MacDon A30-D User manual

The harvesting specialists worldwide.
A30-D and A40-D
Pull-Type Mower Conditioner and
Self-Propelled Auger Header
Operator’s Manual
169000 Rev. F
Original Instruction

MACDON A40-D SELF-PROPELLED AUGER HEADER
MACDON A30-D PULL-TYPE MOWER CONDITIONER

169000 1Revision F

169000 2Revision F

169000 3Revision F
1 INTRODUCTION
This instructional manual describes the operating and maintenance procedures for the Model A30-D and A40-D
Auger Headers. 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.
MODEL * DESCRIPTION CONFIGURATION KNIFE SIZE (FT) FEATURES
A30-D A- Auger Header
with Conditioner Pull-Type Only
D- Double
14, 16 and 18 Hydraulic Drive
A40-D A- Auger Header
with Conditioner Self-Propelled ** 14, 16, and 18 Separate Hydraulic Auger,
Knife and Reel Drives,
Grass Seed Option.
* Model availability depends on Dealer affiliation
** When attached to a MacDon M-Series Windrower.
CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE, OR
USE THE MACHINE.
Use this manual as your first source of information about the machine. If you follow the instructions given here,
your header/mower conditioner will work well for many years. A parts catalog is also supplied with your new
header/mower conditioner. If you require more detailed service information, see your Dealer for availability of a
technical manual.
Use the Table of Contents and the Index to guide you to specific areas. Study the Table of Contents to familiarize
yourself with how the material is organized. Keep this manual handy for frequent reference, and to pass on to new
Operators or Owners. Contact your Dealer if you need assistance, information, or additional copies of
this manual.
RECORD THE SERIAL NUMBERS OF THE HEADER AND ARTICULATING POWER TONGUE (APT) IN THE
SPACES BELOW.
HEADER SERIAL NUMBER:
_______________________________________
Serial Number plate is located at the top of the left
hand end frame.
Published: August, 2013
Original Instruction
APT SERIAL NUMBER (PULL-TYPE):
_________________________________________
Serial Number plate is located at the top aft end of
the APT.
PTO SPEED: 1000 RPM

169000 4Revision F

TABLE OF CONTENTS
Section/Title __Page
169000 5Revision F
1INTRODUCTION...............................................................................................................................................3
2SAFETY ............................................................................................................................................................9
2.1 SAFETY ALERT SYMBOL..................................................................................................................9
2.2 SIGNAL WORDS ................................................................................................................................9
2.3 SAFETY SIGNS..................................................................................................................................9
2.3.1 Safety Sign Installation................................................................................................................9
2.3.2 2-Panel Safety Sign Locations: Pull-Type.................................................................................10
2.3.3 2-Panel Safety Sign Locations: Self-Propelled.........................................................................13
2.3.4 Safety Sign Interpretations........................................................................................................15
2.4 GENERAL SAFETY..........................................................................................................................20
3DEFINITIONS..................................................................................................................................................22
4COMPONENT IDENTIFICATION...................................................................................................................23
4.1 PULL-TYPE.......................................................................................................................................23
4.2 SELF-PROPELLED........................................................................................................................... 26
5SPECIFICATIONS ..........................................................................................................................................27
5.1 PULL-TYPE HEADERS ....................................................................................................................27
5.2 SELF-PROPELLED HEADERS........................................................................................................29
6OPERATION...................................................................................................................................................31
6.1 OWNER/OPERATOR RESPONSIBILITIES.....................................................................................31
6.2 OPERATIONAL SAFETY..................................................................................................................31
6.3 TRACTOR SETUP: PULL-TYPE......................................................................................................32
6.3.1 Tractor Requirements ...............................................................................................................32
6.3.2 Drawbar Adjustment..................................................................................................................32
6.3.3 Drawbar Hitch Set-Up...............................................................................................................33
6.3.4 3 Point Hitch (Cat. II, III or IIIN) Set-Up.....................................................................................34
6.4 MOWER CONDITIONER / TRACTOR HOOKUP: PULL-TYPE.......................................................35
6.4.1 Drawbar Hook-Up .....................................................................................................................35
6.4.2 3 Point Hitch (Cat. II, III, or IIIN) Hook-Up................................................................................ 36
6.4.3 Hydraulic Connections..............................................................................................................37
6.5 MOWER CONDITIONER / TRACTOR UNHOOK: PULL-TYPE.......................................................38
6.5.1 Drawbar Hitch Unhook..............................................................................................................38
6.5.2 3-Point Hitch Unhook................................................................................................................40
6.6 HEADER ATTACHMENT: SELF-PROPELLED...............................................................................41
6.6.1 A40-D........................................................................................................................................41
6.6.2 Reverser Valve Jumper Hose...................................................................................................50
6.7 HEADER DETACHMENT: SELF-PROPELLED .............................................................................. 51
6.7.1 A40-D Detachment....................................................................................................................51
6.8 TRANSPORTING MOWER CONDITIONER....................................................................................53
6.8.1 Self-Propelled............................................................................................................................53
6.8.2 Pull-Type: Towing .....................................................................................................................53
6.8.3 Pull-Type: Flatbed.....................................................................................................................56
6.9 BREAK-IN PERIOD........................................................................................................................... 61
6.10 PRE-SEASON CHECK.....................................................................................................................61
6.11 DAILY START-UP CHECK ...............................................................................................................61
6.12 SHUTDOWN PROCEDURE.............................................................................................................62
6.13 ENGAGING THE POWER TAKE-OFF (PTO): PULL-TYPE............................................................62
6.14 LIFT CYLINDER LOCK-OUTS..........................................................................................................62
6.14.1 Self-Propelled............................................................................................................................62

TABLE OF CONTENTS
Section/Title ____ __Page
169000 6Revision F
6.14.2 Pull-Type...................................................................................................................................62
6.15 STEERING: PULL-TYPE ..................................................................................................................63
6.15.1 Right Side Operation: Pull-Type................................................................................................63
6.15.2 Left Side Operation: Pull-Type..................................................................................................64
6.15.3 Avoiding Obstacles ...................................................................................................................64
6.15.4 Square Corners.........................................................................................................................64
6.15.5 180 Degree Turn.......................................................................................................................65
6.16 UNPLUGGING THE HEADER / MOWER CONDITIONER..............................................................66
6.16.1 Unplugging Conditioner: Pull-type.............................................................................................66
6.16.2 Unplugging Knife.......................................................................................................................66
6.17 HEADER OPERATION.....................................................................................................................67
6.17.1 Lean Bar Position......................................................................................................................67
6.17.2 Auger Speed .............................................................................................................................68
6.17.3 Reel Speed................................................................................................................................69
6.17.4 Auger Position...........................................................................................................................70
6.17.5 Reel Position.............................................................................................................................75
6.17.6 Tine Aggressiveness Adjustment..............................................................................................79
6.17.7 Reel Tine to Header Pan Clearance.........................................................................................80
6.17.8 Cutting Height............................................................................................................................80
6.17.9 Header Angle ............................................................................................................................81
6.17.10 Header Flotation........................................................................................................................82
6.17.11 Feed Pan / Rock-Drop Tine Position ........................................................................................83
6.17.12 Hay Conditioner.........................................................................................................................84
6.17.13 Roll Tension ..............................................................................................................................87
6.17.14 Forming Shields ........................................................................................................................88
6.17.15 Tall Crop Dividers......................................................................................................................90
6.17.16 Ground Speed...........................................................................................................................91
6.17.17 Grass Seed Windrowing ...........................................................................................................92
6.17.18 Recommended Settings............................................................................................................94
6.18 HAYING TIPS....................................................................................................................................95
6.18.1 Curing........................................................................................................................................95
6.18.2 Topsoil Moisture........................................................................................................................95
6.18.3 Weather and Topography .........................................................................................................95
6.18.4 Windrow Characteristics ...........................................................................................................95
6.18.5 Driving On Windrow ..................................................................................................................95
6.18.6 Raking and Tedding..................................................................................................................95
6.18.7 Chemical Drying Agents............................................................................................................95
6.19 STORAGE.........................................................................................................................................96
7MAINTENANCE AND SERVICING................................................................................................................97
7.1 PREPARATION FOR SERVICING...................................................................................................97
7.2 RECOMMENDED SAFETY PROCEDURES....................................................................................97
7.3 MAINTENANCE SPECIFICATIONS.................................................................................................98
7.3.1 Recommended Torques............................................................................................................98
7.3.2 Recommended Fluids and Lubricants ....................................................................................102
7.3.3 Conversion Chart....................................................................................................................103
7.4 DRIVESHIELDS..............................................................................................................................104
7.5 LIFT CYLINDER LOCK-OUTS........................................................................................................104
7.5.1 Self-Propelled..........................................................................................................................104
7.5.2 Pull-Type.................................................................................................................................104
7.6 LUBRICATION ................................................................................................................................105
7.6.1 Greasing Procedure................................................................................................................105
7.6.2 Lubrication Points....................................................................................................................105
7.6.3 Oiling.......................................................................................................................................113

TABLE OF CONTENTS
Section/Title __Page
169000 7Revision F
7.6.4 Installing Sealed Bearing ........................................................................................................114
7.7 HYDRAULICS.................................................................................................................................115
7.7.1 Hydraulics: Self-Propelled.......................................................................................................115
7.7.2 Hydraulics: Pull-Type..............................................................................................................115
7.7.3 Hoses and Lines .....................................................................................................................116
7.8 KNIFE AND KNIFE DRIVE..............................................................................................................117
7.8.1 Replacing Knife Section..........................................................................................................117
7.8.2 Removing Knife.......................................................................................................................117
7.8.3 Installing Knife.........................................................................................................................118
7.8.4 Removing Knife Head Bearing................................................................................................118
7.8.5 Installing Knife Head Bearing..................................................................................................118
7.8.6 Spare Knife..............................................................................................................................119
7.8.7 Knife Guards ...........................................................................................................................119
7.8.8 Knife Hold-Downs ...................................................................................................................122
7.8.9 Knife Drive Belts: A30-D .........................................................................................................124
7.8.10 Knife Drive Belts: A40-D .........................................................................................................129
7.8.11 Adjusting Knife Drive Timing...................................................................................................133
7.8.12 Knife Drive Box .......................................................................................................................135
7.9 REEL AND REEL DRIVE: A30-D....................................................................................................138
7.9.1 Reel Drive Chain: A30-D.........................................................................................................138
7.9.2 Reel Drive Belts: A30-D..........................................................................................................139
7.9.3 Reel Tines and Tine Bar Bearings: A30-D..............................................................................140
7.10 REEL AND REEL DRIVE: A40-D....................................................................................................142
7.10.1 Reel Drive: A40-D ...................................................................................................................142
7.10.2 Reel Tines and Tine Bar Bearings: A40-D.............................................................................142
7.11 AUGER AND AUGER DRIVE: A30-D............................................................................................. 147
7.11.1 Auger Drive Chain: A30-D.......................................................................................................147
7.11.2 Auger Drive Belts: A30-D........................................................................................................148
7.11.3 Auger Pans..............................................................................................................................149
7.11.4 Rubber Fingers .......................................................................................................................149
7.11.5 Stripper Bars ...........................................................................................................................149
7.12 AUGER AND AUGER DRIVE: A40-D............................................................................................150
7.13 CONDITIONER...............................................................................................................................151
7.13.1 Changing Gearbox Oil.............................................................................................................151
7.13.2 Removing Forming Shield.......................................................................................................151
7.13.3 Disassembling Forming Shield................................................................................................152
7.13.4 Assembling Forming Shield ....................................................................................................152
7.13.5 Installing Forming Shield.........................................................................................................152
7.13.6 Removing Hydraulic Drive Motor: All Models..........................................................................153
7.13.7 Installing Hydraulic Drive Motor: All Models............................................................................153
7.13.8 Removing Gearbox: A30-D.....................................................................................................154
7.13.9 Installing Gearbox: A30-D.......................................................................................................156
7.13.10 Removing Gearbox: A40-D.....................................................................................................158
7.13.11 Installing Gearbox: A40-D.......................................................................................................159
7.14 WHEELS, TIRES, AND HITCH: PULL-TYPE.................................................................................161
7.14.1 Wheel Bolts.............................................................................................................................161
7.14.2 Removing Wheel.....................................................................................................................161
7.14.3 Installing Wheel.......................................................................................................................161
7.14.4 Inflating Tire.............................................................................................................................162
7.15 REPLACING SKID SHOE WEAR PLATE.......................................................................................163
7.16 GAUGE ROLLERS.......................................................................................................................... 164
7.17 ELECTRICAL..................................................................................................................................164
7.18 MAINTENANCE SCHEDULE .........................................................................................................165

TABLE OF CONTENTS
Section/Title ____ __Page
169000 8Revision F
7.18.1 Self-Propelled Mower Conditioner ..........................................................................................165
7.18.2 Pull-Type Mower Conditioner..................................................................................................167
8TROUBLESHOOTING..................................................................................................................................169
8.1 WINDROWER PERFORMANCE....................................................................................................169
8.2 MECHANICAL.................................................................................................................................172
9OPTIONS AND ATTACHMENTS.................................................................................................................174
9.1 HYDRAULIC HEADER ANGLE KITS: PULL-TYPE........................................................................174
9.2 ADDITIONAL SKID SHOES............................................................................................................174
9.3 GAUGE ROLLER KIT .....................................................................................................................174
9.4 REPLACEMENT REEL BAT KITS: A30-D......................................................................................174
9.5 STUB GUARD CONVERSION KIT.................................................................................................174
9.6 TALL CROP DIVIDER KIT..............................................................................................................174
10 UNLOADING AND ASSEMBLY...................................................................................................................175
INDEX .............................................................................................................................................................176

SECTION 2 SAFETY
169000 9Revision F
2 SAFETY
2.1 SAFETY ALERT SYMBOL
This safety alert symbol indicates important
safety messages in this manual and on safety
signs on the machine.
This symbol means:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Carefully read and follow the safety message
accompanying this symbol.
WHY IS SAFETY IMPORTANT TO YOU?
ACCIDENTS DISABLE AND KILL.
ACCIDENTS COST.
ACCIDENTS CAN BE AVOIDED.
2.2 SIGNAL WORDS
Note the use of the signal words DANGER,
WARNING, and CAUTION with safety
messages. The appropriate signal word for each
message has been selected using the
following guidelines:
DANGER
Indicates an imminently hazardous situation
that, if not avoided, will result in death or
serious injury.
WARNING
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.
2.3 SAFETY SIGNS
•The safety signs appear on the
header/mower conditioner at the locations
shown on pages 8 to 12.
•Keep safety signs clean and legible at
all times.
•Replace safety signs that are missing or
become illegible.
•If original parts on which a safety sign was
installed are replaced, be sure the repair
part also bears the current safety sign.
•Safety signs are available from your Dealer
Parts Department.
2.3.1 Safety Sign Installation
a. Be sure the installation area is clean and dry.
b. Decide on the exact location before you remove
the decal backing paper.
c. Remove the smaller portion of the split
backing paper.
d. Place the sign in position, and slowly peel back
the remaining paper, smoothing the sign as it
is applied.
e. Small air pockets can be smoothed out or
pricked with a pin.

SECTION 2 SAFETY
169000 10 Revision F
2.3.2 2-Panel Safety Sign Locations: Pull-Type
Left-Hand Side Decal Location
A – MD #174632 B – MD #184422 C – MD #166452 D – MD #113482
E – MD #194464 F – MD #174436 G – MD #171287 H – MD #171279
J – MD #36651 K – MD #194521

SECTION 2 SAFETY
169000 11 Revision F
2-Panel Safety Sign Locations: Pull-Type (cont’d)
Right-Hand Side Decal Location
A – MD #171279 B – MD #184372 C – MD #171287
D – MD #184422 E – MD #174632 F – MD #166452

SECTION 2 SAFETY
169000 12 Revision F
2-Panel Safety Sign Locations: Pull-Type (cont’d)
Hitch Decal Location
A – MD #194464 B – MD #113482 C – MD #174436
D – MD #171281 E – MD #171281 F – MD #171286

SECTION 2 SAFETY
169000 13 Revision F
2.3.3 2-Panel Safety Sign Locations: Self-Propelled
Left-Hand Side Decal Location
A – MD #174632 B – MD #184422 C – MD #166452
D – MD #174436 E – MD #171288 F – MD #184372
G – MD #194464 H – MD #194521 J – MD #36651

SECTION 2 SAFETY
169000 14 Revision F
2-Panel Safety Sign Locations: Self-Propelled (cont’d)
Right-hand side decal location
A – MD #184422 B – MD #174632 C – MD #166452

SECTION 2 SAFETY
169000 15 Revision F
2.3.4 Safety Sign Interpretations
In the safety explanations below, (a) refers to
the top or left position panel, (b) refers to the
bottom or right position of the safety decal
depending on decal orientation.
NOTE
If there are more than two panels in a
decal, the lettering will continue
downward, or to the right, depending on
decal orientation.
1. MD #36651
a. Rotating driveline
b. DANGER
•Stop engine and remove key before
opening shield.
•Do not operate if guard is missing or
shields not in place.
•Failure to comply will result in death or
serious injury.
2. MD #113482
a. General hazard pertaining to machine
operation and servicing.
b. CAUTION
To avoid injury or death from improper or unsafe
machine operation:
•Read the operator’s manual, and follow
all safety instructions. If you do not have
a manual, obtain one from your dealer.
•Do not allow untrained persons to
operate the machine.
•Review safety instructions with all
operators annually.
•Ensure that all safety signs are installed
and legible.
•Make certain everyone is clear of
machine before starting engine, and
during operation.
•Keep riders off the machine.
•Keep all shields in place, and stay clear
of moving parts.
•Disengage header drive, put
transmission in neutral, and wait for all
movement to stop before leaving
operator’s position.
•Shut off engine and remove key from
ignition before servicing, adjusting,
lubricating, cleaning, or
unplugging machine.
•Engage locks to prevent lowering of
header, or reel before servicing in the
raised position.
•Use slow moving vehicle emblem, and
flashing warning lights when operating
on roadways unless prohibited by law.
(continued next page)

SECTION 2 SAFETY
169000 16 Revision F
3. MD #166452
a. Pinch point hazard
b. WARNING
•To avoid injury, stop engine before
opening engine hood.
4. MD #171279
a. Crushing hazard
b. DANGER
•Read the operator’s manual, and follow
all safety instructions. If you do not have
a manual, obtain one from your dealer.
•Rest header on ground or engage
hydraulic lock-out valves before going
under unit.
5. MD #171281
a. Hot fluid under pressure
b. CAUTION
•Coolant is under pressure, and may be
hot. Never remove radiator cap when
engine is hot.
6. MD #171286
a. Lock PT hydraulic for transport.
b. WARNING
•Charge cylinder with oil before towing.
•Rotate valve handle to lock in
transport position.
•Maximum towing speed 20 mph
(32 kph).
•Failure to comply could result in death
or serious injury.
(continued next page)

SECTION 2 SAFETY
169000 17 Revision F
7. MD #171287
a. Install lock panel
b. WARNING
•Rotate valve handle to lock before going
under unit.
•Failure to comply could result in death
or serious injury.
8. MD #171288
a. Entanglement hazard
b. CAUTION
•To avoid injury from entanglement with
rotating auger, stand clear of header
while machine is running.
9. MD #174436
a. High pressure oil hazard
b. WARNING
•High pressure oil easily punctures skin
causing serious injury, gangrene,
or death.
•If injured, seek emergency medical help.
Immediate surgery is required to
remove oil.
•Do not use finger, or skin to check
for leaks.
•Lower load, or relieve hydraulic
pressure before loosening fittings.
10. MD #174632
a. Sharp component hazard
b. CAUTION
•Wear heavy canvas or leather gloves
when working with knife.
•Be sure no one is near the vertical knife
when removing or rotating knife.
(continued next page)

SECTION 2 SAFETY
169000 18 Revision F
11. MD #184372
a. General hazard pertaining to machine
operation and servicing.
b. CAUTION
To avoid injury or death from improper or unsafe
machine operation:
•Read the operator’s manual, and follow
all safety instructions. If you do not have
a manual, obtain one from your dealer.
•Do not allow untrained persons to
operate the machine.
•Review safety instructions with all
operators annually.
•Ensure that all safety signs are installed
and legible.
•Make certain everyone is clear of
machine before starting engine, and
during operation.
•Keep riders off the machine.
•Keep all shields in place, and stay clear
of moving parts.
•Disengage header drive, put
transmission in neutral, and wait for all
movement to stop before leaving
operator’s position.
•Shut off engine and remove key from
ignition before servicing, adjusting,
lubricating, cleaning, or
unplugging machine.
•Engage locks to prevent lowering of
header or reel before servicing in the
raised position.
•Use slow moving vehicle emblem, and
flashing warning lights when operating
on roadways unless prohibited by law.
12. MD #184422
a. Keep shields in place hazard
b. WARNING
•To avoid injury, stop engine before
opening power drive system shield.
•Keep all shields in place.
13. MD #194464
a. Shut down for service
b. WARNING
•Remove key from ignition.
•Read tractor and mower manufacturer’s
manuals for inspection, and
maintenance instructions.
(continued next page)