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MacDon M 2009 Series, Assembly Instructions Manual

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TABLE OF CONTENTS 

Form 169542

 

4

 

Revision F

 

 

 

INTRODUCTION ........................................................................................................................................................ 3

 

GENERAL SAFETY .................................................................................................................................................. 6

 

RECOMMENDED TORQUES ................................................................................................................................... 8

 

A.

 

GENERAL ........................................................................................................................................... 8

 

B.

 

SAE BOLTS......................................................................................................................................... 8

 

C.

 

METRIC BOLTS .................................................................................................................................. 8

 

D.

 

FLARE TYPE HYDRAULIC FITTINGS ............................................................................................... 9

 

E.

 

O-RING BOSS (ORB) HYDRAULIC FITTINGS .................................................................................. 9

 

F.

 

O-RING FACE SEAL (ORFS) HYDRAULIC FITTINGS .................................................................... 10

 

CONVERSION CHART ........................................................................................................................................... 11

 

DEFINITIONS ........................................................................................................................................................... 11

 

STEP 1.

 

UNLOAD CONTAINER ......................................................................................................................... 12

 

STEP 2.

 

MOVE TO ASSEMBLY AREA .............................................................................................................. 13

 

STEP 2.

 

MOVE TO ASSEMBLY AREA .............................................................................................................. 13

 

A.

 

CRANE METHOD ............................................................................................................................. 13

 

B.

 

FORKLIFT METHOD ........................................................................................................................ 14

 

STEP 3.

 

REMOVE WHEEL AND STEP ASSEMBLY ......................................................................................... 15

 

STEP 4.

 

REMOVE DRIVE WHEELS ................................................................................................................... 17

 

STEP 5.

 

REMOVE PLATFORMS ........................................................................................................................ 18

 

STEP 6.

 

REMOVE HAND RAILS AND EXHAUST STACK ................................................................................ 19

 

STEP 7.

 

REMOVE LEG ASSEMBLIES ............................................................................................................... 20

 

STEP 8.

 

REMOVE WHEEL AND PLATFORM SUPPORT ................................................................................. 21

 

STEP 9.

 

ASSEMBLE WINDROWER SUPPORT STAND ................................................................................... 21

 

STEP 10.

 

LIFT WINDROWER ONTO STAND ...................................................................................................... 22

 

A.

 

CRANE METHOD ............................................................................................................................. 22

 

B.

 

FORKLIFT METHOD ........................................................................................................................ 23

 

STEP 11.

 

INSTALL LEGS ..................................................................................................................................... 24

 

STEP 12.

 

INSTALL FRONT WHEELS .................................................................................................................. 26

 

STEP 13.

 

INSTALL CASTER WHEELS ................................................................................................................ 28

 

STEP 14.

 

INSTALL HYDRAULICS ....................................................................................................................... 30

 

A.

 

M205 .................................................................................................................................................. 30

 

B.

 

M155 .................................................................................................................................................. 33

 

C.

 

M105 .................................................................................................................................................. 37

 

STEP 15.

 

INSTALL PLATFORMS ......................................................................................................................... 40

 

STEP 16.

 

INSTALL STEPS ................................................................................................................................... 42

 

STEP 17.

 

INSTALL EXHAUST STACK ................................................................................................................ 43

 

A.

 

M205 .................................................................................................................................................. 43

 

B.

 

M155, M105....................................................................................................................................... 44

 

STEP 18.

 

POSITION LIGHT AND MIRROR ASSEMBLIES ................................................................................. 45

 

STEP 19.

 

INSTALL BATTERIES ........................................................................................................................... 46

 

A.

 

M205, M155....................................................................................................................................... 46

 

B.

 

M105 .................................................................................................................................................. 47

 

STEP 20.

 

PRIME HYDRAULIC SYSTEM .............................................................................................................. 48

 

A.

 

M205 .................................................................................................................................................. 48

 

B.

 

M155 .................................................................................................................................................. 49

 

C.

 

M105 .................................................................................................................................................. 51

 

Summary of Contents for M 2009 Series

Page 1: ...Form 169242 Revision F Published July 2012 M Series Self Propelled Windrower UNLOADING AND ASSEMBLY INSTRUCTIONS for CONTAINER SHIPMENTS ...

Page 2: ...Form 169242 2 Revision E MACDON M SERIES SELF PROPELLED WINDROWER ...

Page 3: ...livery requirements for the MacDo n M Series Self Propelled Windrowers that have been shipped in containers Use the Table of Contents to guide you to specific areas Retain this instruction for future reference CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD ASSEMBLE OR USE THE MACHINE ...

Page 4: ... STEP 5 REMOVE PLATFORMS 18 STEP 6 REMOVE HAND RAILS AND EXHAUST STACK 19 STEP 7 REMOVE LEG ASSEMBLIES 20 STEP 8 REMOVE WHEEL AND PLATFORM SUPPORT 21 STEP 9 ASSEMBLE WINDROWER SUPPORT STAND 21 STEP 10 LIFT WINDROWER ONTO STAND 22 A CRANE METHOD 22 B FORKLIFT METHOD 23 STEP 11 INSTALL LEGS 24 STEP 12 INSTALL FRONT WHEELS 26 STEP 13 INSTALL CASTER WHEELS 28 STEP 14 INSTALL HYDRAULICS 30 A M205 30 B ...

Page 5: ...ULE CDM 88 A M205 M155 DETAILED PROGRAMMING INSTRUCTIONS 89 B M105 DETAILED PROGRAMMING INSTRUCTIONS 95 STEP 30 PERFORM HYDRAULIC PURGE 100 STEP 31 PERFORM PRE DELIVERY CHECKS 102 A FINAL DRIVE LUBRICANT LEVEL 102 B TIRE PRESSURES AND BALLAST REQUIREMENTS 102 I Tire Pressures 102 II Ballast Requirements 102 C ENGINE AIR INTAKE 104 D HYDRAULIC OIL LEVEL 105 E FUEL SEPARATOR 105 F ENGINE COOLANT 105...

Page 6: ...first aid kit for use in case of emergencies Keep a fire extinguisher on the machine Be sure the extinguisher is properly maintained and be familiar with its proper use Keep young children away from machinery at all times Be aware that accidents often happen when the Operator is tired or in a hurry to get finished Take the time to consider the safest way Never ignore warning signs of fatigue Wear ...

Page 7: ...oily floors are slippery Wet spots can be dangerous when working with electrical equipment Be sure all electrical outlets and tools are properly grounded Use adequate light for the job at hand Keep machinery clean Do not allow oil or grease to accumulate on service platforms ladders or controls Clean machines before storage Never use gasoline naphtha or any volatile material for cleaning purposes ...

Page 8: ...rque values by 5 B SAE BOLTS BOLT DIA A in NC BOLT TORQUE SAE 5 SAE 8 ft lbf N m ft lbf N m 1 4 9 12 11 15 5 16 18 24 25 34 3 8 32 43 41 56 7 16 50 68 70 95 1 2 75 102 105 142 9 16 110 149 149 202 5 8 150 203 200 271 3 4 265 359 365 495 7 8 420 569 600 813 1 640 867 890 1205 Torque categories for bolts and capscrews are identified by their head markings C METRIC BOLTS BOLT DIA A STD COARSE BOLT TO...

Page 9: ... ORB HYDRAULIC FITTINGS a Inspect O ring and seat for dirt or obvious defects b On angle fittings back off the lock nut until washer A bottoms out at top of groove B in fitting c Hand tighten fitting until back up washer A or washer face if straight fitting bottoms on part face C and O ring is seated d Position angle fittings by unscrewing no more than one turn e Tighten straight fittings to torqu...

Page 10: ...e or hose nut until hand tig ht The nut should turn freely until itis bottomed out Torque fitting further to the specified number of F F F T Flats From Finger Tight or to a given torque value in the table shown in the opposite column NOTE If available always hold the hex on the fitting body to prevent unwanted rotation of fitting body and hose when tightening the fitting nut e When assembling unio...

Page 11: ... second ft s x 0 3048 meters per second m s miles per hour mph x 1 6063 kilometers per hour km h Volume US gallons US gal x 3 7854 liters L ounces oz x 29 5735 milliliters ml cubic inches in 3 x 16 3871 cubic centimeters cm 3 or cc Weight pounds lb x 0 4536 kilograms kg DEFINITIONS TERM DEFINITION API American Petroleum Institute ASTM American Society of Testing And Materials Cab Forward Windrower...

Page 12: ... area a Move trailer into positio n and blo ck trailer wheels b Lower trailer storage stands c Open container doors and remove all blocking d Check container floor for nails or other obstructions and remove if necessary e Position platform or ramp at container opening f Attach chain pull strap to slots in support channels as shown g Slowly pull windrower from co ntainer onto platform ...

Page 13: ...0 lb 9072 kg CHAIN Type Overhead 1 2 in Lifting Quality Minimum Working Load 7 100 lb 3221 kg a Attach chains or cable to the four lift points on the lifting frame MacDon Part 1638 71 and connect loop ends to crane hook Use cable or chain with a minimum lifting capacity of 7 100 lb 3221 kg b Attach lifting frame asse mbly MacDon Part 163871 to the four designated lift po ints on windrower shipping...

Page 14: ...ity 20 000 lb 9072 kg At 48 inches 1220 mm from back end of forks IMPORTANT Forklifts are normally rated for a lo ad located 24 inches 610 mm ahead of back end of the forks To obtain the forklift capa city at 48 inches 1220 mm check with your forklift distributor WARNING Be sure forks are secure before moving away from load Stand clear when lifting a Approach windrower from the h ood end and slide...

Page 15: ... support b Lay hose support off to the side c Remove the two 3 4 in x16 5 long bolts one per side at front fram e beam Retain for re installation d Remove the 1 inch 2 5 4 mm pin at the center link e Remove the four two per side carriage bolts at the rear of the wheel step assembly f Remove plastic cable tie and shipping wire securing hose bundles to frame continued next page ...

Page 16: ...F g Attach a chain to wheel step assembly and pull away from shipping assembly with lifting device h Lift center link so that it clea rs wheel step assembly frame i Re install leg bolts washers and nuts to secure the lifting plate onto the mainframe ...

Page 17: ...b Remove one bolt at rear of hood directly under center of drive wheel c Attach a lifting device to lift hooks located in the center of each drive wheel d Carefully lift wheels off frame IMPORTANT Ensure that tire is g uided away fro m cab roof when lifting wheels to prevent damage to the cab Chain on forward wheel should be snug and loose on the aft wheel e Set wheels aside for later installation...

Page 18: ...ight of 13 feet 4 m c Remove two 5 8 in x 5 0 bolts at top of vertical supports and two 5 8 in x 1 25 bolts at taching angle braces to platforms NOTE The M105 windrower is equipped with only one platform d Carefully lift platform off frame e Back away from windrower and set assembly on a level surface f Unhook one sling and chain g Lift end of assembly so that it can be inverted and laid down agai...

Page 19: ...ng wire and foam from exhaust stack c Remove nuts from clamp and remove exhaust stack and clamp from shipping frame d Re install nuts onto clamp and set stack aside for later installation e Remove the two bolt s securing hand rail to shipping frame and remove hand rail f Repeat for o ther hand rail on oppo site side Retain hardware g Set parts aside for later installation ...

Page 20: ...n to lifting bar on leg assembly and hook up to lifting device with a minimum lifting capacity of 5 000 lb 2 268 kg c Remove two bolts at lower support channel d Remove two bolts near top of leg and remove bars from leg NOTE Insert cardboard or foam between leg assembly and hood to prevent damage to hood e Lift off leg assembly an d set securely on level ground f Repeat above steps for second leg ...

Page 21: ...ng a 20 000 lb 9 072 kg load Assemble factory stand as follows a Remove all shipping materials from stand b Arrange forward and rear stands on level ground so that attachment lugs on each stand face each other c Attach four suppo rt tubes to stands a s shown with hardware provided and tighten d Set up air control valve tripod Remove plug on valve and install a 100 psi 689 kPa air line e The stand ...

Page 22: ...m Lifting Capacity 20 000 lb 9072 kg CHAIN Type Overhead 1 2 in Lifting Quality Minimum Working Load 7 100 lb 3221 kg a Attach four chains or cables to the four lift points on the lifting frame Ma cDon Part 163871 and connect loop ends to crane hook Use cable or chain with a minimum lifting capacity of 7 100 lb 3221 kg b Attach the lifting frame to the four designated lift points on windrower ship...

Page 23: ...FT METHOD LIFTING VEHICLE Minimum Lifting Capacity 20 000 lb 9072 kg At 48 inches 1220 mm from back end of forks a Approach windrower from aft end and slide forks fully into shipping support channels b Raise windrower and place onto stand c Back away forklift ...

Page 24: ...o lifting device with lifting bar c Position leg at frame d Feed hydraulic hose bundle into frame and through hole at center of frame e Insert leg into frame and line up holes in frame and leg at the first position widest tread with one exposed hole f Insert pins and secure with 3 4 in x 16 5 long bolts washers and nuts Torque to 100 ft lbf 136 N m g Repeat above steps for other leg continued next...

Page 25: ...UNLOADING AND ASSEMBLY Form 169542 25 Revision F h Slightly lift the header lift arms with lifting device and remove lifting bars from leg s Re locate spring locking pins to front of lift arms ...

Page 26: ...proximately 7 inches 178 mm above the stand 3 Verify that all three locks are engaged before to proceeding to next step NOTE Lock is engaged when witness hole above pin is exposed 4 Release pressure so that locks suppor t weight of windrower b Remove shipping supports on drive wheel hubs and remove wheel lug nuts c Position wheel against hub so that that air valves are on the outside and tire trea...

Page 27: ...542 27 Revision F f Install wheel nuts a nd tighten to 220 ft lbf 300 N m using the tigh tening sequence as shown above NOTE To avoid damage to wheel disks do not over tighten wheel nuts g Repeat sequence three times 1 5 3 7 8 2 4 6 ...

Page 28: ...move ship ping frame NOTE Shipping frame does not need to be removed if air bag lifting stand is used Ensure bolts are removed prior to moving windrower off stand c Repeat above for oppo site shipping frame channel d Remove tie bar between the two caster wheels e Remove the two braces from caster wheels and frame Retain bolts for attaching caster to walki ng beam f Attach a chain to RH caster and ...

Page 29: ... walking beam i Insert RH caster extension into walking beam and position for desired tread j Install six 3 4 in bolts and hardened washers into walking beam and caster beam Use longer bolts through anti shimmy bracket k Tighten bolts as follows 1 Snug up the two bolts underneath beam 2 Tighten the four back bolts to 330 ft lbf 447 N m 3 Tighten bolts underneath beam to 330 ft lbf 447 N m l Repeat...

Page 30: ...s and matching coloured ties A union is connected to one of the hoses f Remove caps and connect these two ho ses together Position hoses in frame g Retrieve the four remaini ng capped off hoses coming out of frame h Loosen bolts A and move valve block to improv e access through hole in frame for wrenches when tightening fittings i Remove caps on hoses and matching valve block fittings j Make conne...

Page 31: ...ses with short elbows to re spective side of pump ei ther yellow or no tie Tighten fittings 2 Remove caps and atta ch hoses with long elbows to respective side of pump either red or no tie Tighten fittings p Retrieve the two motor case drain hoses 111312 at front frame and the 7 8 in tee fitting on the hose from the pump q Remove caps from the hoses only continued next page VIEW LOOKING FORWARD CA...

Page 32: ... Revision F r Remove one cap on tee fitting and quickly attach hose to minimize oil spillage s Remove second cap from tee andquickly connect other hose t Tighten fittings u Push hoses into frame v Secure hoses with plastic ties as required ...

Page 33: ...s under clip as shown and tighten bolts b Connect hoses as follows using colored plastic cable ties as a guide 1 Locate two hoses 111327 green tie s in frame opening and existing tee fitting green tie 2 Remove caps on green lines and tee and make connections Tighten fittings NOTE Remove caps on tee last to minimize oil loss 3 Position hoses into frame 4 Locate two hoses white ties in side frame an...

Page 34: ...e block fitting white tie and make connection Ti ghten fitting 13 Remove the caps from three fittings blue orange and yellow ties on the valve b lock from inboard side of frame 14 Loosen bolts and mov e valve block to improve access through hole in fram e for wrenches when tightening fittings 15 Retrieve matching hoses and make connections on valve block Tighten fittings 16 Re position valve block...

Page 35: ... hoses with short elbows to re spective side of pump ei ther yellow or no tie Tighten fittings 2 Remove caps and atta ch hoses with long elbows to respective side of pump either red or no tie Tighten fittings f Retrieve the two motor case drain hoses 111312 at front frame and the 7 8 in tee fitting on the hose from the pump continued next page LONG NO TIE LONG RED SHORT NO TIE SHORT YELLOW VIEW LO...

Page 36: ...ickly connect other hose j Tighten fittings k Locate hose bundle from valve blocks on LH side of frame Route h ose ends with electrical harness through hose support l Disengage hook and rotate to up position Position hose bundle over hose support and locate under hook Rotate hook and re engage in bracket m Attach reel hose support tube to the RH reel leg with two 3 8 in x 1 0 carriage bolts and nu...

Page 37: ...loss 3 Position hoses into frame 4 Locate two hoses white ties in side frame and hose 111324 with tee white tie 5 Remove caps make connections and tighten fittings 6 Push hoses into frame 7 Locate two hoses red ties inside frame 8 Route RH hose behind bundle 9 Remove caps make connection and tighten fitting 10 Push hose into frame 11 Retrieve long hose 11 9328 white tie and route through hole in L...

Page 38: ...nnect drive hoses to pump as follows 1 Remove caps and attach hoses green and yellow ties to matching fittings on top of pump Tighten fittings 2 Remove caps and attach hoses red and white ties to matching fittings on b ottom of pump Tighten fittings c Retrieve the two motor case drain hos es 111312 at front frame and the 7 8 in tee fitting on the hose from the pump d Remove caps from the hoses onl...

Page 39: ...150 mm intervals from frame opening j Attach hose supports to windrower frame a s follows 1 Locate hose bundle from valve blocks on LH side of frame Route hose ends with electrical harness through hose support 2 Disengage hook and rotate to up po sition Position hose bundle over hose support and locate under hook Rotate hook and re engage in bracket 3 Attach reel hose support tube to the RH leg wi...

Page 40: ...ails Retain hardware b Remove shipping brackets from platform assembly Retain hardware c Attach a sling to platform and other end to lifting device CAUTION Stand clear when lifting as platform may swing d Position platform against windrower frame e Attach main beam of platform to side frame with three 1 2 in x 1 25 lo ng carriage bolts Bolt heads face inboard Tig hten just enough for adjustment f ...

Page 41: ...with cab posts when viewing from the rear Laterally adjust king pin mounting as required i Check that rubber bumper is contacting the frame and that front of platform is contacting the guide j Adjust platform horizontally with the1 2 in x 2 25 bolt as required k If major adjustment is required re locate steering arm into either of the other holes on the bracket l Tighten the three main beam attach...

Page 42: ... The M105 has a LH platform only RH installation is shown LH instal lation is opposite a Remove the two existing upper bolts b Check that two lo wer bolts are not threaded in fully c Hang step assembly on bolts If required back off bolts d Install two b olts in upp er holes in step and tighten e Tighten lower bolts f Repeat for other step assembly except M105 ...

Page 43: ...d connect stack B and clamp A to muffler D NOTE If shroud E interferes with the stack loosen the wing nut F on the shroud and move the shroud so that stack can be installed e Tighten both clamps A and C but just enough so stack can be moved f Slowly close hood so that stack B e nters hole G in hood Adjust the position of the stack as required to clear the hole in the hood g Raise the hood h Tighte...

Page 44: ...and clamp A to muffler D NOTE If shroud E interferes with the stack loosen the wing nut F on the shroud and move the shroud so that stack can be installed e Tighten both clamps A and C but o nly just enough so stack can be moved f Slowly close hood so that stack B enters hole G in hood Adjust the position of the stack as required to clear the hole in the hood g Raise the hood h Tighten clamps A an...

Page 45: ...evision F STEP 18 POSITION LIGHT AND MIRROR ASSEMBLIES a Remove nut and bolt A from shipping position b Swing mirror light assembly B fo rward up to stop c Re install bolt A and nut in other hole d Repeat for opposite mirror assembly A B A B ...

Page 46: ...ble ties securing battery clamps and cables to frame d Position new batteries on holder A e Install clamp B with bolts C provided and tighten securely IMPORTANT BATTERY IS NEGATIVE GROUNDED Always connect starter cable to th e positive terminal of battery an d battery ground cable to negative terminal of battery Reversed polarity in battery or alternator may r esult in permanent damage to electri ...

Page 47: ...attery clamps and cables to frame d Position new batteries on holder A e Install strap B with bolts C IMPORTANT BATTERY IS NEGATIVE GROUNDED Always connect starter cable to th e positive terminal of battery and battery ground cable to negative terminal of battery Reversed polarity in battery or alternator may r esult in permanent damage to electri cal system f Attach negative black cable cl amps D...

Page 48: ...ove allen screw A with a 4 mm allen wrench and remove ECM conn ector B from engine This prevents engine from starting during cranking CAUTION Check to be sure all bystanders have cleared the area d Crank engine with starter for 15 seconds to prime the system e Re install ECM connector B with screw A f Re connect brake engage solenoid plug g Check hydraulic oil level in reservoir Add SAE15W 40 oil ...

Page 49: ...sen plug to bl eed pump h ousing Re tighten plug once oil starts to run out d Locate plug on TOP of HEADER d rive pump housing from above and l oosen plug to bleed pump housing Re tighten plug once oil starts to run out e Locate plug on TOP of TRACTION drive pump housing from above and l oosen plug to bleed pump housing Re tighten plug once oil starts to run out f Replace hydraulic oil reservoir f...

Page 50: ...ntenance platform on RH side M205 M155 k Open circuit breaker fuse box and remove ECM ignition fuse 5A CAUTION Check to be sure all bystanders have cleared the area l To prime the system crank engine with starter f or 15 seconds m Re connect electrical connection at fuel pump and at brake engage solenoid n Re install ECM ignition fuse and close fuse box o Close engine compartment hood p Check hydr...

Page 51: ... oosen plug to bleed pump housing Re tighten plug once oil starts to run out d Locate plug on TOP of TRACTION drive pump housing from above and l oosen plug to bleed pump housing Re tighten plug once oil starts to run out e Replace hydraulic oil reservoir filler cap f Open maintenance platform on LH side g Disconnect brake engage solenoid connector P V3 at valve block on LH side of windrower conti...

Page 52: ...nition fuse 5A CAUTION Check to be sure all bystanders have cleared the area j To prime the system crank engine with starter f or 15 seconds k Re connect electrical connection at fuel pump and at brake engage solenoid l Re install ECM ignition fuse and close fuse box m Close engine compartment hood n Check hydraulic oil level in re servoir If necessary add SAE15W 40 oil ...

Page 53: ...r than 15 seconds at a time If engine does not start wait at least two minutes before trying again After the third 15 second crank attempt allow starter motor to cool for 10 minutes before further cranking attempts If engine still does not start refer to the following table PROBLEM SOLUTION Controls Not In NEUTRAL Move GSL to NEUTRAL Move steering wheel to locked position Disengage header clutch O...

Page 54: ...ngine above 1500 rpm until engine temperature gauge is above 100 F 40 C STEP 22 CHECK TRACTION DRIVE CAUTION Check to be sure all bystanders have cleared the area a With engine running move GSL out of N DETENT and slowly move GSL forward b Drive wheels should be rotating in the forward direction and at the same speed c Turn steering wheel and observe motion of drive wheels They should rotate at di...

Page 55: ... by slowly re leasing pressure to air bag system CAUTION Ensure all three lifts have fully retracted and are clear of windrower frame before driving windrower ahead d Start engine and drive machine straight ahead leaving shipping support channels supported on rear support stand B FIELD CONSTRUCTED STAND a Position a jack under the jack point of each drive wheel leg and another under the rear hitch...

Page 56: ...e radio panel by removingfour screws A c Remove screw and nuts B and C to remove support D from panel Retain metric nut C and lockwasher d Remove the cut out by cutting the tabs E in the panel Remove sharp edges on panel e Locate receptacle F supplied with radio in opening and secure by bendi ng tabs G on receptacle against panel f Insert radio into receptacle and attach radio bezel En sure radio ...

Page 57: ...Engineering Industries REI of Omaha Nebraska j Attach stud supplied with radio to center rear of radio k Attach support D to stud on b ack of radio chassis with lock washer and metric nut C that was supplied with the support Support can be attached to chassis in multiple locations to allow for proper mounting of radio l Re install radio panel with original screws m Adjust bracket J if necessary by...

Page 58: ...base on beacon bracket making sure mounting holes in rubber base line up with holes in bracket d Connect orange wire from harness to the re d wire in beacon Black harness wire connects to ground terminal in beacon e Fit beacon onto base making sure beacon is oriented as shown with the point on lens facing forward Cab Forward f Mount beacon to base with lockwashers and nu ts supplied with beacon g ...

Page 59: ... INSTALL SLOW MOVING VEHICLE SMV SIGN a Install SMV sign shipped in cab on Windrower in accordance with instructions supplied with the sign b The SMV signs must be visible when travelling on the road ENGINE FORWARD CAB FORWARD ALTERNATE LOCATION CAB FORWARD ...

Page 60: ...s Kit Description Kit Number Base Kit B5491 Completion B5496 Coupler B5497 IMPORTANT To prevent damage to the lift system when lowering header lift linka ges without a header or weight box attached to windrower ensure that float enga gement pin is installed in storage location A and not installed at hole location B a If not install ed attach draper header boots supplied with header to windrower li...

Page 61: ...header lift cylinders d Slowly drive windrower forward so that boots D enter header legs G Continue to drive slowly forward until lift linkages contact support plates in the header legs and header nudges forward e Check that l inkages are properly engaged in header legs contacting support plates f Adjust the position of the center link cylinder with the REEL UP and REEL DOWN switches and HEADER TI...

Page 62: ...o storage position by pulling pin J and lifting stand into uppermost position Release pin J CAUTION Check to be sure all bystanders have cleared the area l Remove pin from storage position K in linkage and insert in hole L to engage float springs Secure with hairpin m Disengage lift cylinder stops n Start engine and push HE ADER DOWN switch on GSL to lower header fully o Stop engine and remove key...

Page 63: ...ns supplied with the kits Kit Description Kit Number Base Kit B5491 Completion B5492 Coupler B5497 a Remove hairpin from pin A and remove pin from left and right header boots B on header IMPORTANT To prevent damage to the lift system when lowering header lift linka ges without a header or weight box attached to windrower ensure that float enga gement pin is installed in storage location C and not ...

Page 64: ...the REEL UP and REEL DOWN switches and HEADER TILT switches on the GSL to position the hook above the header attachment pin e Lower the center link onto the header with REEL DOWN switch until it locks into position handle is down f Raise the h eader fully with the HE ADER UP switch on the GSL Stop engine and remove key DANGER To avoid bodily injury from fall of raised header always engage header l...

Page 65: ...sition by inverting stand and re locating on bracket as shown Re insert pin F and secure with lynch pin l Remove pin H from storage position in linkage and insert in hole J to engage float springs Secure with lynch pin m Disengage lift cylinder stops n Start engine and activate HEADER DOWN switch on GSL to lower header fully Stop engine and remove key o Connect header drive hydraulics K and electr...

Page 66: ...nstalled and the installation of a separate motor and hose bundle is necessary a If required o btain kit n umber B5456 from your MacDon Dealer and install it in accordance with the instructions supplied with the kit b Remove hairpin from pin A and remove pin from on left and right header boots B on header IMPORTANT To prevent damage to the lift system when lowering header lift linka ges without a ...

Page 67: ...EL UP and REEL DOWN switches and HEADER TILT switches on the GSL to position the hook above the header attachment pin f Lower the center link onto the header with REEL DOWN switch until it locks into position handle is down g Raise the h eader fully with the HE ADER UP switch on the GSL Stop engine and remove key DANGER To avoid bodily injury from fall of raised header always engage header lift cy...

Page 68: ...et j Remove pin F from storage position in linkage and insert in hole G to engage float sprin gs Secure with hairpin k Disengage lift cylinder stops l Start engine and activate HEADER DO WN switch on GSL to lower header fully Stop engine and remove key m Connect header drive hydraulics and electrical harness to h eader Refe r to your Rotary Disc Header Unloading and Assembly Instructions A G F ...

Page 69: ... reel fore aft hydraulics Windrowers equipped with D Series hydraulics have four header drive hoses on the LH side and up to five reel drive hoses on the RH side If necessary obtain the following kits from your MacDon Dealer and install them in accordance with instructions supplied with the kits KIT DESCRIPTION KIT NUMBER M155 M105 Base Kit B5577 B5577 Completion Reverser B4656 DRAPER HEADER REEL ...

Page 70: ...hat float engagement pin is installed in storage location A and not installed at hole location B If not installed attach draper header boots supplied with header to windrower lift linkage as follows a Remove pin C from boot D b Locate boot D on lift linkage E and re install pin C Pin may be installed from either side of boot c Secure pin C with hairpin d Repeat for opposite side B A D E C C D ...

Page 71: ...tachment pin on the header by o ne of the following methods 1 If the optional center link self alignment kit is installed activate the REEL UP switch on the GSL to raise the center link G 2 Without the self alignment kit re locate the pin J at the frame linkage as required to raise the center link G h Slowly drive windrower forward so that boots D enter header legs K Continue to drive slowly forwa...

Page 72: ...ed onto header by pressing the REEL UP switch on the GSL 4 Proceed to step g on next page HYDRAULIC LINK WITHOUT SELF ALIGNMENT KIT M155 M105 OPTIONAL 1 Activate HEADER TILT cylinder switches on GSL to extend or retract center link cylinder G so that the hook lines up with the header attachment pin 2 Stop engine and remove key from ignition 3 Push down on rod end of link cylinder G until hook enga...

Page 73: ...er to maximum height NOTE If one end of the header does not raise fully the lift cylinders require re phasing If re phasing is needed proceed as follows 1 Press and hold the HEADER UP switch until both cylinders stop moving 2 Continue to hold the switch for 3 4 seconds 3 Cylinders are phased DANGER To avoid bodily injury from fall of raised header always engage header lift cylinder stops when work...

Page 74: ...opposite lift cylinder stop CAUTION Check to be sure all bystanders have cleared the area r Start engine and activat e HEADER DOWN switch on GSL to lower header fully Stop engine and remove key WARNING Stop windrower engine and remove key before making adjustments to machine A child or even a pet could engage the drive s Connect header drive hoses V and electrical harness W to head er Refer to th ...

Page 75: ...er and install it in accordance with instructions supplied with the kits KIT DESCRIPTION KIT NUMBER Basic Drive B5491 Completion Reverser B5492 a Remove hairpin from pin A and remove pin from left and right header boots B on header IMPORTANT To prevent damage to the lift system when lowering header lift linkages without a h eader or weight box attached to windrower ensure that float engagement pin...

Page 76: ...ove the attachment pin on the header by one of the two following methods shown in next column 1 If the optional center link self alignment kit is installed activate the REEL UP switch on the GSL to raise the center link E 2 Without the self alignment kit re locate the pin G at the frame linkage as required to raise the center link E d Slowly drive windrower forward so that feet H on windrower ente...

Page 77: ...to header by pressing the REEL UP switch on the GSL 4 Proceed to step f on next page HYDRAULIC LINK WITHOUT SELF ALIGNMENT KIT M155 M105 OPTIONAL 1 Activate HEADER TILT cylinder switches on GSL to extend or retract center link cylinder E so that the hook lines up with the header attachment pin 2 Stop engine and remove key from ignition 3 Push down on rod end of link cylinder E until hook engages p...

Page 78: ...needed proceed as follows 1 Press and hold HEADER UP switch until both cylinders stop moving 2 Continue to hold the switch for 3 4 seconds 3 Cylinders are phased 4 WARNING Stop windrower engine and remove key before making adjustments to machine A child or even a pet could engage the drive DANGER To avoid bodily injury from fall of raised header always engage header lift cylinder stops when workin...

Page 79: ... shown l Re insert pin O and secure with lynch pin m Remove pin Q from storage position in linkage and insert in hole R to engage float springs Secure with lynch pin n Disengage lift cylinder stop by turning l ever L downward to raise stop until lever lo cks into vertical position o Repeat for opposite cylinder stop CAUTION Check to be sure all bystanders have cleared the area p Start engine and a...

Page 80: ...op windrower engine and remove key before making adjustments to machine A child or even a pet could engage the drive q Stop engine and remove key r Connect header drive hydraulics S and electrical harness T to header Refer to Auger Header Operator s Manual T S ...

Page 81: ...5 windrower requires the installation of hydraulic valve Kit B4657 See your MacDon Dealer a Remove hairpin from pin A and remove pin from on left and right header boots B on header IMPORTANT To prevent damage to the lift system when lowering header lift linkages without a header or weig ht box attached to windrower ensure that float engagement pin is installed in storage location C and not install...

Page 82: ...ove the attachment pin on the header by o ne of the following 2 methods shown in next column 1 If the optional center link self alignment kit is installed activate the REEL UP switch on the GSL to raise the center link E 2 Without the self alignment kit re locate the pin G at the frame linkage as required to raise the center link E d Slowly drive windrower forward so that feet H on windrower enter...

Page 83: ... locked onto header by pressing the REEL UP switch on the GSL 4 Proceed to step g on next page HYDRAULIC LINK WITHOUT SELF ALIGNMENT KIT M155 OPTIONAL 1 Activate HEADER TILT cylinder switches on GSL to extend or retract center link cylinder E so that the hook lines up with the header attachment pin 2 Stop engine and remove key from ignition 3 Push down on rod end of link cylinder E until hook enga...

Page 84: ...ink to required length for proper header angle by rotating barrel K Tighten nut J ag ainst barrel A slight tap with a hammer is sufficient CAUTION Check to be sure all bystanders have cleared the area g Start engine if not running and press HEADER UP switch to raise header to maximum height NOTE If one end of the header does not raise fully the lift cylinders require re phasing If re phasing is ne...

Page 85: ...r even a pet could engage the drive 1 Stop engine and remove key from ignition 2 Pull lever M and rotate toward header to release and lower cylinder stop N onto cylinder 3 Repeat for opposite lift cylinder i Install pin O through each boot and foot and secure with hairpin IMPORTANT Ensure pin O is fully inserted and hairpin is installed behind bracket j Remove pin P from storage position in linkag...

Page 86: ...TION USE SAE Multi Purpose High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base As Required Unless Otherwise Specified a Wipe grease fitting with a clean cloth before greasing to avoid injecting dirt and grit b Inject grease through fitting with grease gun until grease overflows fitting except where noted c Leave excess grease on fitting to k...

Page 87: ...INK TWO FITTINGS BOTH SIDES WALKING BEAM PIVOT CASTER PIVOT BOTH SIDES FORKED CASTER SPINDLE BEARINGS TWO PLACES BOTH WHEELS FORMED CASTER WHEEL BEARING 1 PLACE BOTH WHEELS High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base ...

Page 88: ...e prog ramming mode accordingly a Turn ignition key to RUN or start the engine Refer to STEP 21 START ENGINE b Press PROGRAM and SELECT switches together on CDM to enter programming mode Header ID code is displayed c Press SELECT TRA CTOR SETUP is displayed d Press SET KNIFE SPEED is displayed e Press SELECT until DWA INSTALLED is displayed f Press or g Press SELECT to advance to the next L1 item ...

Page 89: ...PROGRAMMING INSTRUCTIONS Ignition ON Engine Running or Not Header Disengaged Press PROGRAM and SELECT on CDM to enter programming mode If necessary refer to the M Series Windrower Operator s Manual for programming to specific crop types and conditions continued next page ...

Page 90: ...UNLOADING AND ASSEMBLY Form 169242 Revision F 90 continued next page ...

Page 91: ...UNLOADING AND ASSEMBLY Form 169242 Revision F 91 IMPORTANT ENGINE MUST BE RUNNING TO CALIBRATE SENSORS continued next page ...

Page 92: ...UNLOADING AND ASSEMBLY Form 169242 Revision F 92 continued next page ...

Page 93: ...UNLOADING AND ASSEMBLY Form 169242 Revision F 93 continued next page ...

Page 94: ...UNLOADING AND ASSEMBLY Form 169242 Revision F 94 ...

Page 95: ... L1 C x x x S E T T I R E S I Z E L2 M x x x 1 8 4 X 2 6 T U R F L2 M x x x 1 8 4 X 2 6 B A R L2 M x x x 2 3 1 X 2 6 T U R F L2 M x x x 6 0 0 6 5 R 2 8 L1 C x x x S E T E N G I N E I S C R P M L2 M x x x O F F O N S E T C O N T R O L L O C K S L1 C x x x S E T C O N T R O L L O C K S L2 M x x x N O Y E S V I E W C O N T R O L L O C K S Programming Menu Flow Chart If NO then jump to Use the arrow k...

Page 96: ...C x x x C A B D I S P L A Y S E T U P L2 M x x x N O Y E S C A L I B R A T E S E N S O R S L1 C x x x D I S P L A Y L A N G U A G E L2 M x x x E N G L I S H L2 M x x x E S P A N O L L2 M x x x R U S S I A N L1 C x x x D I S P L A Y U N I T S L2 M x x x I M P E R I A L L2 M x x x M E T R I C The arrow keys are used to select between IMPERIAL or METRIC The default value will be displayed first This ...

Page 97: ... M x x x E X T E N D T L T T O S T A R T L1 C x x x C A L I B R A T I N G T I L T L2 M x x x E X T E N D T I L T H O L D L2 M x x x E X T E N D T I L T D O N E L1 M x x x H D R T I L T S E N S O R C A L L2 M x x x P R E S S R E T R A C T T I L T L1 C x x x C A L I B R A T I N G T I L T L2 M x x x R E T R A C T T I L T H O L D L2 M x x x H D R T I L T C O M P L E T E L1 C x x x T O C A L I B R A T ...

Page 98: ...U T L2 M x x x H D R H E I G H T 3 5 9 V L1 C x x x S E N S O R I N P U T L2 M x x x H E A D E R A N G L E 1 8 4 V L1 C x x x S E N S O R I N P U T L2 M x x x K N I F E S P E E D 1 2 3 H Z L1 C x x x S E N S O R I N P U T L2 M x x x R E E L S P E E D 1 2 3 H Z L1 C x x x S E N S O R I N P U T L2 M x x x W H E E L S P E E D 1 2 3 H Z L1 C x x x E X I T R E A D S E N S O R S L2 M x x x N O Y E S S E...

Page 99: ... E S T A R T E D L2 M x x x P R E S S A N D H O L D L1 C x x x P U R G E C Y C L E E N D E D L2 M x x x L1 C x x x P U R G E C Y C L E E N D E D L2 M x x x N O E X I T Y E S L1 C x x x E X I T F U N C T I O N M E N U L2 M x x x N O Y E S H E A D E R D O W N U P L1 C x x x E X I T D I A G N O S T I C S L2 M x x x N O Y E S D I A G N O S T I C M O D E If NO then jump to If NO then jump to ACTIVATE H...

Page 100: ...header Program the M205 Windrower CDM for the R Series rotary header IMPORTANT Do not engage the header drive c Simultaneously press th e PROGRAM and SELECT buttons to bring up the TRACTOR SETUP screen d Push the SELECT button several times until the DIAGNOSTIC MODE screen is displayed e Highlight YES with the ARROW buttons and then press the SELECT button f Press SELECT until the ACTIVATE FUNCTIO...

Page 101: ...UNLOADING AND ASSEMBLY Form 169242 Revision F 101 k Message PURGE CYCLE ENDED appears when cycle is complete Release the ARROW button l Press PROGRAM button to return to operating screens ...

Page 102: ...ure tire pressure with a gauge Bar 32 psi 221 kPa Turf 20 psi 138 kPa Caster 10 psi 69 kPa II BALLAST REQUIREMENTS Fluid ballasting of re ar caster tires is recommended to provid e adequate machine stability when usi ng large headers on the windrower Also the stability of machine varies with different attachments windrower options terrain and Operator s driving technique Ballast capability per tir...

Page 103: ... D Series 25 FT and Down 30 FT SR or DR W O Conditioner 35 FT SR 18 69 380 170 30 115 630 288 30 FT DR Steel Fingers and Conditioner 35 FT DR 5 or 6 Bat Level Ground 10 X 16 16 5 X16 1 Hills 16 5 X 16 1 30 115 630 288 41 158 830 377 40 FT 16 5 X 16 1 R Series All Options 13 FT 7 5 X 16 10 X 16 16 5 X16 1 0 M205 A Series All Options All 7 5 X 16 10 X 16 16 5 X16 1 0 D Series 25 FT and Down 30 FT SR...

Page 104: ...s shown d Check constant torque clamps B on charge air cooling duct connection at turbocharger inlet M205 Constant torque type clamps B should be tightened to achieve gap as shown e Check constant torque clamps C on charge air cooling duct connections at turbocharger outlet and engine air intake Cl amps C should be tightened to achieve gap as shown opposite M205 M155 M105 A HOLD 0 018 in 0 46 mm G...

Page 105: ...FUEL SEPARATOR a Place a container under the filter drain b Turn drain v alve by ha nd 1 1 2 to 2 turns counterclockwise until draining occurs c Drain the filter sump of water and sediment until clear fuel is visible Clean as necessary d Turn the valve clockwise to close the drain e Safely dispose of fluid in container F ENGINE COOLANT a Check the coolant level in the coolant recovery tank Tank sh...

Page 106: ...VEL a Remove plug A The lubricant should be visible through the hole or slightly running out b Replace plug and tighten H A C COMPRESSOR BELT a Tension on A C compressor belt should be such that a force of 8 to 12 lbf 35 55 N deflects the belt 3 16 inch 5 mm at mid span A ...

Page 107: ...t down do the following 1 Open engine compartment hood 2 Pry the steering interlock away from pintle arms by inserting a wedge or pry bar between one of the interlock channels and pintle arm 3 Insert a wood block approximately 3 4 inch 19 mm thick between the other channel and pintle arm so that the interlock channel is clear of the pintle arm 4 Turn the steering wheel off center and move the GSL ...

Page 108: ...ud t one sounds and engi ne warning lights illuminate II START ENGINE Refer to ST EP 21 START ENGINE and the n proceed as follows a The brakes should engage and the machine should not move after engine start up b Ensure the steering wheel is cente red Move GSL A straight out of N DETE NT neither forward nor reverse The machine should not move c With the GSL out of N DETENT check that the steering ...

Page 109: ...ELECT switch on CDM to display VOLTS The display indicates the condition of the battery and alternator Refer to following table IGNITION ENGINE READING INDICATED CONDITION ON Running 13 8 15 0 Normal 16 0 See Note Regulator Out of Adjustment 12 5 See Note Alternator Not Working OR Regulator Out of Adjustment Shutdown 12 0 Battery Normal NOTE Display flashes voltage reading with single loud tone Re...

Page 110: ... position 2 Move GSL o ut of N DET ENT The e ngine should shutdown and the lower display will flash LOCK SEAT BAS E CENTER STEERING WHEEL NOT IN NEUTRAL 3 Swivel and lock the Operator s station and the display should return to normal 4 If the engine does not shut down the seat position switches require adjustment Refer to Technical Service Manual d With the windrower moving at less than 5 mph 8 km...

Page 111: ... and check that all lights are functioning as shown below d Activate HIGH LOW switch e Activate turn signals and hazard warning lights with switches on CDM f Turn lights OFF continued next page REAR CAB FORWARD FIELD LIGHTS SWATH LIGHTS HIGH LOW FRONT CAB FORWARD HIGH LOW ROAD FIELD LIGHTS SMV SIGN REAR CAB FORWARD TAIL LIGHTS RED If Installed TURN SIGNALS HAZARDS AMBER FRONT CAB FORWARD HIGH LOW ...

Page 112: ...g as shown below i Activate HIGH LOW switch and check lights j Activate turn signals and hazard warning lights with switches on CDM and check lights k Switch beacons ON and check that they are working properly BEACON LIGHTS AMBER REAR ENGINE FORWARD TAIL BRAKE LIGHTS RED TURN SIGNALS HAZARDS AMBER HIGH LOW ROAD FRONT ENGINE FORWARD TURN SIGNALS HAZARDS AMBER ...

Page 113: ...W switch c Switch ROAD lights ON and check that all lights shown are functioning as shown below d Activate HIGH LOW switch e Activate turn signals and hazard warning lights with switches on CDM continued next page SWATH LIGHTS FIELD LIGHTS REAR FRONT FIELD LIGHTS REAR TURN SIGNALS HAZARDS AMBER TAIL LIGHTS RED TURN SIGNALS HAZARDS AMBER HIGH LOW LIGHTS FRONT ...

Page 114: ...ON and check that they are working properly VIII INTERIOR LIGHTS a Switch lights ON and OFF with switches on each light Overhead ambient light only works with ROAD FIELD light switch ON b Check gauge lights M155 M205 BEACON LIGHTS AMBER M155 M205 SHOWN M105 SIMILAR ...

Page 115: ...times M155 M205 OUTSIDE AIR SWITCH Controls Air Source FRESH AIR Starts Booster Fan and Filtered Outside Air Drawn Into Cab RECIRCULATE Stops Booster Fan and Cab Air Is Re circulated AIR CONDITIONING SWITCH Controls A C System OFF A C Does Not Operate ON A C Operates With Blower Switch ON TEMPERATURE CONTROL Controls Cab Temperature INCREASE Clockwise DECREASE Counterclockwise BLOWER SWITCH Contro...

Page 116: ...rator s seat MODEL OPERATOR S MANUAL PARTS CATALOG QUICK CARD ENGINE MANUAL M105 Engl 169552 Rus 169553 169549 169570 166240 M155 Engl 169563 Rus 169546 169564 169565 M205 Engl 169469 Rus 169482 169472 169475 L CAB INTERIOR a Remove plastic coverings from Cab Display Module and seats after pre delivery check is complete M155 M205 M105 ...

Page 117: ... Pty Ltd A C N 079 393 721 P O Box 243 Suite 3 143 Main Street Greensborough Victoria Australia 3088 t 03 9432 9982 f 03 9432 9972 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Centre t 7 495 775 6971 direct line f 7 495 967 7600 CUSTOMERS www macdon com DEALERS www macdonDealers com Trademarks of products are the marks of their respect...

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