................................................................................................... 105 Oiling ....................................................................................................................................... 115 Sealed Bearing Installation ..................................................................................................... 117 7.7 HYDRAULICS .......................................
TABLE OF CONTENTS 7.14.3 Wheel Installation .................................................................................................................... 173 7.14.4 Tire Inflation............................................................................................................................. 174 7.15 SKID SHOE WEAR PLATE REPLACEMENT ................................................................................ 175 7.16 GAUGE ROLLERS.......................................................
SAFETY 2 SAFETY 2.1 WARNING 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.
SAFETY 2.3.
SAFETY 3-Panel Safety Sign Locations: Pull-Type (cont’d) #115100 - BOTH SIDES #109843 #44944 #171029 #30316 Form 169000 / 169040 8 Revision C
SAFETY 3-Panel Safety Sign Locations: Pull-Type (cont’d) #142908 - BACK-SIDE #44944 #142912 #28403 - BOTH ENDS #115148 #32738 - BOTH ENDS Form 169000 / 169040 9 Revision C
SAFETY 2.3.
SAFETY 3-Panel Safety Propelled Sign Locations: Self- #32738 #28403 Form 169000 / 169040 11 Revision C
SAFETY 2.3.
SAFETY 2-Panel Safety Sign Propelled (Cont’d) Locations: Self- #174632 #184371 #184371 - BOTH ENDS Form 169000 / 169040 13 Revision C
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.
SAFETY GENERAL SAFETY (Cont’d): • 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.
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 the header and the machine that tilts the header.
COMPONENTS 4 COMPONENT IDENTIFICATION 4.
COMPONENTS PULL-TYPE (Cont’d) HEADER DRIVE HAZARD LIGHT TAIL-LIGHT FORMING SHIELD ADJUSTER BOLTS FLOAT SPRING DRIVESHIELD Form 169000 / 169040 18 Revision C
COMPONENTS PULL-TYPE (Cont’d) ARTICULATING POWER TONGUE STEERING CYLINDER LOCKOUT VALVE PUMP - 1000 RPM PTO JACK CONTROL HOSES SAFETY CHAIN DRIVELINE DRAWBAR HITCH TOWING ADAPTER 3-POINT HITCH YOKE Form 169000 / 169040 19 Revision C
COMPONENTS 4.
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 18 FT A30-S A30-D A30-D FRAME and STRUCTURE Width Length Height Transport 26 ft-7 in. (8130 mm) Field 26 ft-7 in. (8130 mm) Transport 86 in. (2184 mm) Field 86 in. (2184 mm) Approx.
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 95.7 in.
SPECIFICATIONS 5.2 SELF-PROPELLED HEADERS HEADER SIZE HEADER MODEL 14 FT A30-S 16 FT A30-D A40-D A30-S A30-D 18 FT A40-D A30-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 n/a n/a 19 ft-3 in.
SPECIFICATIONS SELF-PROPELLED HEADERS (Cont’d) 14 FT HEADER SIZE HEADER MODEL A30-S A30-D 16 FT A40-D A30-S 18 FT A30-D A40-D A30-D A40-D -- 14.2 in (232 cc) /rev REEL 3 Hydraulic Direct Mounted Motor 3 -- 14.2 in (232 cc) /rev -- 14.2 in (232 cc) /rev 2 Belts/Chain Final Drive --- 2 Belts/Chain Final Drive --- 5 Bat (6 Bat Opt) 6 Bat (7 Opt) 5 Bat (6 Opt) 6 Bat (7 Opt) Drive Mechanical From Auger Type Tines 3 2 Belts/ Chain Final Drive 5 Bat (6 Opt) -6 Bat (7 Opt) Steel - 0.
OPERATION If you do not have a tractor/windrower manual, get one from your Dealer and read it thoroughly. 6 OPERATION • Never attempt to start the 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. It is your responsibility to read and understand this manual completely before operating the header/mower conditioner. Contact your Dealer if an instruction is not clear to you.
OPERATION 6.3 6.3.2 TRACTOR SETUP: PULL-TYPE 6.3.1 Drawbar Adjustment CAUTION Tractor Requirements HEADER WIDTH 14 FT 16 FT 18 FT 90 (68) 110 (83) MINIMUM DRAWBAR CAPACITY LBF (N) 1400 (6227) 1450 (6449) 130 (98) 1500 (6672) MINIMUM POWER HP (KW) MINIMUM HYDRAULICS psi (MPA) Shut off tractor, engage parking brake, and remove key before working around hitch. PTO 2000 (13.
OPERATION 6.3.3 Drawbar Hitch Set-Up a. Secure the 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.
OPERATION 6.3.4 3 Point Hitch (Cat. II, III, or IIIN) SetUp F C NOTE Bushings (F) on pins can be removed to suit hole size in tractor hitch arms. B A G a. Attach the 3 point hitch yoke (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. The arms (D) on APT yoke can be set up to suit the tractor hitch arms: J H d. Assemble PTO driveline male half (G) onto PTO shaft (H) on APT.
OPERATION 6.4 E MOWER CONDITIONER / TRACTOR HOOKUP: PULL-TYPE F CAUTION Shut off tractor, engage parking brake, and remove key before working around hitch. CAUTION G Never attach mower conditioner to tractor rear axle or three-point hitch arms. 6.4.1 H e. Attach driveline (E) to tractor PTO shaft as follows: 1. Position driveline onto tractor PTO shaft (F). 2. Pull back collar on driveshaft, and push driveshaft until it locks. Release collar. f.
OPERATION 6.4.2 3 Point Hitch (Cat. II, III, or IIIN) Hook-Up CAUTION DRIVELINE SHAFT SIZE DISTANCE ‘X’ 1.375 in. (34 mm) 14 in. (356 mm) 1.75 in. (43 mm) 17 in. (432 mm) Shut off tractor, engage parking brake, and remove key before working around hitch. G A F e. Change locations of pins (F) in APT arms to hole (G) to locate implement closer to tractor (if necessary). C B J CAT. II and IIIN CONFIGURATION a. Position tractor, and align tractor hitch arms (A) with mower conditioner arms (B).
OPERATION K L Q P i. Attach down-stop chains (K) to pin (L) on tractor. k. CAUTION Raise jack (P), pull pin (Q), and move jack to storage position on side of APT. The downstop chains limit the downward travel of the 3-point hitch lifting arms to prevent damaging the PTO driveline on the mower-conditioner. Ensure chains are attached when operating the mowerconditioner. j. Q Adjust chain length as required by relocating end link at tractor end of chain as follows: O l. Secure jack with pin (Q).
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.
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 f. Rotate hook (C) to “lower” position. g. Pull back collar on driveline (B), and slide coupler off tractor PTO shaft, and position driveline in hook. Drawbar Hitch Unhook a.
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.
OPERATION 6.5.2 3-Point Hitch Unhook C a. Park machine on flat level surface. b. Lower header onto blocks or leave header raised. Engage lift cylinder lock-out valves if leaving in raised position. c. If necessary, raise 3-point hitch arms to release tension on downstop chains. D CAUTION To prevent accidental movement of tractor, shut off engine, engage parking brake, and remove key. h. Pull pin (C) securing jack (D) to APT, and move to “working” position. Secure jack with pin (C).
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. Refer to the following procedures for electrical and hydraulic connections. The header drive hydraulic hoses and electrical harness are located on the LH cab-forward side of the windrower. 6.6.1 A30-S, A30-D 6.6.1.
OPERATION 6.6.1.2 M205 E 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.
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. C E 6.6.2.1 M100 D b. Remove the cap (C) from electrical connector, and remove connector from support bracket. c. Disengage and rotate lever (D) counter clockwise to “fully up” position to release the hose bundle (E). The M100 is factory equipped with four hoses. E F J G H B A d.
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, A30-D and A40-D Auger Self-Propelled Windrower Header Unloading and Assembly Instructions - Form 169078” that was supplied with your A40-D header.
OPERATION o. Open header LH driveshield. p. Check hose routing at the reel motor. The hose routing depends on which windrower model the header is being attached to. The header is factory assembled for M150 and M200 windrowers. D C E FACTORY CONFIGURATION q. Change hoses as follows if header is being mounted on a M100 windrower: 1. Disconnect hose (C) at tee (E). 2. Disconnect hose (D) at reel motor. 3. Disconnect tee (E) at motor lower port and relocate to upper port. D E C M100/M205 CONFIGURATION 4.
OPERATION 6.6.2.2 M150 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) counter clockwise 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. Move hose/electrical bundle (E) to header. e.
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. H k.
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) counter clockwise to “fully up” position to release the hose bundle (E). The Windrower requires four hoses to run an A40-D header.
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.
OPERATION 6.6.2.4 M205 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. B A a. Disengage rubber latch (A), and open driveline shield (B). C E D AUGER HEADER HYDRAULICS The M205 must be equipped with an auger drive basic kit and a completion kit as shown above.
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.
OPERATION 6.6.3 IMPORTANT Configure Reverser Valve Jumper Hose If a reverser valve block (A) has been installed, the jumper hose (B) must be routed as shown opposite. Do not operate the headers unless hose is routed as shown. An optional reverser valve block to reverse the header drive in the event of plugging, may have been installed on the M150 and M200 windrowers. A jumper hose on this valve block has a specific routing for each model of auger header.
OPERATION c. To route hose (B) from A30-S, A30-D position to A40-D position: R4 A B C 1. Disconnect jumper hose (B) at 90° fitting in port R4. A C2 D 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.
OPERATION 6.7 c. 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, A30-D Detachment 1. Line up slot (C) in collar with pin (D) on connector. 2. Push collar toward pin, and pull connector to disengage. 3. Install caps on connectors and hose ends (if equipped). B A G a.
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. e. Install caps on connectors and hose ends if equipped.
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.
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, M200, and M205). d. Secure with bolts (A), spacers, and nuts. e. Repeat above steps for other light.
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.
OPERATION e. If steering cylinder is not fully charged, install temporary transport lock pin as follows: Otherwise, proceed to step f. 6.8.2.3 Preparing Mower Conditioner for Transport a. Charge the steering circuit as follows: 1. Connect the two APT steering cylinder hoses to a tractor hydraulic circuit. 2. Steer the header completely to the left, then right. Repeat three or four times. b. Steer the mower conditioner so that it is centered behind the towing vehicle. 1.
OPERATION 6.8.3 f. 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.
OPERATION 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. i. Swing APT to the left as far as possible without damaging hydraulic lines.
OPERATION IMPORTANT K The APT must not widen the shipping package. L l. j. 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. Secure APT to frame hook to prevent movement. Use cardboard or suitable material under the tie to protect paint. M k. Secure the steering cylinder to the frame with wire.
OPERATION CAUTION Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment may result in chain breakage, vehicle tipping or machine damage. Lifting Vehicle: Minimum Lifting Capacity: 8500 lb (3865 kg) Minimum Lifting Height: 15 ft (4.5 m) Chain: 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.
OPERATION h. Remove tie securing APT to frame. l. 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. Form 169000 / 169040 59 Move lift cylinder lock out valve handles to “vertical” position.
OPERATION 6.9 6.11 DAILY START-UP CHECK BREAK-IN PERIOD Do the following each day before start-up: 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. CAUTION • Be sure tractor/windrower and mower conditioner/header are properly attached, all controls are in NEUTRAL, and tractor/windrower brake is engaged.
OPERATION 6.12 SHUTDOWN PROCEDURE 6.14 LIFT CYLINDER LOCK-OUTS CAUTION WARNING Before leaving the tractor/windrower seat for any reason: • • • • • • • • To avoid bodily injury or death from fall of raised machine, always lock-out lift cylinders before going under mower conditioner for any reason. Park on level ground if possible. Lower the header/mower conditioner fully. Place all controls in NEUTRAL or PARK. Disengage PTO. Engage the park brake. Stop engine, and remove key from ignition.
OPERATION 6.15.1 6.15 STEERING: PULL-TYPE Right Side Operation: Pull-Type Steering the mower conditioner is controlled by the tractor 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.
OPERATION 6.15.2 6.15.3 LH Side Operation: Pull-Type Avoiding Obstacles Move steering lever as required to avoid obstacles. Move steering lever backward to achieve desired position of mower conditioner on LH side of tractor. 6.15.4 To adjust tracking of mower conditioner during LH side operation, the steering cylinder stroke control can be re-positioned: Square Corners The following procedure is intended only as a guide to developing a turning procedure for the tractor being used.
OPERATION 6.15.5 c. 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 the 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.
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. A child or even a pet could engage the drive.
OPERATION 6.17 HEADER OPERATION 6.17.1 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.
OPERATION 6.17.2 Auger Speed B The auger speed must be high enough to carry the 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. A30-S Refer to Section 5.
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, the 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/M200/M205), 15 to 50 rpm (M100), and is controlled from the Operator’s station on the self-propelled windrower.
OPERATION 6.17.4 6.17.4.1 Auger Fore-Aft Adjustment: A30-S a. Open LH endshield. b. Loosen auger drive chain (A) as follows: 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 The auger position has been factory set and should not normally require adjustment.
OPERATION i. j. Open RH endshield. Loosen reel drive belts as follows: H O J P N o. Check reel drive chain tension. Total chain slack at (N) should be 1/4 in. (6 mm). If necessary, adjust as follows: 1. Loosen bolt (O) on sprocket, and jam-nut on adjuster bolt (P). 2. Turn adjuster bolt (P) to move idler sprocket “downward” 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.
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.
OPERATION O P N n. Check reel drive chain tension. Total chain slack at (N) should be ¼ in. (6 mm). If necessary, adjust as follows: 1. Loosen bolt (O) on sprocket, and jam-nut on adjuster bolt (P). 2. Turn adjuster bolt (P) to move idler sprocket “downward” 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.
OPERATION g. 6.17.4.3 Auger Fore-Aft Adjustment: A30-D Open RH endshield. CAUTION H 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. G a. Open LH endshield. b. Loosen auger drive chain (A) as follows: F A h. Loosen reel drive belts (F) as follows: 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.
OPERATION L M K l. Check reel drive chain tension. Total chain slack at (K) should be 1/4 in. (6 mm). If necessary, adjust as follows: 1. Loosen bolt (L) on sprocket and jam-nut on adjuster bolt (M). 2. Turn adjuster bolt (M) to move idler sprocket “downward” 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.
OPERATION g. Open RH endshield. 6.17.4.4 Auger Vertical Adjustment: A30-D CAUTION 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. F a. Open LH endshield. A E h. Loosen reel drive belts (E) as follows: 1. Loosen nuts (F). 2. Loosen jam-nut on adjuster bolt (G), and turn adjuster bolt (G) to loosen reel drive belts (E). B C b. Loosen auger drive chain (A) as follows: 1.
OPERATION L M K l. Check reel drive chain tension. Total chain slack at (K) should be 1/4 in. (6 mm). If necessary, adjust as follows: 1. Loosen bolt (L) on sprocket and jam-nut on adjuster bolt (M). 2. Turn adjuster bolt (M) to move idler sprocket “downward” 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.
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 the four nuts (E). c. Loosen jam-nuts on adjuster bolts (F), and turn bolts (B) to adjust auger “vertical” position. d. Tighten jam-nuts. e. Tighten nuts (E). f. Open RH endshield. B a. Open LH endshield. b.
OPERATION 6.17.5 d. Tighten jam-nut and four nuts (A). e. Open RH endshield. Reel Position Reel position has been found to be a critical factor in achieving good results in adverse conditions. The reel position is factory set for average straight standing crop. It can be adjusted both vertically and horizontally (fore-aft) for different crop conditions. D See the chart below for recommended reel position in unusual crop conditions.
OPERATION e. Open RH endshield. 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. E a. Open LH endshield. C A f. Loosen the reel drive chain (C) as follows: 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 the four nuts (A). B g. Loosen the four nuts (F). G c.
OPERATION 6.17.5.3 Reel Fore-Aft Position: A40-D NOTE D The reel must be adjusted equally on both sides. 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. C a. Open LH endshield. j. k. l. Tighten the reel drive chain (C) as follows: 1. Turn adjuster bolt (E) to tighten chain until total chain slack at (C) is 1/4 in. (6 mm). 2. Tighten jam-nut at (E) and nut (D) and re-check tension.
OPERATION 6.17.5.4 Reel Vertical Position: A40-D a. Open LH endshield. f. Open RH endshield. G E G E g. Loosen the four nuts (G). b. Loosen the 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 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.
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). e.
OPERATION 6.17.7 e. Check that skid shoes or gauge rollers are adjusted to the same position. f. Check header float and adjust if required. Refer to Section 6.17.9 Header Flotation. Cutting Height Cutting height is controlled with a combination of skid shoes or gauge rollers, and header angle adjustment, not with the header lift cylinders.
OPERATION 6.17.8 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 6.17.7 Cutting Height. g. Check header float, and adjust if required. Refer to Section 6.17.9 Header Flotation. 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.
OPERATION 6.17.9 Header Flotation Header flotation springs are normally set so 70 lbf (311 N) is required to lift either end of the header just off the ground. In rough or stony conditions, it may be desirable to change setting to 35 - 50 lbf (156 - 222 N) to protect cutting components. 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.
OPERATION 6.17.10 Feed Pan / Rock-Drop Tine Position The rear of the feed pan is adjustable “up” and “down” to raise or lower the feed pan and rock drop tines. • Lowering the feed-pan helps prevent plugging in heavy crop. • 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.
OPERATION 6.17.11 Hay Conditioner 0 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 the 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 C 9 10 PULL-TYPE SELF-PROPELLED c. Loosen and “back-off” upper jam-nut (A), on both sides of conditioner. d.
OPERATION NOTE 6.17.11.2 Roll Timing and Alignment If the distance ‘X’ varies more than 1/16 in. (1.6 mm) from one end to the other, the rolls should be re-aligned. Refer to next Section 6.17.11.2.2 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.
OPERATION NOTE 6.17.11.2.2 Roll Alignment The rolls are aligned if the distance ‘X’ varies less than 1/16 in. (1.6 mm) from 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. The 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.
OPERATION 6.17.12 Roll Tension The roll tension (the force holding the rolls together) is factory set, and is adjustable. There is a spring (A) for each end of the roll. See illustration below. CAUTION 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 the header fully. b. Stop engine, and remove key. A B C c.
OPERATION a. Set forming shield side deflectors to desired width by re-positioning adjuster bars as follows: 6.17.13 Forming Shields WARNING Keep hands and feet away from discharge opening. Keep everyone several hundred feet away from your operation. Never direct the discharge toward anyone. Stones or other foreign objects can be ejected with force. A B The position of the forming shields controls the width and placement of the windrow.
OPERATION 6.17.13.2 Rear Deflector (Fluffer Shield) The rear deflector (D) slows the crop exiting the conditioner rolls, directs the flow downward, and "fluffs" the material. CAUTION 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.
OPERATION 6.17.14 Tall Crop Dividers The tall crop dividers attach to the ends of the header for clean crop dividing and reel entry in tall crops. They can be easily adjusted to suit the crop, or removed when not required. A H C d. Reposition 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 reposition divider (C) to align with alternate hole location (D). c. Re-install bolts (B) and tighten. d.
OPERATION 6.17.15 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 two 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.
OPERATION 6.17.16.4 Auger Pan Extensions 6.17.16 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: 6.17.16.1 Stub Guards and Hold-Downs WIDE C The cutterbar is equipped with stub guards for effective cutting in tough grass crops. See Section 7.8.
OPERATION 6.17.16.5 Windrow Forming Rods Forming rods are provided to assist in forming the narrow windrows preferred for this application. a. Bend the rods to modify the windrow shape. Use the forming rods in conjunction with the auger pan extensions to achieve the width and shape of windrows you desire.
OPERATION 6.18 HAYING TIPS 6.18.1 6.18.4 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. 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. Leaving the windrow as wide and thin as possible makes for the quickest curing c.
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.
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. 7.1 • Wear protective shoes with slip-resistant soles, a hard hat, protective glasses or goggles and heavy gloves.
MAINTENANCE/SERVICE 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.
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.
MAINTENANCE/SERVICE 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 SPEC SAE MultiPurpose Gear Lubricant Hydraulic Oil Form 169000 / 169040 DESCRIPTION USE CAPACITIES High Temp. Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2).
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 Pressure pounds per square inch psi x 6.8948 = kilopascals kPa x .
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 the LH and right driveshields on the header, press a screwdriver against latch in opening at (A). a.
MAINTENANCE AND SERVICING 7.6 LUBRICATION 7.6.2 Lubrication Points The 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 for identifying lubrication points for your specific model: Refer to Section 7.3.2 Recommended Fluids and Lubricants for recommended greases.
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.
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 REEL SHAFT BEARING (1 PLC) AUGER SHAFT BEARING (1 PLC) Form 169000 / 169040 107 Revision C
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 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.
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 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.
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 over grease.
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.
MAINTENANCE AND SERVICING IV.
MAINTENANCE AND SERVICING V.
MAINTENANCE AND SERVICING VI.
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.
MAINTENANCE AND SERVICING Oiling (Cont’d) A30-D HEADER LH SIDE SAE 30 AUGER DRIVE CHAIN (1 PLC) CHECK ROLL GEARBOX (1 PLC) WOBBLE BOX (A30-S 1 PLC) (A30-D / A40-D 2 PLCS) (CHECK OIL LEVEL WITH TOP OF WOBBLE BOX HORIZONTAL) Form 169000 / 169040 116 Revision C
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) the flangette bolts (E). d. When the 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.
MAINTENANCE AND SERVICING 7.7 7.7.2.3 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.
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.
MAINTENANCE AND SERVICING 7.8 SICKLE AND SICKLE DRIVE 7.8.2 CAUTION Sickle Removal WARNING To avoid personal injury, before servicing header/mower conditioner or opening drive covers, follow procedures in Section 7.1 PREPARATION FOR SERVICING. Stand to rear of sickle during removal to reduce risk of injury from cutting edges. Wear heavy gloves when handling sickle. a. Stroke sickle to its outer limit. WARNING Keep hands clear of the area between guards and sickle at all times.
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 D M REMOVAL B b.
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 right end as shown. Ensure sickle is secured in place. 7.8.7.1 b. Spare sickles with the knife head for double knife headers may be stored inside the lean bar.
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.
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.
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 the 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.
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.
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 - 0.024 in. (0.
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 the 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.
MAINTENANCE AND SERVICING 7.8.9 7.8.9.2 Removal: A30-S Sickle Drive Belt 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: A30-S Sickle Drive Belt 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). d.
MAINTENANCE AND SERVICING 7.8.9.3 Installation: A30-S Sickle Drive Belt B g. Install bolt-in plate in LH end sheet at wobble 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 end sheet onto wobble 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.
MAINTENANCE AND SERVICING 7.8.10 7.8.10.2 Removal: LH Sickle Drive Belts, A30-D a. Open LH endshield. 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. a. Open LH endshield. D C b. Loosen nut (E) on idler sprocket. c.
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 end sheet at wobble box. i. Slip belt off wobble box pulley, and route belt through this hole to remove it.
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.
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.
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 G C E 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). B A D E a.
MAINTENANCE AND SERVICING 7.8.11 Double V-Belts 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.
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 B Timing Belt D J A C b. Disconnect hoses from auger drive motor (J). Protect hose ends and motor ports with clean, lint-free cloths or clean plastic bags. c.
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.
MAINTENANCE AND SERVICING 7.8.11.6 Installation: RH Sickle Drive Belt, A40-D 7.8.11.5 Removal: 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 end sheet onto wobble box pulley and sickle drive pulley (J) as shown. B NOTE When installing new belt, never pry belt over pulley.
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 7.8.11.5 Removal: RH Sickle Drive Belt, A40-D.
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) counter clockwise. 4.
MAINTENANCE AND SERVICING 7.8.13 Wobble Box D 7.8.13.1 Mounting Bolts CAUTION E C 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. 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.
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 the underside of the sickle head until the pin is flush with the upper face of the pitman arm (C). 7.8.13.
MAINTENANCE AND SERVICING 7.8.13.6 Changing Wobble Box Oil 7.8.13.4 Pulley Removal a. Remove wobble box. See previous page. NOTE Change wobble box lubricant after the first 50 hours operation, and every 1000 hours (or 3 years) thereafter. A a. Raise header to allow a suitable container to be placed under wobble box drain to collect oil. 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.
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 Reel Drive Chain: A30-S, A30-D 7.9.1.1 Tension B NOTE D For major adjustments, such as after repositioning reel or auger, adjust belt tension before chain tension. C A b.
MAINTENANCE AND SERVICING 7.9.2 Reel Drive Belts: A30-S, A30-D 7.9.2.1 Tension Adjustment 7.9.2.2 Removal Remove reel drive belts (A) as follows: 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.
MAINTENANCE AND SERVICING 7.9.3 h. Remove nut, bolt, and keeper on each tine to be removed, and slide tine off the bar. Reel Tines and Tine Bar Bearings: A30-S, A30-D 7.9.3.2 IMPORTANT Keep reel tines in good condition. Straighten or replace as required. 7.9.3.1 Installation: Tines and Bearings, Cam End CAUTION Removal: Tines and Bearings, Cam End 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.
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). Install nut with flat side against tine bar.
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. 7.10.1 C 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. 7.10.2 b.
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).
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.
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. To replace tine bar bearing, refer to Section 7.6.
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 G F 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.
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. 7.11.1 C A D B Auger Drive Chain: A30-S 7.11.1.1 Tension Adjust chain (A) tension as follows: CAUTION b. c. d. e.
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 (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.
MAINTENANCE AND SERVICING 7.11.3 7.11.3.2 Removal a. Open LH endshield. Auger Drive Belt: A30-S 7.11.3.1 Tension IMPORTANT C To prolong drive life, do not over-tighten belts. Belt slippage is used to protect the auger in an overload situation. E D A B NOTE 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. Adjust auger drive belts (A) tension as follows: CAUTION b.
MAINTENANCE AND SERVICING 7.11.4 7.11.4.2 Removal a. Open LH endshield. Auger Drive Belts: A30-D 7.11.4.1 Tension IMPORTANT D To prolong drive life, do not over-tighten belt. Belt slippage is used to protect the auger in an overload situation. NOTE E 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. F b. Remove auger drive chain (D) as follows: 1.
MAINTENANCE AND SERVICING 7.11.5 Auger Pans 7.11.7 The high density polyethylene auger pans are repairable and replaceable. Refer to the Technical Service Manual, MacDon Form #169048 for details on replacing the pans. AUGER 1 - 4 mm (1/32 - 5/32”) 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.
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 a.
MAINTENANCE AND SERVICING f. Replace drain plug (C), and add oil at (A) to required level. Use Gear Lubricant, SAE 85W140, API Service Class GL-5, 1.5 qts (1.4 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. 7.13.1 7.13.
MAINTENANCE AND SERVICING 7.13.3 e. Disassemble fluffer shield (J) from forming shield cover. 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 procedure 7.13.3 Disassemble Forming Shield. 7.13.5 F Install Forming Shield E M G a.
MAINTENANCE AND SERVICING 7.13.6 Hydraulic Drive Motor Removal: All Models a. Open shield covering conditioner drive. b. On pull-type machines, disconnect the 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 the two bolts (A) securing motor to gearbox, and remove motor. 7.13.
MAINTENANCE AND SERVICING 7.13.8 Gearbox Removal: A30-S a. Remove hydraulic drive motor. Refer to Section 7.13.6 Hydraulic Drive Motor Removal: All Models. G NOTE It is not necessary to disconnect the motor hoses for this operation. F C f. B Remove the auger drive pulley (F) as follows: 1. Remove the three bolts from the tapered bushing (G) in pulley (F). 2. Install bolts in the two threaded holes in bushing, and tighten to release the bushing. 3. Remove the pulley, bushing, and key. B J b.
MAINTENANCE AND SERVICING 7.13.9 Gearbox Installation: A30-S J H A G B F e. Install auger drive pulley (F) as follows: 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 in tapered bushing (G), and tighten to 18 ft·lbf (25 N·m). 5. Tap bushing and re-torque. Repeat until bolts no longer turn at 18 ft·lbf (25 N·m).
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 6.17.11.2 Roll Timing and Alignment. j. Clean off excess sealant from motor flange and gearbox face. k.
MAINTENANCE AND SERVICING 7.13.10 Gearbox Removal: A30-D D a. Open shield covering conditioner drive. E F A f. Remove auger drive chain (D) from small sprocket as follows: 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 the two bolts (A) securing motor to gearbox, and remove motor. NOTE It is not necessary to disconnect the motor hoses for this operation. H G 1.
MAINTENANCE AND SERVICING h. Remove the auger drive pulley (K) as follows: Q L P M O K i. 1. Remove the three bolts (L) from hub (M), and remove hub and sprocket. Remove the two bolts (O), and nut and bolt (P) attaching channel (Q) to end sheet, and remove channel (Q). S K R N j. 2. Remove the three bolts (N) from the tapered bushing. 3. Install bolts in the two threaded holes in bushing, and tighten to release the bushing. 4. Remove the pulley (K), bushing, and key.
MAINTENANCE AND SERVICING 7.13.11 Gearbox Installation: A30-D A F J B H G f. a. Position gearbox (A) as shown, picking up the three holes in the end sheet. b. Install three flanged locknuts at (B) but do not tighten. E C Install drive pulley (F) as follows: 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.
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 6.17.11.2 Roll Timing and Alignment. q. Clean off excess sealant from motor flange and gearbox face. r.
MAINTENANCE AND SERVICING e. Open the 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 the sickle drive pulley (G) as follows: 1. Remove the three bolts from the tapered bushing (H) in pulley (D). 2.
MAINTENANCE AND SERVICING j. N M F O D H E j. G Remove the three flanged lock nuts (M) that secure gearbox (N) to header end sheet, and remove gearbox. f. Install drive pulley (G) as follows: 1. Slide pulley (G) onto shaft with key. 2. Install tapered bushing (H) onto shaft, ensuring holes are aligned with holes in pulley. 3. Align faces of pulley (G) and countershaft pulley (O) to within .06 in. (1.5 mm). 4. Install three bolts in tapered bushing (H), and tighten to 18 ft·lbf (25 N·m). 5.
MAINTENANCE AND SERVICING l. m. n. o. p. q. Adjust roll timing. Refer to Section 6.17.11.2 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 (U) and washers, and torque to 75 ft·lbf (102 N·m). Re-connect hoses to motor. Close all shields before operating machine.
MAINTENANCE AND SERVICING 7.14 WHEELS, TIRES, AND HITCH: PULL-TYPE 7.14.3 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. 7.14.1 Wheel Installation The “uncountersunk” holes do not seat the bolts correctly.
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.
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 The skid shoes are equipped with replaceable wear plates that can be reversed for increase service life. It is recommended that the wear plates be replaced when the skid shoe weldment becomes exposed. IMPORTANT If bolt heads are worn down, replace with new ½ in.
MAINTENANCE AND SERVICING NOTE 7.16 GAUGE ROLLERS Use a socket and ratchet wrench to access the nuts. The gauge rollers can be removed for replacement or repair. Proceed as follows to remove the gauge rollers: c. Tighten nuts. d. Remove pins (B), and adjust rollers to desired height. Re-install the two pins (B). Removal: a. Raise header, and engage lift cylinder stops. D E CAUTION Stop engine, and remove key from ignition before leaving Operator's seat for any reason.
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.
MAINTENANCE AND SERVICING 7.18.1.3 Maintenance Record - SP Self-Propelled Windrower Header ACTION: 9 - Check 6 - Lubricate S - Change MAINTENANCE RECORD Hour Meter Reading Date Serviced By BREAK-IN Refer To Section 7.18.1.1 Break-In Inspection - SP 100 HOURS OR ANNUALLY 9 6 9 9 Conditioner Drive Gearbox Lube Level Wheel Hub Bearings Wobble Box Bolt Torque Wobble Box Lubricant Level END OF SEASON Refer To Section 6.
MAINTENANCE AND SERVICING 7.18.2 Pull-Type Mower Conditioner 7.18.2.1 Break-In Inspection - PT HOURS ITEM CHECK Wheel Bolts 1 120 ft·lbf (160 N·m) Section 7.14.1 Torque Steering Cylinder Clevis and Stroke Control Auger Drive Belt 5, 25, 50 Section 7.9.2 Tension Sickle Drive Belt Sections 7.8.9 and 7.8.10 Hardware Torque Section 7.3.1 Reel Drive Chain Tension/ Lubricate Sections 7.11.1 and 7.11.2 Wobble Box Mounting Bolts Torque 200 ft·lbf (270 N·m) Section 7.8.
MAINTENANCE AND SERVICING 7.18.2.3 Maintenance Record - PT ACTION: 9 - Check MAINTENANCE RECORD Date Serviced By Refer To Section 7.18.2.1 Break-In Inspection - PT Hydraulic Oil Filter - First 100 H Only Conditioner Drive Gearbox Lube Level Wheel Bolt Torque Wheel Hub Bearings Wobble Box Bolt Torque Wobble Box Lubricant Level END OF SEASON 10 HOURS OR DAILY 6 9 9 6 6 9 9 S - Change Hour Meter Reading FIRST USE 100 HOURS OR ANNUALLY S 9 9 6 9 9 6 - Lubricate Refer To Section 6.
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. 6.17.11 Reel speed too fast. Reduce reel speed. 6.17.3 Roll gap too small. Increase roll gap. 6.17.11 Rolls improperly timed. Adjust roll timing. 6.17.11.
TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION Pulling Material By The Roots Ground speed too slow. Or Tall Material Leaning Into Reel position incorrect. Machine. Ragged Or Uneven Cutting Of Crop. Conditioner Plugging. Form 169000 / 169040 --- 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 adjust if necessary. 7.8.
TROUBLESHOOTING SYMPTOM Sickle Plugging (cont’d). Uneven Formation And Bunching Of Windrow. Uneven Windrow Formation In Light Crop. Reel Causes Seed Loss (e.g. Grass Seed). Auger Plugging In Heavy Grass Seed. PROBLEM SOLUTION 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.
TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION Grass Seed Windrow Too Wide or Too Narrow. Pan extensions not adjusted properly. Adjust pan extensions. SYMPTOM PROBLEM SOLUTION Auger And/Or Conditioner Rolls Damaged By Stones. Feed pan doesn't allow stones to fall through. Lower rock-drop tines. 6.17.10 Ground speed too high in stony conditions. Reduce ground speed. --- Cutting height too low in stony conditions. Raise cutting height with skid shoes. 6.17.
TROUBLESHOOTING SYMPTOM Knocking In Sickle Drive. Header Turns While Unloaded But Slows Or Stops When Starting To Cut. Sickle Back Breakage. Windrower Side Drift. Lights Malfunctioning. Form 169000 / 169040 PROBLEM SOLUTION SECTION Worn needle bearing in sickle head. Replace. 7.8.4 Worn sickle head pin. Replace. 7.8.3 Incorrect end guards. Replace with special end guards. 7.8.7 Cold oil in system. Reduce ground speed until oil reaches operating temperature. Dull sickle. Replace. 7.8.
OPTIONS AND ATTACHMENTS 9.4 9 OPTIONS AND ATTACHMENTS 9.1 REPLACEMENT REEL BAT KITS: A30-S, A30-D HYDRAULIC HEADER ANGLE KITS: PULL-TYPE Consists of one complete bat assembly for ease of replacement. 9.5 This kit allows the header angle to be adjusted hydraulically with a cylinder replacing the standard mechanical link. A separate hydraulic circuit is required or the existing APT steering cylinder hydraulic circuit can be utilized, depending on the tractor hydraulics.
UNLOADING AND ASSEMBLY 10 UNLOADING AND ASSEMBLY Header-specific instructional manual for unloading, assembly and set-up procedures are included with your shipment.
INDEX A40 auger ........................................................... 77 A40 reel............................................................... 80 Forming Rods ......................................................... 96 Forming Shields ..................................................... 91 Gauge Roller Kit ................................................... 186 Gauge Rollers adjustment .......................................................... 83 removal/installation .............................
gap ...................................................................... 87 tension ................................................................ 90 timing .................................................................. 88 unplugging .......................................................... 65 Rubber Fingers..................................................... 158 Safety general ................................................................ 14 owner ...............................................
INDEX Unhook Pull-Type ................................................... 33 Unloading ....................................................... 58, 187 Unplugging rolls ..................................................................... 65 sickle ................................................................... 65 Valve Blocks ........................................................... 50 Vertical Adjust A30-D auger ....................................................... 75 A30-S auger .................
