MacDon M1 Series Unloading And Assembly Instructions Download Page 20

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215620

Revision A

Figure 1.17: Cab Connectors

NOTE:

To disconnect the remaining circular Deutsch connectors, rotate
the outer collar counterclockwise.

•

Cab connectors (A)
Two round connectors: C1 and C2

Location: Under the cab

Figure 1.18: Roof Connectors

•

Roof connectors (A)
Four connectors: C10, C12, C13, and C14

Location: Under the cab at the base of the left cab post

Figure 1.19: Chassis Relay Module

•

Chassis relay module (A)
Three connectors: P240, P241, and P242

Location: Outside the left frame rail near the batteries

SAFETY

Summary of Contents for M1 Series

Page 1: ...M1 Series Windrowers Unloading and Assembly Instructions Container Shipments 215620 Revision A Original Instruction The Harvesting Specialists ...

Page 2: ...mation in this publication is based on the information available and in effect at the time of printing MacDon Industries Ltd makes no representation or warranty of any kind whether expressed or implied with respect to the information in this publication MacDon Industries Ltd reserves the right to make changes at any time without notice ...

Page 3: ...pt Russia MarketingEurope macdon com Russia shortageanddamage macdon com The windrower is Dual Direction and can be driven in cab forward or engine forward mode Right and left designations are determined by the operator s position facing the direction of travel This manual uses the terms right cab forward left cab forward right engine forward and left engine forward when referencing specific locat...

Page 4: ... page 93 Changed the entire procedure because the lift stands have changed ECN 62447 4 1 1 Recording Serial Numbers page 95 Step 1 page 95 Step 2 page 95 Added steps and illustration Technical Publications 4 1 5 Checking Engine Coolant Level page 99 Step 3 page 99 to Step 5 page 99 Added steps and illustration Technical Publications 4 1 9 Checking Air Conditioning Compressor Belts page 103 Step 2 ...

Page 5: ...taching R85 Rotary Disc Header page 162 5 3 2 Connecting R85 Rotary Disc Header Hydraulics page 166 Added R85 topics for reference only Technical Publications 5 4 R1 Series Rotary Disc Header page 173 Separated all Attaching Connecting R1 Series Rotary Disc Header topics from Attaching Connecting R2 Series Rotary Disc Header topics for clarity Technical Publications 5 5 R2 Series Rotary Disc Heade...

Page 6: ...ist die Erklärung auszustellen 6 ist die technischen Unterlagen zu erstellen Benedikt von Riedesel General Manager MacDon Europe GmbH Hagenauer Straße 59 65203 Wiesbaden bvonriedesel macdon com ES Nosotros 1 declaramos que el producto Tipo de máquina 2 Nombre y modelo 3 Números de serie 4 directriz 2006 42 EC 7 2 EN ISO 4254 1 2013 EN ISO 4254 7 2009 Lugar y fecha de la declaración 5 draw redactar...

Page 7: ...EN ISO 4254 1 2013 EN ISO 4254 7 2009 Data și locul declarației 5 pentru întocmirea declarației 6 Numele și semnătura persoanei autorizate pentru întocmirea cărții tehnice Benedikt von Riedesel Manager General MacDon Europe GmbH Hagenauer Straße 59 65203 Wiesbaden Germania bvonriedesel macdon com SV Vi 1 Maskintyp 2 Namn och modell 3 Serienummer 4 2006 42 EG Harmonierade standarder används såsom a...

Page 8: ......

Page 9: ...oving Caster Wheel Shipping Assembly 29 2 4 Removing Fuel Tank Right Platform Shipping Assembly 32 2 5 Removing Left Platform 36 2 6 Removing Wheel Leg Assemblies 38 2 7 Removing Upper Shipping Supports 40 Chapter 3 Assembling Windrower 43 3 1 Lifting Windrower onto Assembly Stand 43 3 2 Removing Remaining Items from Shipping Configuration 46 3 3 Installing Wheel Legs 48 3 4 Installing Drive Wheel...

Page 10: ...g Air Conditioning Compressor Belts 103 4 1 10 Starting Engine M1240 Windrower 104 4 1 11 Checking and Adding Wheel Drive Lubricant 10 Bolt Wheels 107 4 1 12 Checking Traction Drive 108 4 1 13 Checking Tire Pressure 108 4 2 Performing Operational Checks 111 4 2 1 Checking Operating Safety System 111 4 2 2 Checking Harvest Performance Tracker Display Gauges 112 Navigating the Harvest Performance Tr...

Page 11: ...Only Configuration Hard Plumbed Fittings 186 Rotary Disc Only Configuration Quick Coupler Connections 188 5 4 4 Detaching R1 Series Rotary Disc Header 190 5 5 R2 Series Rotary Disc Header 196 5 5 1 Attaching Forming Shield 196 5 5 2 Attaching R2 Series Rotary Disc Header 196 5 5 3 Connecting R2 Series Rotary Disc Header Hydraulics and Electrical Systems M1170 Windrower 203 5 5 4 Connecting R216 Ro...

Page 12: ...ttings Adjustable 243 6 3 4 O Ring Boss Hydraulic Fittings Non Adjustable 244 6 3 5 O Ring Face Seal Hydraulic Fittings 245 6 3 6 Tapered Pipe Thread Fittings 246 6 4 Conversion Chart 248 6 5 Definitions 249 Predelivery Checklist 251 TABLE OF CONTENTS ...

Page 13: ... safety related information Signal words are 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 may also be used to alert against unsafe practices CAUTION Indicates a potentially hazardo...

Page 14: ...vy gloves Wet weather gear Respirator or filter mask Figure 1 2 Safety Equipment In addition take the following precautions Be aware that exposure to loud noises can cause hearing impairment Wear suitable hearing protection devices such as earmuffs or earplugs to help protect against loud noises Figure 1 3 Safety Equipment Provide a first aid kit in case of emergencies Keep a properly maintained f...

Page 15: ...ctionality and or safety of the machine It may also shorten the machine s service life To avoid injury or death from the unexpected startup of the machine ALWAYS stop the engine and remove the key from the ignition before leaving the operator s seat for any reason Figure 1 6 Safety around Equipment Keep the machine service area clean and dry Wet and or oily floors are slippery Wet spots can be dan...

Page 16: ...nsure that the tire is correctly seated on the rim before inflating it If the tire is not correctly positioned on the rim or is overinflated the tire bead can loosen on one side causing air to escape at high speed and with great force An air leak of this nature can thrust the tire in any direction endangering anyone in the area Do NOT stand over the tire when inflating it Use a clip on chuck and e...

Page 17: ...h it with cool clean water for 5 minutes Call a doctor immediately If electrolyte is spilled or splashed on one s clothing or their body neutralize it immediately with a solution of baking soda and water then rinse the strained area with clean water Figure 1 11 Safety around Batteries WARNING To avoid injury from a spark or short circuit disconnect the battery ground cable before servicing any par...

Page 18: ...operation performed on the machine IMPORTANT Ensure that the windrower is parked on a level surface the ignition is turned off and the key is removed before disconnecting anything The following items need to be disconnected Figure 1 12 Negative Terminals Negative battery terminals A two connections IMPORTANT Always disconnect the battery terminals first and reconnect them last Figure 1 13 Master C...

Page 19: ...rs insert the end of a small 3 6 mm 1 8 1 4 in blade screwdriver into the connector s locking tab Gently pry upward no more than 6 mm 1 4 in to unlock the connector tab and then pull the connector away from the module Figure 1 16 Engine Control Module Engine Control Module ECM Two connectors for Cummins P100 A and J1 Cummins Proprietary ECM Connector B Location On the engine To disconnect the conn...

Page 20: ...nnectors A Two round connectors C1 and C2 Location Under the cab Figure 1 18 Roof Connectors Roof connectors A Four connectors C10 C12 C13 and C14 Location Under the cab at the base of the left cab post Figure 1 19 Chassis Relay Module Chassis relay module A Three connectors P240 P241 and P242 Location Outside the left frame rail near the batteries SAFETY ...

Page 21: ...6 Location Under the center of the frame just behind the front cross member IMPORTANT To connect the circular Deutsch connectors without bending the pins fully align the plug with the receptacle before pressing the connector in To align the connectors 1 Observe the channel cuts and mating channel protrusions on the inner part of the circular walls of the connectors 2 Face the mating connectors tow...

Page 22: ...ocedure in the Starting Engine section of the operator s manual Following the correct procedure will help prevent major damage to engine components and prevent personal injury To ensure that the jacket water heater if equipped and or lubricant oil heater if equipped are working correctly check the water temperature gauge and or oil temperature gauge during heater operation Engine exhaust contains ...

Page 23: ...NOT touch the harness connector for the electronic unit injectors while the engine is operating Failure to follow this instruction could result in personal injury or death This engine has a comprehensive programmable engine monitoring system The ECM has the ability to monitor engine operating conditions If certain conditions exceed their allowable range the ECM will initiate immediate action The e...

Page 24: ...ld take extra precautions before operating the controls They are usually yellow Figure 1 23 Operator s Manual Decal Keep safety signs clean and legible at all times Replace safety signs that are missing or illegible If the original part on which a safety sign was installed is replaced ensure that the repair part displays the current safety sign SAFETY ...

Page 25: ...trols Stop the engine and remove the key from the ignition before performing any maintenance or service on the steering linkage or the neutral interlock system Refer to the windrower and header operator s manuals for inspection and maintenance instructions Figure 1 26 MD 166454 MD 166454 General hazard pertaining to machine operation and servicing DANGER To prevent injury or death from improper or...

Page 26: ... the key from the ignition before servicing adjusting lubricating cleaning or unplugging the machine Engage the safety locks to prevent lowering of the header or reel before servicing the header when it is in the raised position Use a slow moving vehicle emblem and activate the machine s warning lights when operating on roadways unless these actions are prohibited by law SAFETY ...

Page 27: ...lubricating cleaning or unplugging the machine Engage the safety locks to prevent the lowering of the header or the reel before servicing the header when it is in the raised position Use a slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited by law Run over hazard DANGER The machine will move if the steering wheel is turned while the engine is running...

Page 28: ...ions are prohibited by law If the width of the attached header impedes other vehicle traffic remove the header and install a MacDon approved weight box onto the windrower Refer to the windrower and header operator s manuals for instructions on safely towing the header Figure 1 29 MD 166824 MD 166824 Hot fluid spray hazard and fluid fill rate information CAUTION Hydraulic fluid is under pressure an...

Page 29: ... or death High pressure oil can easily puncture skin and can cause serious injury gangrene or death Do NOT go near hydraulic oil leaks Do NOT use fingers or skin to check for hydraulic oil leaks Lower the load or relieve hydraulic pressure before loosening fittings If injured seek emergency medical help Immediate surgery is required to remove the oil which has penetrated the skin Figure 1 32 MD 16...

Page 30: ...ery and do NOT connect boosting or charging cables incorrectly Refer to the operator s manual for battery boosting and charging procedures Figure 1 34 MD 166836 MD 166836 Battery acid hazard WARNING To prevent injury from corrosive and poisonous battery acid Wear protective clothing and personal protective devices when handling battery acid Acid can severely burn your body and clothing SAFETY ...

Page 31: ...ard WARNING To prevent injury Do NOT operate the engine with the engine hood open Stop the engine and remove the key before opening the engine hood Figure 1 36 MD 166838 MD 166838 Hot surface hazard CAUTION To prevent injury Keep a safe distance from hot surfaces SAFETY ...

Page 32: ...en sharp changes to your speed while turning such as hard braking When travelling on steep slopes Reduce the machine s speed and lower the header Move the ground speed lever to the slow end of the range Shift the high low speed control to the low range When the windrower is operating without a header attached weight must be added over the drive wheels so that the Operator can maintain steering con...

Page 33: ...ch into the pinch area Figure 1 40 MD 306179 306180 306181 MD 306179 306180 306181 Header crushing hazard DANGER To prevent injury or death from the fall of a raised header Fully raise the header stop the engine remove the key from the ignition and engage the safety props before going under the header SAFETY ...

Page 34: ......

Page 35: ...nders and to avoid striking them with machinery do NOT allow people to stand in the unloading area Figure 2 1 Windrower Shipping Assembly 1 Move the trailer into position and block the trailer wheels 2 Lower the trailer storage stands 3 Unlock and open the container doors and remove all blocking 4 Check the container floor for nails or other obstructions and remove them if necessary 5 Position the...

Page 36: ...ly DANGER To prevent injury to bystanders and to avoid striking them with machinery do NOT allow people to stand in the unloading area DANGER The equipment used for loading or unloading a header must meet or exceed the requirements specified in this document Using inadequate equipment may result in chain breakage vehicle tipping machine damage or bodily harm to operators or bystanders Figure 2 2 L...

Page 37: ...ables or chains with a minimum lifting capacity of 3221 kg 7100 lb Figure 2 4 Shipping Frame Lifting Points 2 Attach the lift sling to the four designated lifting points on the windrower shipping frame as shown DANGER To avoid injury or death from a swinging or falling load keep all bystanders clear when lifting Equipment used for lifting must exceed the maximum requirements specified in this sect...

Page 38: ...vent injury to bystanders and to avoid striking them with machinery do NOT allow people to stand in the unloading area DANGER The equipment used for loading or unloading a header must meet or exceed the requirements specified in this document Using inadequate equipment may result in chain breakage vehicle tipping machine damage or bodily harm to operators or bystanders IMPORTANT Refer to the shipp...

Page 39: ...pping Assembly Specifications Table 2 1 Shipping Assembly Specifications Shipping Assembly Specifications Weight 6337 kg 13970 lb Center of gravity A 2690 mm 105 9 in Length B 6005 mm 236 4 in Height C 2481 mm 97 7 in UNLOADING WINDROWER ...

Page 40: ... Points 1 Approach the windrower from the hood end and slide forks underneath the lifting framework 2 Raise the windrower off the platform and move it to the assembly area Figure 2 8 Windrower Shipping Assembly on Blocks 3 Lower the windrower onto 152 mm 6 in blocks A as shown 4 Check for shipping damage and missing parts UNLOADING WINDROWER ...

Page 41: ...poses This shipping assembly needs to be pulled away from the windrower Figure 2 9 Caster Wheel Assembly 1 Locate caster wheel shipping assembly A Figure 2 10 Center Link 2 Remove shipping wire A securing center link B Figure 2 11 Center Link 3 Disconnect center link A and discard the pin and hardware B UNLOADING WINDROWER ...

Page 42: ...lts and Caps 5 Remove leg pin bolts A from both sides and retain caps B two per side for reuse NOTE If you will be moving the windrower shipping assembly with a crane retain the leg pin bolts and nuts for reinstallation Figure 2 14 Front Skid Bolts 6 Remove two bolts A securing front the skids to lifting plates B on each side UNLOADING WINDROWER ...

Page 43: ...y from the windrower Figure 2 16 Reinstalling Leg Pin Bolt Crane Lift Only 8 If moving with a crane reinstall wheel leg pin bolts A caps B and nuts C to secure lifting plates D on both sides Figure 2 17 Removing Lifting Plates 9 If moving with a forklift remove bolt A from lifting plate C slide pin B out and retain for reuse Remove lifting plates C on both sides UNLOADING WINDROWER ...

Page 44: ...om handrails B and from the hydraulic hoses Set the hoses down beside the machine Figure 2 19 Handrails on Right Side 2 Supporting upper handrail A remove three bolts B securing the handrail to the upper shipping support and then set the handrail aside 3 Supporting lower handrail C remove three bolts D and then set the handrail aside NOTE Use care to prevent handrail C from contacting and scratchi...

Page 45: ...oints 7 With the lifting device positioned behind the windrower secure the fuel tank assembly to the lifting device with three chains as follows IMPORTANT To avoid damaging windrower make sure the load is balanced a Attach a 147 cm 58 in chain A to the right lifting point on the fuel tank shipping assembly NOTE Avoid snagging the fuel filler neck with the chain b Attach a 145 cm 57 in chain B to t...

Page 46: ...igure 2 24 Handrail and Wheel Legs 11 Slowly lift the fuel tank shipping assembly C away from the windrower Avoid snagging handrail A on wheel leg assemblies B Figure 2 25 Handrail under Fuel Tank Shipping Assembly 12 With the fuel tank shipping assembly suspended off the ground support handrail A remove and retain hardware B and then set the handrail aside Keep the hardware with the handrail for ...

Page 47: ...215620 35 Revision A Figure 2 26 Left Platform Stairs 14 Remove four bolts A remove stairs B from the windrower shipping assembly and set the stairs aside Repeat on the opposite side UNLOADING WINDROWER ...

Page 48: ...t and bushing B and platform bar C Retain hardware B for reuse Figure 2 28 Supporting Left Platform 2 Position the lifting device behind the windrower and attach straps chains to lifting points A to support the left platform Figure 2 29 Left Platform on Left Side 3 Remove nut A from long bolt B on the bottom left side of the platform Retain nut A To prevent the tool box from falling out leave long...

Page 49: ...NOTE To show the door stop under the platform the windrower wheel legs and shipping supports have been removed from this illustration Figure 2 31 Left Platform Right Side 5 Remove and discard nuts and bolts A and B 6 Carefully lift the platform assembly off the frame and set it down on a level surface Figure 2 32 Left Platform 7 Reinstall nut A on retained long toolbox bolt B UNLOADING WINDROWER ...

Page 50: ...t side 2 Secure the hydraulic hoses to avoid damaging the windrower hood Figure 2 34 Attaching Lifting Strap 3 Feed lifting strap A through the top of leg assembly Position the strap so that the leg will be balanced but avoid damaging float sensor B Adjust the lifting device to support the leg 4 Before lifting have a second person available to prevent the leg from swinging into the hood Lay down c...

Page 51: ...then pull the shipping bars out of the wheel leg members Figure 2 37 Lowering Right Leg Assembly 8 Lift leg assembly away from the windrower and set it on level ground Lay leg down as shown with leg member on block A 9 Repeat procedure for the second leg assembly UNLOADING WINDROWER ...

Page 52: ...a suitable lifting device 2 Remove two bolts A on each side and then remove the cross member Figure 2 39 Forward Vertical Supports 3 Remove nut and bolt A and remove vertical support B Repeat on the opposite side Figure 2 40 Rear Lift Points 4 If lifting the windrower with a crane Do NOT remove rear vertical channels crane lifting points A until after lifting the machine onto the assembly stand UN...

Page 53: ...cal Channels 5 Remove one nut and bolt A connecting vertical channel B to the walking beam strap 6 Remove two nuts and bolts C connecting the channel to the walking beam and the remove the channel Repeat on the opposite side UNLOADING WINDROWER ...

Page 54: ......

Page 55: ... the unloading area DANGER The equipment used for loading or unloading a header must meet or exceed the requirements specified in this document Using inadequate equipment may result in chain breakage vehicle tipping machine damage or bodily harm to operators or bystanders 1 Before lifting the windrower onto an assembly stand ensure lifting device meets or exceeds the specified requirements and ref...

Page 56: ...tween the assembly stands Rear assembly stand height A is 1240 mm 48 13 16 in Front assembly stand height B is 1291 mm 50 13 16 in 3 Space the stands out so that dimension C is 3470 mm 136 5 8 in 4 Attach diagonal angles D to the stands using 5 8 x 1 5 in bolts and nuts at locations E 5 Torque the nuts to 153 Nm 113 lbf ft ASSEMBLING WINDROWER ...

Page 57: ...215620 45 Revision A Figure 3 2 Windrower on Assembly Stands 6 Lift the windrower on the assembly stand Front assembly stand A must allow removal of fork channels B ASSEMBLING WINDROWER ...

Page 58: ... fork channels Figure 3 3 Rear Light Bezel 1 On the right side of the machine remove two bolts A securing the rear lighting bezel and then remove the bezel Retain two nuts for installation but discard the bolts Figure 3 4 Right Cab Suspension Support 2 Remove two bolts and nuts A and cab suspension shipping support B from below the front cab Repeat on the opposite side ASSEMBLING WINDROWER ...

Page 59: ...nd remove two bolts C from the walking beam Figure 3 6 Fork Channel 4 Remove bolt A from the forward end of fork channel B at the side of the machine 5 Ensure the hoses and electrical harnesses do not catch the lower fork channel and move it away from the windrower 6 Repeat on the opposite side ASSEMBLING WINDROWER ...

Page 60: ...wo caps and pin A and retain for leg installation NOTE If lifting with a forklift the outboard pin was removed previously 2 If lifting with a crane remove bolt nut two caps and pin B Retain for installation 3 If lifting with a crane remove carriage bolt C and lifting plate D Figure 3 8 Wheel Leg 4 Remove shipping material from the hydraulic and electrical bundle on wheel leg 5 Attach lifting strap...

Page 61: ...rical Bundle 8 Feed bundle A through the hole below the windrower at the center of the frame Figure 3 12 Leg Position on Frame 9 Insert the leg into the frame and line up with exposed hole A 10 Insert the pins and secure leg with long bolts B two caps per pin C and nuts D Torque to 136 Nm 100 lbf ft NOTE If necessary use a pry bar to align holes 11 Repeat for the opposite wheel leg ASSEMBLING WIND...

Page 62: ...3 Header Lift Linkage Shipping Pin 12 Remove lynch pin A and clevis pin B from the lift linkages on both wheel legs IMPORTANT Failure to remove the clevis pin from the linkage can result in damage to the linkage ASSEMBLING WINDROWER ...

Page 63: ...ire and raise it slightly 4 Position the wheel against the wheel drive hub so that air valve B is on the outside while tread C points forward NOTE For wheels equipped with turf tires those with a diamond tread pattern be sure that the arrow on the sidewall points cab forward Figure 3 16 Tightening Sequence 10 Bolt Wheel 5 Align the wheel rim with the studs on the hub Push the wheel onto the hub 6 ...

Page 64: ...ing Sequence 12 Bolt Wheel 8 Repeat the tightening sequence two additional times ensuring that the specified torque is achieved each time 9 Repeat Step 2 page 51 to Step 8 page 52 in order to install the right drive wheel ASSEMBLING WINDROWER ...

Page 65: ... A securing anti shimmy dampener brackets B to shipping stand Retain the two M24 bolts and washers for installation Figure 3 19 Caster Wheels Shipping Assembly 2 Use a suitable lifting device to support right caster wheel A Do NOT remove angled support B Figure 3 20 Caster Wheels Shipping Assembly 3 Remove and discard four bolts A and remove horizontal strap B between caster wheels ASSEMBLING WIND...

Page 66: ...A around caster wheel beam and shipping bracket B and lift wheel into position beside walking beam 7 Insert caster wheel approximately 305 mm 12 in into walking beam up to shipping brace B Figure 3 23 Caster Wheel Brace 8 Remove bolts A and B securing shipping brace C to caster wheel Discard bolt and nut from location B 9 Retain M24 bolt and washer from location A Discard brace C 10 Rotate caster ...

Page 67: ...d washers D into the outboard holes on walking beam Figure 3 25 Torquing Bolts Left Wheel Shown 15 Tighten six bolts on walking beam as follows a Snug bottom bolts A then snug rear facing bolts B b Torque back bolts B to 745 770 Nm 550 570 lbf ft c Torque bottom bolts A to 745 770 Nm 550 570 lbf ft Installing left caster wheel Figure 3 26 Caster Wheels Shipping Assembly 16 Use a suitable lifting d...

Page 68: ...face 19 Repeat Step 6 page 54 to Step 15 page 55 to install left caster wheel NOTE It may be necessary to raise the left end of walking beam with a jack when installing the left caster wheel Figure 3 28 SMV Bracket in Working Position 20 On left anti shimmy dampener bracket rotate slow moving vehicle SMV sign bracket A into working position Secure with existing screws B Figure 3 29 Walking Beam Ad...

Page 69: ...B at the aft hole location with one M16 x 90 flange head bolt and M16 lock nut C Install the bolt from under the support Do NOT fully tighten the hardware yet 4 Rotate the caster so that arm D is aligned with the walking beam Figure 3 32 Anti Shimmy System Left Side 5 Attach the rod ends of the anti shimmy dampeners to the arm with M16 x 90 flange head bolt A and three hardened washers B NOTE Wash...

Page 70: ...215620 58 Revision A 9 Repeat Steps 2 page 57 to 8 page 57 to install the anti shimmer system on the opposite side of the windrower ASSEMBLING WINDROWER ...

Page 71: ...ID lift hose A with no cable tie to port HL b Connect the 1 4 in ID float hose B marked with a yellow cable tie to port FL c Connect the 3 8 in ID lift hose C marked with a yellow cable tie to port CL d Connect the 1 2 in ID case drain hose D marked with a red cable tie to port MDL Figure 3 34 Junction Manifold Right Leg Hoses 2 Connect hoses from the right wheel leg to the junction manifold as fo...

Page 72: ...ack cable tie to port BL b Connect the 1 4 in ID float hose D marked with a black cable tie to port FL with extension Figure 3 36 Securing Hoses 5 Use provided cable tie A to secure two hoses B routed from the right leg to the float selector manifold to the case drain hose marked with a blue cable tie 6 Use provided cable tie C to secure two hoses D routed from the left leg to the float selector m...

Page 73: ...onnect the hoses from the wheel drive motors to the traction drive pump as follows a Connect the hose from port B on the right wheel motor to port A the one with extended adapter and marked with a black cable tie b Connect the hose from port A on the right wheel motor to port B the one with extended adapter and marked with a red cable tie c Connect the hose from port B on the left wheel motor to p...

Page 74: ...se support behind the front cross member and connect it to master controller harness B as follows Connect the right wheel motor connector C25B to master controller connector C25A Connect the left wheel motor connector C26B to master controller connector C26A Secure the harness in the hose support with cable ties C ASSEMBLING WINDROWER ...

Page 75: ...and nuts Nuts B should face outward Figure 3 42 Left Platform 3 Remove three existing nuts and bolts A and adjuster bolt B from the left platform bracket Retain hardware for installation 4 Attach a suitable lifting device to lift brackets C and move the left platform next to the left side of windrower Figure 3 43 Left Platform Bracket 5 Align holes in platform bracket A with holes in the windrower...

Page 76: ...he existing hardware to connect platform linkage A to hole in the platform Ensure bushing B remains in the linkage hole nut C is installed below the platform Torque nut to 14 5 Nm 11 lbf ft Figure 3 46 Platform Door Stop 8 Use the existing hardware to mount door stop A onto the left platform Insert bolt B from the top and torque nut C to 28 5 Nm 21 lbf ft ASSEMBLING WINDROWER ...

Page 77: ... and two linkage bolts D to 39 5 Nm 29 lbf ft Installing left platform handrails Figure 3 48 Left Platform Assembly 11 Remove shipping strap A and retain the hardware 12 Remove rear lifting bracket B and discard the hardware 13 Ensure toolbox door C is locked and remove long hinge bolt and nut D Retain the hardware 14 Remove and retain two bolts E next to the toolbox 15 Remove forward lifting brac...

Page 78: ...e platform Torque bolts to 95 Nm 70 lbf ft c Open toolbox tray D and install existing bolt and nut E with the bolt head on top of the platform 17 Set front handrail F on platform and secure it with three existing bolts G Torque bolts to 95 Nm 70 lbf ft Installing left platform steps Figure 3 50 Left Platform Steps 18 Remove two nuts A lock clips B and bolts C from the step ASSEMBLING WINDROWER ...

Page 79: ...Figure 3 51 Left Platform Steps 19 Insert two bolts A into platform and hook steps B onto the bolts 20 Install lock clips C with tabs in the slots and secure with nuts D Torque bolts to 95 Nm 70 lbf ft ASSEMBLING WINDROWER ...

Page 80: ...3 52 Right Platform Shipping Brackets 3 Remove two nuts and bolts A and B to remove shipping bracket C Retain bolt A for installation but discard the nut Retain bolt and nut B for installation 4 Remove bolt and nut D and retain for installation Figure 3 53 Right Platform Shipping Brackets 5 Remove two nuts and bolts A and remove shipping spacer tube B from the handrail channel 6 Remove nuts C from...

Page 81: ...channel 8 Remove bolt and nut C and retain for installation Figure 3 55 DEF Hose Cover 9 On the right chassis frame member remove two bolts A and remove hose cover B Figure 3 56 Hose Clamps on Right Frame 10 Loosen two bolts A securing the hose brackets and move the hoses away from platform mounting bolt B 11 Remove platform mounting bolt B and retain for installation ASSEMBLING WINDROWER ...

Page 82: ...r right front cab shock B and lift the cab until you feel resistance Figure 3 58 Right Platform Fuel Tank Assembly 13 Support right platform assembly A with a suitable lifting device adjust lifting straps B until the platform is parallel to the ground and move it into place on the right side of windrower Move hose bundle C to prevent pinching ASSEMBLING WINDROWER ...

Page 83: ... 19 For the right platform bolt torque values refer to Table 3 1 page 71 Table 3 1 Right Platform Bolt Torque Bolt Location Callout Torque Value Rear support top frame A 500 Nm 379 lbf ft Front support top frame B 500 Nm 379 lbf ft Front side frame C 54 Nm 40 lbf ft Front lower frame D 68 5 Nm 50 lbf ft Rear side frame E 68 5 Nm 50 lbf ft Installing right platform steps Figure 3 60 Platform Steps ...

Page 84: ...lace 23 Rotate shock A up and connect to the steps with the existing hardware Installing right platform handrails Figure 3 62 Front Handrail Right Platform 24 Retrieve forward handrail A Remove and retain existing hardware three bolts and nuts 25 Insert the handrail tube into the channel to the right of the steps and secure with existing hardware B and C 26 Torque the hardware to 35 Nm 26 lbf ft A...

Page 85: ...nstallation Figure 3 64 Rear Handrail Right Platform 30 Insert the rear handrail into the channel next to the DEF tank and the channel left of the steps NOTE Fuel tank hidden to show the hardware locations 31 Secure the bottom of the rail with two nuts and bolts A 32 Secure the rail near the DEF head with two nuts and bolts B 33 Secure the rail in the channel left of the steps with two nuts and bo...

Page 86: ...etween the front platform support and DEF tank 36 Make a loop in drain hoses with cable ties Loop height C should be 190 mm 7 1 2 in maximum the remaining hose length D should hang 120 mm 4 3 4 in below bottom of the platform support 37 Fasten the loop to slot E in the platform support with cable tie 38 Pull the hose ends through hole F in the bottom of the platform support ASSEMBLING WINDROWER ...

Page 87: ...les 2 Remove and discard transport fitting A and separate the DEF heater hoses Retain hose clamps B for installation 3 Clamp the DEF heater hoses to prevent spilling the coolant Figure 3 67 Hose Routing 4 Route DEF heater hoses A under platform to DEF head B Use a fish wire if necessary NOTE Platform is transparent in the illustration at right Figure 3 68 DEF Head Connections 5 Using existing hose...

Page 88: ... pull on the connector to separate the DEF supply lines from the shipping pin Discard the pin not shown Figure 3 71 DEF Supply Module 8 Remove the caps from the DEF supply module and connect the hoses as follows Red hose to inlet port A on the supply module Yellow hose to backflow port B on the supply module Press down on the connectors until they click ASSEMBLING WINDROWER ...

Page 89: ...ring Hoses to Frame with P Clips 11 Secure fuel hoses A DEF heater hoses B and DEF supply module hoses C to the frame with the existing P clamps and torque bolts D to 22 Nm 16 lbf ft Electrical connections Figure 3 74 Electrical Connections 12 Remove the protective caps and connect the following three electrical connectors Connector A from inlet hose to receptacle P173 C Connector B from backflow ...

Page 90: ...C40B from the right platform to the bracket on the frame and secure with washer and nut 15 Connect C40B B to C40A A and secure harness to air cleaner support pipe pipe not shown with large cable tie C 16 Remove the protective cap from fuel level sender connector D and plug into the chassis harness P220 not shown 17 Secure the fuel level sender harness to the auxiliary power harness with cable tie ...

Page 91: ... DEF Head Cover 18 Replace DEF head cover C and secure it with two top bolts A and rear nut bolt B Torque bolts A to 17 Nm 12 5 lbf ft Figure 3 78 DEF Hose Cover 19 Replace hose cover B and secure with two bolts A ASSEMBLING WINDROWER ...

Page 92: ...ror arms Figure 3 80 Mirror Arm in Working Position 4 Tighten retaining nut A to 39 Nm 29 lbf ft 5 Tighten pivot nut B to 26 Nm 19 lbf ft Figure 3 81 Roof Harness and Mirror Harness Secured 6 To prevent pinching wires when adjusting the mirror assemblies ensure that roof harness A and power mirror harness B if installed are secured as follows Roof harness A to supports with cable ties C Mirror har...

Page 93: ... the plastic cover from the breather tube 2 Ensure there are no parts or debris inside the inlet duct Figure 3 82 Air Inlet Duct 3 At the rear right corner of the cab roof set air inlet duct A over the breather tube and rotate to align the predrilled holes for setscrew B 4 Tighten setscrew B and tighten tube clamp C to secure the duct onto the breather tube ASSEMBLING WINDROWER ...

Page 94: ...o unlock the cab door and the toolbox compartment Figure 3 83 SMV Sign Installed on Mirror Light Support Right Cab Forward Side 2 Position sign A on existing bracket B as shown on the right cab forward side mirror light support and secure it with two M6 x 20 hex head bolts and M6 lock nuts C IMPORTANT Ensure that the SMV sign does NOT cover the brake light Figure 3 84 SMV Sign Installed Left Cab F...

Page 95: ...rs Figure 3 85 Rear Hydraulic Multicoupler 1 Remove nuts A from the underside of the knife reel multicoupler and retain the nuts for installation Figure 3 86 Coupler Holder Installed 2 Retrieve hydraulic coupler holder A from inside the windrower cab 3 Install coupler holder A onto the underside of multicoupler using existing hex head screws and secure it with existing nuts B ASSEMBLING WINDROWER ...

Page 96: ...e reel double knife untimed Base 1 1 0 D135XL 10 6 m 35 ft single reel double knife untimed Transport 1 1 B6047 D135XL 10 6 m 35 ft single reel double knife untimed Transport upper cross auger vertical knives 1 2 B6047 D135XL 10 6 m 35 ft double reel double knife untimed Base 1 1 0 D135XL 10 6 m 35 ft double reel double knife untimed Transport 1 1 B6047 D135XL 10 6 m 35 ft double reel double knife...

Page 97: ...upports B 2 Remove nuts C from light supports B Retain the hardware for installation Figure 3 88 Light Supports 3 Remove two bolts A cover B and seal C from behind each light support Figure 3 89 Right Light Support 4 Align connector A and plug the engine forward headlight harness into headlight B as follows Harness P214 to the right engine forward headlight Harness P213 to the left engine forward ...

Page 98: ...ht tail brake light Harness P215 to the left tail brake light 6 Replace cover C and secure it with bolts D 7 Press headlight harness E into clip F on the light support 8 Repeat on opposite side Figure 3 91 Left Light Support 9 Mount light support A to stud B on rear pivot support with existing nut C Repeat on opposite side Figure 3 92 Right Tail Brake Light 10 Plug tail brake light harnesses A int...

Page 99: ...add to the windrower 2 Shut down the engine and remove the key from the ignition Figure 3 94 Bezel Assembly Removed from Windrower 3 Separate light bezel assembly A by removing six hex screws B Figure 3 95 Bezel Assembly Separated 4 Retain center portion A of the light bezel assembly for reinstallation Install six hex screws B on the side bezels NOTE These hex screws will be used when reinstalling...

Page 100: ... the walking beam 6 Install retaining bracket B on each side of the weight bundle IMPORTANT Ensure that retaining bracket B engages slot C in the bracket 7 Install rod D through the retaining bracket and weights with spacers E as required 8 Secure the rod with nuts F Tighten the nuts IMPORTANT Ensure that nuts F are flush with the rod Figure 3 97 Base Ballast Kit Installed 163 kg 360 lb Figure 3 9...

Page 101: ...ring left bezel A close to the frame and connect plug P215 to the back of red tail brake light E 12 Loosely attach left bezel A to the frame with four hex flange bolts B 13 Repeat Step 11 page 89 and Step 12 page 89 attaching plug P210 at right bezel C 14 Turn the IGNITION key to the RUN position and ensure that rear swath lights D and red tail brake lights E are working 15 If the lights are worki...

Page 102: ...emove the key from the ignition 2 Wipe the grease fitting with a clean cloth before greasing to avoid injecting dirt and grit 3 Inject grease through the fitting with a grease gun until the grease overflows the fitting Do NOT overgrease the wheel bearings 4 Leave excess grease on the fitting to keep out dirt 5 Replace any loose or broken fittings immediately 6 Remove and thoroughly clean any fitti...

Page 103: ...to the positive terminal of the battery and the battery ground cable to the negative terminal of the battery Reversed polarity in the battery or alternator may result in permanent damage to the electrical system NOTE Before connecting the electrical harness to the batteries ensure that the positive terminal is positioned on the right side of the battery when the battery is installed on the battery...

Page 104: ...ndrower frame Lift up on the cab end of the cover until it is secured by retaining tab B on the frame 8 Grasp the hood by louver C and lower it until the hood engages the latch IMPORTANT To ensure that the hood is latched make sure that the latch lever is not tilted ASSEMBLING WINDROWER ...

Page 105: ...rom the lift stands before performing pre delivery checks 1 Position a jack under the jack point of each drive wheel leg and under the rear hitch 2 Raise jacks to take the weight off the stands and remove stands 3 Lower windrower slowly to the ground and remove jacks ASSEMBLING WINDROWER ...

Page 106: ......

Page 107: ...ompleting Predelivery Checklist The predelivery checklist contains all the features of the machine that require inspection Perform the final checks and adjustments listed on the following pages and on the Predelivery Checklist page 251 yellow sheet attached to this instruction to ensure that the machine is field ready IMPORTANT Ensure that the Operator or the Dealer retains the completed Predelive...

Page 108: ...ide of the main frame near the walking beam as shown Figure 4 3 Engine Serial Number Location Engine serial number plate A is located on top of the engine cylinder head cover as shown 4 1 2 Checking Engine Air Intake The engine air intake must be clear and all its components properly secured for the engine to work correctly Figure 4 4 Engine Air Intake 1 Check all engine air intake ducting A for l...

Page 109: ... pressure fluids Escaping fluid can penetrate the skin causing serious injury Figure 4 6 Hydraulic Oil Sight Glass 1 Locate sight glass A on the right side of the hydraulic fluid tank NOTE The sight glass allows the operator to visually inspect the oil level and its quality The sight glass can be seen with the hood open or closed 2 Ensure that the hydraulic oil level is between the low and full in...

Page 110: ...at the full indicator mark d Reinstall breather cap A and filler plug B and turn the filler plug handle clockwise until it is secure NOTE After running up a header check the oil level again 4 1 4 Checking Fuel Separator The fuel separator removes water and sediment from the fuel to prevent damage to the engine It will need to be inspected to ensure that it is clean Figure 4 8 Fuel Filter 1 Place a...

Page 111: ...ete Steps 3 page 99 to 5 page 99 NOTE For fluid specifications refer to 6 1 Lubricants Fluids and System Capacities page 237 Figure 4 10 Coolant Recovery Tank Cap and MAX COLD Fill Line 3 To add coolant remove pressurized cap A from the coolant recovery tank 4 Add coolant at a rate not exceeding 11 L min 3 gpm until the recovery tank is half full and the coolant level is at MAX COLD line B 5 Repla...

Page 112: ...nd check the oil level The oil level should be between the LOW L and HIGH H marks on the dipstick If the oil level is below the LOW mark you will need to add oil NOTE Adding 1 9 liters 2 U S quarts of engine oil will raise the level from LOW to HIGH 4 Replace the dipstick and turn it clockwise to lock it If the oil level is too low follow these steps to add oil Figure 4 13 Hood 5 Move latch A towa...

Page 113: ...g Engine Gearbox Lubricant Level and Adding Lubricant M1170 Ensure that the gearbox lubricant level is correct in order to maximize the service life of its components 1 Shut down the engine and remove the key from the ignition NOTE If the engine is hot wait 10 minutes before checking the gearbox lubricant level to allow the lubricant to cool and settle in the gearbox s sump 2 Open the hood Refer t...

Page 114: ... on the type and quantity of gearbox lubricant needed Figure 4 17 Gearbox Lubricant Check Plug 6 Replace oil level check plug A and the breather cap and tighten both 4 1 8 Checking Engine Gearbox Lubricant Level and Adding Lubricant M1240 Ensure that the lubricant level is correct to maximize the service life of the gearbox components Figure 4 18 Gearbox Lubricant Dipstick 1 Remove dipstick A and ...

Page 115: ...ts Fluids and System Capacities page 237 4 1 9 Checking Air Conditioning Compressor Belts The windrower s air conditioner compressor is belt driven The belt must be tensioned correctly for the air conditioning system to function properly Figure 4 20 A C Compressor Belts 1 Ensure that air conditioning A C compressor belts A are tensioned so that a force of 45 N 10 lbf deflects each belt 5 mm 3 16 i...

Page 116: ...ne only from the operator s seat with the controls in PARK NEVER start the engine while standing on the ground NEVER try to start the engine with someone under or near the machine IMPORTANT Do NOT tow the machine to start the engine Damage to the hydrostatic drives will result NOTE When the windrower console receives a wake up signal the console awakens from sleep mode and closes the battery disco...

Page 117: ...ntrols 3 Move GSL A into PARK C 4 Turn the steering wheel until it locks It may be possible to move the steering wheel slightly in the locked position IMPORTANT Do NOT attempt to force the wheel out of the locked position or damage to the steering system may occur 5 Fasten the seat belt 6 Push HEADER ENGAGE switch B to ensure it is in the OFF position PERFORMING PREDELIVERY CHECKS ...

Page 118: ...NITION switch to crank position A NOTE When the engine starts and the header is not engaged the HPT displays header disengaged page B IMPORTANT Do NOT operate the starter for longer than 15 seconds at a time If the engine does not start wait at least 2 minutes before trying again If you crank the engine for more than 30 seconds within a 2 minute period the engine will lock the starter circuit to p...

Page 119: ... ignition before leaving the operator s seat for any reason CAUTION Park on a flat level surface with the header on the ground the ground speed lever GSL in the PARK position and the steering wheel in the locked position centered To confirm that the parking brake is engaged wait for the HPT to beep and display a red P symbol 1 Park the windrower on level ground Figure 4 28 Drive Wheel Hub 2 Positi...

Page 120: ...hat the steering wheel is turned toward 4 Move the GSL backwards into reverse Ensure the wheels are rotating in the reverse direction and at the same speed 5 Move the GSL forward into PARK and shut down the engine 4 1 13 Checking Tire Pressure The tires must be at the correct operating pressure Check the pressure of the windrower tires using a tire pressure gauge Figure 4 30 Windrower Tires Caster...

Page 121: ...ed Base 2 Turf 241 35 D135XL single reel 10 7 m 35 ft double knife untimed Transport 2 Bar 241 35 D135XL single reel 10 7 m 35 ft double knife untimed Transport 2 Turf 241 35 D135XL single reel 10 7 m 35 ft double knife untimed Transport upper cross auger vertical knives 3 Bar 241 35 D135XL single reel 10 7 m 35 ft double knife untimed Transport upper cross auger vertical knives 3 Turf 241 35 D135...

Page 122: ...Turf 241 35 D145XL double reel 13 7 m 45 ft double knife untimed Transport upper cross auger vertical knives 3 Bar 283 41 D145XL double reel 13 7 m 45 ft double knife untimed Transport upper cross auger vertical knives 3 Turf 241 35 Rotary Disc Header M1170 Windrower R113 R116 4 m 13 ft 4 9 m 16 ft No Conditioner Bar or Turf 138 20 R113 R116 4 m 13 ft 4 9 m 16 ft Steel or Poly Roll Bar 179 26 R113...

Page 123: ...e and the HPT should display OPERATOR MUST BE SEATED 3 With the engine running and the seat base unlocked move the ground speed lever GSL out of PARK Confirm that the engine immediately shuts down and that the HPT displays LOCK SEAT BASE and sounds a tone 4 Shut down the engine and press the HEADER ENGAGE switch Try starting the engine to confirm that the HPT displays DISENGAGE HEADER If the engin...

Page 124: ...plays LOCK SEAT BASE If the engine starts the safety system requires adjustment Refer to the windrower s technical manual for the adjustment procedures 4 2 2 Checking Harvest Performance Tracker Display Gauges The Harvest Performance Tracker HPT display shows the windrower s performance gauges Ensure that the gauges appear correctly on the HPT display DANGER To avoid bodily injury or death from un...

Page 125: ...his document either the button on the GSL or the scroll knob on the HPT can be used Figure 4 34 HPT Scroll Knob 1 Turn rotary scroll knob A clockwise to move the selection cursor down the screen to the right of the screen clockwise or to increase a selected setting Push the scroll knob to activate the selected item 2 Turn rotary scroll knob A counterclockwise to move the selection cursor down the ...

Page 126: ...igure 4 37 Language and Units 1 Navigate to the SETTINGS menu with soft key 5 and the Harvest Performance Tracker HPT scroll knob For instructions refer to Navigating the Harvest Performance Tracker page 113 2 Scroll to SCREEN icon A and select it 3 Scroll to LANGUAGE AND UNITS icon B and select it to open the adjustment window 4 Scroll through the available options on the HPT select the desired i...

Page 127: ...vigate to the SETTINGS menu with soft key 5 and the HPT scroll knob For instructions refer to Navigating the Harvest Performance Tracker page 113 2 Scroll to SCREEN option A and select it 3 Scroll to TIME AND DATE option B and select it to open the adjustment window Figure 4 39 Time and Date 4 Scroll through the available options on the HPT display select the desired option and rotate the scroll k...

Page 128: ... Scroll to WINDROWER SETTINGS icon A and select it 3 Scroll to TIRES icon B and select it to display the adjustment window NOTE The F3 shortcut button on the operator s console will also cause the WINDROWER SETTINGS menu to appear Figure 4 41 Tire Selection 4 Scroll to highlight tire sizes A listed under SELECT DRIVE TIRES 5 Press the scroll knob to select the list Figure 4 42 Tire Selection 6 Scr...

Page 129: ...e TIRE SELECTION page by pressing the HOME button NOTE Pressing the BACK or HOME buttons will save the settings to memory Adjusting Header Settings on Harvest Performance Tracker Before operating the header ensure that the Harvest Performance Tracker HPT settings are appropriate for your header Figure 4 45 Header Settings 1 Navigate to the SETTINGS menu using soft key 5 and the HPT scroll knob For...

Page 130: ...rottle to the idle position 3 Check engine speed A on the Harvest Performance Tracker HPT display and compare it to the value in the table below 4 Move the throttle to the maximum rpm position 5 Check engine speed A on the HPT and compare it to the value in the table below NOTE The engine speed mentioned in the table below assumes that the Eco Engine Control EEC feature is not active For more info...

Page 131: ...dicator A will be highlighted This will prevent the SCR process from occurring NOTE If the SCR system is inhibited for an extended period the engine will begin to derate its power levels until manual SCR conditioning is performed Refer to the windrower operator s manual for further details If the SCR conditioning inhibit symbol is highlighted turn SCR inhibit mode off as follows Figure 4 48 HPT Di...

Page 132: ...m over the lights should be removed and all parts of the exterior lighting system should be checked for functionality Figure 4 50 Field Lights 1 For models with LED lighting Remove the plastic film from the LED lighting 2 Rotate the operator s seat to the cab forward position 3 Press FIELD LIGHT switch A 4 Check that front field lights B rear field lights C and rear swath lights D are functioning ...

Page 133: ... lights B and rear red tail brake lights C are functioning 6 Press HIGH LOW switch D and check lights B 7 Press TURN SIGNAL switches E on the console and check amber lights F 8 Press HAZARD LIGHT switch G and check flashing hazard lights F 9 Press the switches to shut off the lights PERFORMING PREDELIVERY CHECKS ...

Page 134: ...ch A and check that front road lights B and rear red tail brake lights C are functioning 12 Press HIGH LOW switch D and check lights B 13 Press TURN SIGNAL switches E on the console and check amber lights F 14 Press HAZARD LIGHT switch G and check flashing hazard lights F 15 Press the switches to shut off the lights PERFORMING PREDELIVERY CHECKS ...

Page 135: ... amber beacons B are functioning 17 Press BEACH switch A to shut off the beacons 4 2 6 Checking Horn The horn is a safety device for notifying other people of the windrower s presence Figure 4 54 Horn Button 1 Push HORN button A and listen for the horn PERFORMING PREDELIVERY CHECKS ...

Page 136: ...ght turns on 5 Push the LIGHT switch to DOOR position C Confirm that the light is off 6 Open the door and check that the light turns on Leave the door open 7 Push switch A to OFF position D Confirm that the light is off 4 2 8 Checking Climate Controls The cab climate system is comprised of the cab air conditioner A C fans vents and the defroster Check all of these features for functionality DANGER...

Page 137: ...TEMPERATURE CONTROL switch B until warm air flows through the cab vents 4 Press BLUE TEMPERATURE CONTROL switch C until cool air enters the cab 5 Press FAN SPEED switch D or and note any change in airflow in the cab The AUTO FAN light should be off 6 Press RECIRCULATING AIR switch E and note any change in airflow in the cab 7 Press WINDSHIELD DEFOG DEFROST switch F and confirm that the windshield ...

Page 138: ... the media is successfully loaded Figure 4 61 Bluetooth Radio 2 To activate the Bluetooth feature a Press POWER button A to turn the radio on b Press and hold VOL SEL knob B for two seconds MENU appears on screen C c Rotate VOL SEL B to highlight BT SET menu and press VOL SEL to select it BLUETOOTH ON OFF C appears d Press VOL SEL to select BLUETOOTH e Rotate the VOL SEL knob so that ON appears an...

Page 139: ...RADIO mode 2 To enter the SERVICE mode press and hold buttons 1 A 3 B and SEL C for 3 seconds each The word SERVICE followed by the current region setting USA or EUR appears 3 Rotate the SEL button C to select the region USA or EUR 4 Presss the SEL button C to save the selection PERFORMING PREDELIVERY CHECKS ...

Page 140: ...ration and maintenance Figure 4 63 Manual Storage Case Manuals are stored in one of the manual storage cases A behind the operator s seat Figure 4 64 Manuals and Quick Card 1 Ensure that the following manuals are included with the windrower Operator s Manual Parts Catalog Quick Card Engine Manual PERFORMING PREDELIVERY CHECKS ...

Page 141: ... Mounting Kit 2 If the optional GPS kit is included locate the GPS mount parts bag with label A inside the cab Install the GPS mount according to the instructions included with the EZ Pilot or Autopilot bundle If you will not be installing the GPS kit store the GPS mount parts bag in the toolbox 3 Remove the Keep This Door Closed sign from the right door AFTER the right leg is repositioned to the ...

Page 142: ......

Page 143: ...fore leaving the operator s seat for any reason Figure 5 1 Header Support 1 Remove hairpin A from pin B and remove the pin from header supports C on both sides of the header WARNING Check to be sure all bystanders have cleared the area 2 Start the engine Figure 5 2 Header Float Springs 3 If you are lowering the header lift legs WITH a header or weight box attached proceed to Step 7 page 132 If you...

Page 144: ...the float Figure 5 5 GSL 7 Press HEADER DOWN switch A on the ground speed lever GSL to fully retract the header lift cylinders 8 If the hydraulic center link self alignment kit is installed press REEL UP switch B on the GSL to raise the center link until the hook is above the attachment pin on the header IMPORTANT Ensure that the center link is positioned high enough that it does not contact the h...

Page 145: ...lignment kit is installed adjust the position of center link cylinder A with the switches on the GSL until hook B is above the header attachment pin 12 If the hydraulic center link self alignment kit is NOT installed push down on the rod end of link cylinder C until the hook engages and locks onto the header pin IMPORTANT Hook release D must be down to enable the self locking mechanism If the rele...

Page 146: ...Safety Prop Lever 18 Engage the safety props on both lift cylinders as follows a Pull lever A toward you to release it and then rotate it toward the header to lower the safety prop onto the cylinder b Repeat the previous step for the opposite lift cylinder IMPORTANT Ensure that the safety props engage over the cylinder piston rods If the safety prop does NOT engage properly raise the header until ...

Page 147: ... Lever 23 Disengage the safety props on both lift cylinders as follows a Turn lever A away from the header to raise the safety prop until the lever locks into the vertical position b Repeat the previous step for the opposite cylinder NOTE If the safety prop will NOT disengage raise the header to release the prop Figure 5 14 GSL WARNING Check to be sure all bystanders have cleared the area 24 Start...

Page 148: ...ght at the cutterbar by approximately 91 kg 200 lb Adjust the float in increments of 0 05 to fine tune the float setting 29 Shut down the engine and remove the key from the ignition 30 Grasp one end of the auger header and lift it The lifting force used should be 357 N 80 lbf at both ends of the auger 5 1 2 Connecting A40DX Auger Electrical and Hydraulics Connecting the A40DX electrical and hydrau...

Page 149: ...s and the latch engages Figure 5 18 Hydraulic Hoses in Storage Position 3 Retrieve hydraulic multicouplers A and electrical harness B from the header 4 Route the hose harness bundle toward the windrower through support C Figure 5 19 Multicoupler 5 Insert hose support B into hole A in the windrower left leg and route header hose bundle C under the windrower to the hydraulic and electrical couplers ...

Page 150: ...n cover G and position multicoupler H onto the receptacle Align the pins in the coupler with the slots in the handle and rotate the handle toward the windrower so that the coupler is locked onto the receptacle and button E snaps out Figure 5 21 Knife Pressure Hose Positions 1 Hose in Storage Position Rotary Configuration 2 Hose to Knife Pressure Receptacle Auger Draper Configuration 11 If you are ...

Page 151: ...ceptacle A and connect the electrical harness from the header Figure 5 23 Left Cab Forward Platform 13 Push latch A to unlock platform B Figure 5 24 Left Cab Forward Platform 14 Pull platform A towards the cab until it stops and the latch is engaged ATTACHING A HEADER TO THE WINDROWER ...

Page 152: ... speed lever GSL to raise the header to maximum height 2 If one end of the header does NOT rise fully rephase the cylinders as follows a Press and hold HEADER UP A switch until both cylinders stop moving b Continue to hold the switch for 3 4 seconds The cylinders are now phased 3 Shut down the engine and remove the key from the ignition Figure 5 26 Safety Prop Lever 4 Engage the safety props on bo...

Page 153: ... with the hairpin WARNING Check to be sure all bystanders have cleared the area Figure 5 29 Safety Prop Lever 7 Disengage the safety props on both lift cylinders as follows a Turn lever A away from the header to raise the safety prop until the lever locks into the vertical position b Repeat the previous step for the opposite cylinder NOTE If the safety prop will NOT disengage raise the header to r...

Page 154: ...hook B off header pin NOTE If the optional center link self alignment kit is installed lift release A and then operate the link lift cylinder with the REEL UP switch on the GSL to disengage the center link from the header Figure 5 32 Left Cab Forward Platform 13 Approach platform A on the left cab forward side of the windrower and ensure the cab door is closed 14 Push latch B and pull platform A t...

Page 155: ...ve hydraulics A and electrical harness B from the windrower Figure 5 34 Left Cab Forward Platform 16 Push latch A to unlock platform B Figure 5 35 Left Cab Forward Platform 17 Pull platform A towards the cab until it stops and the latch is engaged ATTACHING A HEADER TO THE WINDROWER ...

Page 156: ...ydraulics electrical bundle A in the storage position on the header 19 Back the windrower slowly away from the header Figure 5 37 Header Support 20 Reinstall clevis pin B into header support C and secure with hairpin A Repeat for the opposite side ATTACHING A HEADER TO THE WINDROWER ...

Page 157: ... before leaving the operator s seat for any reason If not installed attach the draper header support supplied with the header to the windrower lift linkage as follows 1 Shut down the engine and remove the key from the ignition Figure 5 38 Draper Header Support 2 Remove the hairpin from clevis pin B on draper header support A Remove clevis pin B Figure 5 39 Draper Header Support 3 Position draper h...

Page 158: ...tor s seat for any reason NOTE Draper header supports must be installed onto the windrower lift linkage before starting this procedure For instructions refer to 5 2 1 Attaching Draper Header Supports page 145 1 Shut down the engine and remove the key from the ignition Figure 5 40 Forming Shield bracket R85 Figure 5 41 Forming Shield bracket R2 Series 2 If an R85 or R2 Series Rotary Disc Header is ...

Page 159: ... this step on the opposite header leg DANGER Ensure that all bystanders have cleared the area 5 Start the engine Figure 5 44 Header Float Springs 6 If you are lowering the header lift legs WITH a header or weight box attached to the windrower proceed to Step 10 page 148 If you are lowering the header lift legs WITHOUT a header or weight box attached to the windrower fully release the tension in he...

Page 160: ...it Figure 5 46 HPT Display 9 On the FLOAT ADJUST page press soft key 3 A to remove the float Figure 5 47 GSL Switches A Reel Down B Reel Up C Header Tilt Down D Header Tilt Up E Header Down F Header Up 10 Windrowers equipped with the self aligning center link kit a Press HEADER DOWN switch E on the ground speed lever GSL to fully retract the header lift cylinders b Press REEL UP switch B on the GS...

Page 161: ...ove the key from the ignition Manually push hook release C down after the hook engages the header pin c Lower center link A onto the header with the REEL DOWN switch on the GSL until the center link locks into position and hook release C is down d Check that the center link is locked onto the header by pressing the REEL UP switch on the GSL Figure 5 50 Hydraulic Center Link 14 Windrowers without t...

Page 162: ...er 17 Engage the safety props on both lift cylinders as follows a Pull lever A toward you to release it and then rotate it toward the header to lower the safety prop onto the cylinder b Repeat the previous step for the opposite lift cylinder IMPORTANT Ensure that the safety props engage over the cylinder piston rods If the safety prop does NOT engage properly raise the header until the safety prop...

Page 163: ...der NOTE If the safety prop will NOT disengage raise the header to release the prop Figure 5 55 GSL DANGER Ensure that all bystanders have cleared the area 21 Start the engine and press HEADER DOWN switch A on the GSL to fully lower the header Figure 5 56 HPT Display 22 Press rotary scroll knob A on the HPT to highlight the QuickMenu options 23 Rotate scroll knob A to highlight HEADER FLOAT symbol...

Page 164: ...th ends 28 Proceed to 5 2 3 Connecting D1X or D1XL Series Draper Header Hydraulics page 152 5 2 3 Connecting D1X or D1XL Series Draper Header Hydraulics Connecting the header s hydraulics to the windrower is a simple procedure thanks to the hydraulic hose management system There is an additional step to perform if you are switching from using a rotary header to using a draper header IMPORTANT To p...

Page 165: ...acle and pull handle C fully away from the windrower 8 Open cover D and position the coupler onto the receptacle Align the pins in the coupler with the slots in handle C and push the handle toward the windrower so that the coupler locks onto the receptacle and knob B pops out 9 Remove hose quick disconnect F from the storage location and connect it to the receptacle on the frame NOTE Hose quick di...

Page 166: ... the receptacle Align the pins in the coupler with the slots in handle C and push the handle toward the windrower so that the coupler locks onto the receptacle and knob B snaps out Figure 5 63 Hydraulic Multicouplers and Hose Routing 14 Ensure that the hydraulic hose routing is as straight as possible IMPORTANT Straight routing will prevent abrasion damage to the hydraulic hoses Figure 5 64 Left C...

Page 167: ...e always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Lower the header fully 2 Shut down the engine and remove the key from the ignition Figure 5 66 Left Cab Forward Platform 3 Approach platform A on the left cab forward side of the windrower and ensure the cab door is closed 4 Push latch B and pull platform A toward the walking beam unti...

Page 168: ...ve any debris that may have accumulated on the receptacle Close cover E Figure 5 68 Draper Reel Multicoupler 8 Push lock button B and pull handle C to disengage multicoupler A Disconnect the hydraulics from the windrower draper drive reel lift receptacle 9 Disconnect electrical connector E 10 Remove any debris that may have accumulated on the windrower front receptacle and close cover D Figure 5 6...

Page 169: ...m 14 Pull platform A towards the cab until it stops and the latch is engaged Figure 5 72 Hydraulic Hose Management System 15 Disconnect hose management system A from windrower by pulling latch lever B to open the latch Keep latch open and move hose management system A away from header with handle C ATTACHING A HEADER TO THE WINDROWER ...

Page 170: ...er Figure 5 74 Header Stand 17 Remove the header leg pin B by removing the hairpin A from header leg on both sides 18 Lower header stand D by pulling spring loaded pin C Release spring pin to lock stand Figure 5 75 Center Link 19 Windrowers with self aligning center link Release center link latch A before returning to the cab ATTACHING A HEADER TO THE WINDROWER ...

Page 171: ...ows a Turn lever A away from the header to raise the safety prop until the lever locks into the vertical position b Repeat the previous step for the opposite cylinder NOTE If the safety prop will NOT disengage raise the header to release the prop 21 Repeat for the opposite side ATTACHING A HEADER TO THE WINDROWER ...

Page 172: ...6 Windrowers with self aligning center link a Press REEL UP switch C to disengage center link from header b Proceed to Step 28 page 160 Figure 5 78 Hydraulic Center Link 27 Windrowers without self aligning center link a Shut off the engine and remove the key b Disconnect center link by lifting release B and lift hook A off header DANGER Ensure that all bystanders have cleared the area c Start the ...

Page 173: ...itching to an R85 or R2 Series Rotary Disc Header retrieve the forming shield support brackets A from the toolbox and attach the brackets as follows a install support bracket A b Install hardware B to secure the support to the windrower leg c Repeat on the opposite windrower leg ATTACHING A HEADER TO THE WINDROWER ...

Page 174: ...pin from header support C on both sides of the header IMPORTANT Remove the protective cover from the exhaust stack prior to starting the engine DANGER Ensure that all bystanders have cleared the area 2 Start the engine Figure 5 83 Header Float Springs 3 If you are lowering the header lift legs WITH a header or weight box attached to the windrower proceed to Step 7 page 163 If you are lowering the ...

Page 175: ...oft key 3 will say REMOVE FLOAT if the header float has been removed then the icon will say RESUME FLOAT Figure 5 86 GSL A Reel Down B Reel Up C Header Tilt Down D Header Tilt Up E Header Down F Header Up 7 Press HEADER DOWN switch E on the ground speed lever GSL to fully retract the header lift cylinders 8 Press REEL UP switch B on the GSL to raise the center link until the hook is above the atta...

Page 176: ... header with the REEL DOWN switch on GSL until it locks into position When this happens hook release C will be in the down position Refer to Figure 5 86 page 163 for an illustration of the GSL controls 13 Ensure that the center link is locked onto the header by pressing the REEL UP switch on the GSL Refer to Figure 5 86 page 163 for an illustration of the GSL controls DANGER Ensure that all bystan...

Page 177: ...d Figure 5 91 Header Support 19 Install clevis pin A through the support and foot and secure it with hairpin B Repeat this step to install the clevis pin on the opposite side of the header IMPORTANT Ensure that clevis pin A is fully inserted and that the hairpin is installed behind the bracket Figure 5 92 Safety Prop Lever 20 Disengage the safety props on both lift cylinders as follows a Turn leve...

Page 178: ...ess the knob when you are finished NOTE Float adjustments of 1 0 out of 10 change the header weight at the cutterbar by approximately 91 kg 200 lb Adjust the float in increments of 0 05 for best performance 26 Shut down the engine and remove the key from the ignition 27 Grasp one end of the rotary header and lift The lifting force should be 448 N 100 lbf and should be the same at both ends 5 3 2 C...

Page 179: ...e underside of the windrower frame IMPORTANT Route the hoses as straight as possible To prevent damage to hoses from abrasion ensure that the hoses are not in contact with rub or wear points 4 Insert pin B into hole C in the windrower frame Place hose bundle on support D Figure 5 98 Knife Drive Hose on Rotary Disc and Draper Ready Windrower 5 Windrowers configured for both rotary disc and draper h...

Page 180: ... G NOTE Ensure that the hydraulic hoses have sufficient slack to clear the multicoupler without coming into contact with it If necessary increase the slack in the hoses by loosening the hose holder at the windrower frame and moving the hoses as required Figure 5 100 Hard Plumbed Hydraulic and Electrical Connections on a Rotary Disc Ready Windrower 7 Windrowers equipped with hard plumbed fittings N...

Page 181: ...ER To prevent bodily injury or death from the unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason Figure 5 103 Ground Speed Lever DANGER Ensure that all bystanders have cleared the area 1 Start the engine and press header raise switch A to raise the header to the maximum height 2 Shut down the engine and re...

Page 182: ...roperly raise the header until the safety prop fits over the rod 4 Open the platform For instructions refer to Figure 5 105 Header Drive Hydraulics 5 Disconnect the following electrical harness and hydraulic hoses from the windrower a Disconnect the disc pressure hose from fitting A b Disconnect the disc return hose from fitting B c Disconnect the case drain hose from fitting C d Disconnect the el...

Page 183: ...rop will NOT disengage raise the header to release the prop DANGER Ensure that all bystanders have cleared the area 9 Start engine and remove header float when prompted by the Harvest Performance Tracker HPT NOTE If not prompted by the HPT to remove float remove float manually 10 Lower the header to the ground Figure 5 109 GSL 11 For windrowers with self aligning center link Use HEADER TILT cylind...

Page 184: ...the key 14 Lift hook release B and lift hook A off header pin DANGER Ensure that all bystanders have cleared the area 15 Start the engine Figure 5 111 Header Support 16 Slowly back the windrower away from header 17 Reinstall clevis pin A through support C and secure with hairpin B Repeat for opposite side ATTACHING A HEADER TO THE WINDROWER ...

Page 185: ...e engine and remove the key from the ignition before leaving the operator s seat for any reason DANGER Ensure that all bystanders have cleared the area 1 Shut down the engine and remove the key from the ignition Figure 5 112 Hydraulic Center Link 2 Windrowers without the self aligning center link kit Remove pin A and raise center link B until the hook is above the attachment pin on the header Repl...

Page 186: ...e float manually IMPORTANT When lowering the header lift legs without a header or weight box attached to the windrower ensure that the tension on the float springs is fully released This will prevent damage to the header lift linkages Figure 5 115 HPT Display 6 Press rotary scroll knob A on the Harvest Performance Tracker HPT to highlight the QuickMenu options 7 Rotate scroll knob A to highlight H...

Page 187: ... the feet engage the supports and the header is nudged forward 12 Ensure that feet A are properly engaged in supports B Figure 5 119 Hydraulic Center Link 13 Windrowers equipped with the self aligning center link kit a Adjust the position of center link cylinder A with the switches on the GSL until hook B is above the header attachment pin IMPORTANT Hook release C must be down to enable the self l...

Page 188: ...ing mechanism to function If the hook release is open in the up position manually push it down after the hook engages the pin d Check that center link A is locked onto the header by pulling upward on rod end B of the cylinder DANGER Ensure that all bystanders have cleared the area e Start the engine Figure 5 121 GSL 15 Press HEADER UP switch A to raise the header to its maximum height NOTE If one ...

Page 189: ... Figure 5 123 Header Support 18 Install clevis pin A through the support and windrower lift arm and secure it with hairpin B Repeat this step for the opposite side of the header IMPORTANT Ensure that clevis pin A is inserted as far as possible and that the hairpin is installed behind the bracket Figure 5 124 Safety Prop Lever 19 Disengage the safety props on both lift cylinders as follows a Turn l...

Page 190: ...y scroll knob A on the Harvest Performance Tracker HPT to highlight the QuickMenu options b Rotate scroll knob A to highlight Header Float icon B and press the scroll knob to select it The float setting page appears Figure 5 127 HPT Display 23 Press soft key 3 A to restore the header float NOTE If the header float is active the icon at soft key 3 displays Remove Float if the header float has been ...

Page 191: ... and electrical connectors to the windrower s receptacles IMPORTANT To prevent contamination of the hydraulic system use a clean rag to remove dirt and moisture from all hydraulic couplers 1 Retrieve the hydraulic hoses from the header Figure 5 128 Left Cab Forward Platform 2 Push latch A to unlock platform B Figure 5 129 Left Cab Forward Platform 3 Pull platform A towards the cab until it stops a...

Page 192: ...le and avoid rub wear points that could cause damage Figure 5 131 Knife Pressure Hose Positions 1 Knife Pressure Hose in Storage Position Rotary Configuration 2 Hose to Knife Pressure Receptacle Auger Draper Configuration 5 If you are switching from an auger draper header to a rotary header Disconnect hose A from knife pressure receptacle C on the frame and move it to storage location B ATTACHING ...

Page 193: ... against the multicoupler and becoming damaged You can increase slack in the hoses by loosening and adjusting the hose holder on the front windrower leg and pulling the hoses backward toward the windrower Figure 5 133 Left Cab Forward Platform 7 Push latch A to unlock platform B Figure 5 134 Left Cab Forward Platform 8 Pull platform A towards the cab until it stops and the latch is engaged 9 If ne...

Page 194: ...ided included with the kit The procedure for connecting the R113 s hydraulic connections to the windrower depends on the windrower s configuration Auger rotary disc draper header ready windrowers are equipped with a set of hydraulic quick couplers which are compatible with the header drive hoses on the rotary disc header Rotary disc header ready windrowers are equipped with hard plumbed hydraulic ...

Page 195: ...e multicoupler bracket without contacting it To adjust the slack in the hose loosen the clamps below pin B adjust the hoses then retighten the hose holder Figure 5 137 Header Hydraulics Configurations Auger Rotary Disc Draper Ready Proceed with the steps that are relevant to your windrower configuration Auger rotary disc draper ready configuration A For instructions refer to Auger Rotary Disc Drap...

Page 196: ...ic connections needed to pair with an auger rotary disc or a draper header Figure 5 140 Couplers Auger Rotary Draper Header Ready Configuration with Case Drain Kit Installed 1 Ensure that hose A is disconnected from windrower receptacle B and placed in storage cup C on the multicoupler Figure 5 141 Hydraulic Quick Couplers 2 Remove the extra hydraulic quick couplers from pressure hose A and return...

Page 197: ...Pressure Case Drain kit MD B6698 has been installed IMPORTANT Do NOT connect the case drain coupler to other 1 2 in flat faced coupler E d Connect the electrical harness to receptacle D Figure 5 143 Left Cab Forward Platform 4 Push latch A to unlock platform B Figure 5 144 Left Cab Forward Platform 5 Pull platform A towards the cab until it stops and the latch is engaged 6 If necessary calibrate b...

Page 198: ...Rotary Disc Header Hose Bundle 1 Remove the existing quick couplers and elbow fittings if they are installed from header hydraulic pressure hose A and return hose B Do NOT remove the fittings from case drain hose C Figure 5 146 Hard Plumbed Connections on Disc Header Ready Windrower with Case Drain Kit 2 Connect the hydraulic hoses to the windrower as follows a Connect rotary disc pressure hose A ...

Page 199: ...d header position sensors whenever you are Attaching the header to the windrower for the first time Changing the speed sensor or hydraulic drive motor on the header Changing the header drive pump associated with the knife drive Harvest Performance Tracker HPT or the master controller on the windrower For instructions refer to 5 7 1 Calibrating Knife Drive on Harvest Performance Tracker Display pag...

Page 200: ...9 Hard Plumbed Connections Rotary Disc Ready Windrower 1 Remove extension fittings and elbows A from the rotary disc header s hydraulic pressure and return connections Figure 5 150 Hydraulic Quick Couplers 2 Remove and retain the extra hydraulic quick couplers from pressure hose A and return hose B Figure 5 151 Quick Couplers on Rotary Disc Ready Windrower 3 Install the male quick coupler at windr...

Page 201: ...e that the case drain hose is connected to port C NOT port E d Connect the header s electrical harness to receptacle D Figure 5 153 Left Cab Forward Platform 6 Push latch A to unlock platform B Figure 5 154 Left Cab Forward Platform 7 Pull platform A towards the cab until it stops and the latch is engaged 8 If necessary calibrate both the knife drive and header position sensors on the windrower Ca...

Page 202: ...xpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason DANGER Ensure that all bystanders have cleared the area Figure 5 155 GSL 1 Start the engine 2 Press switch A to raise the header to its maximum height 3 Shut down the engine and remove the key from the ignition Figure 5 156 Safety Prop Lever 4 Engage the safe...

Page 203: ... B and pull platform A toward the walking beam until it stops and the latch engages Figure 5 158 Header Drive Hydraulics M1240 Connection Locations Low Pressure Case Drain Kit MD 6698 Installed Figure 5 159 Header Drive Hydraulics M1170 Connection Locations 7 Disconnect electrical harness D and hydraulic hoses A B and C from the windrower ATTACHING A HEADER TO THE WINDROWER ...

Page 204: ... A to unlock platform B Figure 5 161 Left Cab Forward Platform 9 Pull platform A towards the cab until it stops and the latch is engaged Figure 5 162 Hoses on Windrower 10 Remove hose support A and the hose bundle from the windrower frame ATTACHING A HEADER TO THE WINDROWER ...

Page 205: ...ydraulic Storage Plate 12 Store hoses A and electrical harness B disconnected from the windrower into storage plate C NOTE Install caps and plugs on open lines to prevent the buildup of dirt and debris while the header is in storage NOTE Some parts have been removed from the illustration for the sake of clarity ATTACHING A HEADER TO THE WINDROWER ...

Page 206: ...ver A away from the header to raise the safety prop until the lever locks into the vertical position b Repeat the previous step for the opposite cylinder NOTE If the safety prop will NOT disengage raise the header to release the prop 16 Repeat for the opposite side DANGER Ensure that all bystanders have cleared the area 17 Start the engine 18 Remove the header float when prompted by the Harvest Pe...

Page 207: ...nd remove the key from the ignition Figure 5 169 Hydraulic Center Link 23 Windrowers WITHOUT center link self alignment kit Lift hook release A and lift hook B off of the header pin DANGER Ensure that all bystanders have cleared the area 24 Windrowers WITHOUT center link self alignment kit Start the engine Figure 5 170 Header Support 25 Back the windrower slowly away from the header 26 Shut down t...

Page 208: ...o straight pin C at the rear of the windrower leg Secure it with washer B and lynch pin A 3 Repeat Step 1 page 196 to Step 2 page 196 at the opposite side of the forming shield 5 5 2 Attaching R2 Series Rotary Disc Header The windrower may have an optional self aligning hydraulic center link which allows control over the vertical position of the center link from the cab If the windrower is so equi...

Page 209: ...ve the key from the ignition Figure 5 174 Hydraulic Center Link 2 Windrowers equipped with a hydraulic center link without self alignment Remove pin A and raise center link B until the hook is above the attachment pin on the header Replace pin A to hold the center link in place IMPORTANT Ensure that the center link is positioned high enough that it does not contact the header as the windrower appr...

Page 210: ...ed to Step 11 page 199 If you are lowering the header lift legs WITHOUT a header or weight box attached to the windrower fully release the tension in header float springs A If prompted by the Harvest Performance Tracker HPT to remove the float then remove the float and proceed to Step 11 page 199 If not prompted by the HPT to remove the float then proceed to Step 8 page 198 to remove the float man...

Page 211: ...header lift cylinders 12 Windrowers equipped with a self aligning hydraulic center link Press REEL UP switch B on the GSL to raise the center link until the hook is above the attachment pin on the header IMPORTANT Ensure that the center link is positioned high enough that it does not contact the header as the windrower approaches the header Figure 5 181 Header Support 13 Drive the windrower slowly...

Page 212: ...ed onto the header by pressing the REEL UP switch on the GSL Figure 5 183 Hydraulic Center Link 16 Windrowers without the self aligning center link kit a Press the HEADER TILT UP or HEADER TILT DOWN cylinder switches on the GSL to extend or retract the center link cylinder until the hook is aligned with the header attachment pin b Shut down the engine and remove the key from the ignition c Push do...

Page 213: ...as follows a Pull lever A toward you to release it and then rotate it toward the header to lower the safety prop onto the cylinder b Repeat the previous step for the opposite lift cylinder IMPORTANT Ensure that the safety props engage over the cylinder piston rods If the safety prop does NOT engage properly raise the header until the safety prop fits over the rod Figure 5 186 Header Support 20 Ins...

Page 214: ...op Figure 5 188 GSL 22 Start the engine and press HEADER DOWN switch A on the GSL to fully lower the header 23 Shut down the engine and remove the key from the ignition Figure 5 189 HPT Display 24 If you are not prompted by the HPT display to restore the header float restore the header float manually by doing the following a Press rotary scroll knob A on the Harvest Performance Tracker HPT to high...

Page 215: ...necting the R2 series header s hydraulic and electrical systems to the windrower involves attaching the header s knife drive pressure return case drain and electrical connectors to the windrower s receptacles IMPORTANT To prevent contamination of the hydraulic system use a clean rag to remove dirt and moisture from all hydraulic couplers Figure 5 191 Left Cab Forward Platform 1 Approach platform A...

Page 216: ...ses To prevent abrasion damage the hoses should have enough slack to pass by the multicoupler bracket without contacting it To adjust the slack in the hoses loosen the clamps below pin B adjust the hoses then retighten the hose holder Figure 5 193 Knife Pressure Hose Positions 1 Knife Pressure Hose in Storage Position Rotary Configuration 2 Hose to Knife Pressure Receptacle Auger Draper Configurat...

Page 217: ...o connect a grass seed header Connect the four additional hydraulic hoses supplied with the grass seed version of the header as follows a Connect hose green cable tie with female quick coupler A to coupler B on the windrower frame b Connect hose yellow cable tie with male quick coupler C to coupler D on the windrower frame c Remove the cap not shown from inboard bulkhead fitting E Connect hose F r...

Page 218: ...ter harness B 10 If you are connecting the standard configuration R2 header equipped with the optional electric baffle control kit Connect electric baffle control harness C to adapter harness D 11 If you are connecting an R2 header configured for grass seed harvesting Connect actuator harness C to adapter harness D Figure 5 198 Left Cab Forward Platform 12 Push latch A to unlock platform B ATTACHI...

Page 219: ...needed 19 Tighten all the cables along the harness 20 If necessary calibrate both the knife drive and header position sensors on the windrower Calibrate both the knife drive and header position sensors whenever you are Attaching the header to the windrower for the first time Changing the speed sensor or hydraulic drive motor on the header Changing the header drive pump associated with the knife dr...

Page 220: ...platform A toward the walking beam until it stops and the latch engages Figure 5 202 Header Hydraulics Configurations Auger Rotary Disc Draper Ready Proceed with the steps relevant to your windrower configuration Auger rotary disc draper ready configuration A For instructions refer to Auger Rotary Disc Draper Ready Configuration Quick Coupler Connections page 209 Figure 5 203 Header Hydraulics Con...

Page 221: ... system use a clean rag to remove dirt and moisture from all fixed and movable hydraulic couplers Figure 5 205 Hose Support Attachment 1 Retrieve hydraulic hoses A from the header and route the hose bundle under the windrower frame NOTE Adding anti seize compound to the hose holder pin will make future removal easier 2 Insert pin B into hole C in the windrower frame IMPORTANT Route the hydraulic h...

Page 222: ...gure 5 207 Header Hydraulic Fittings 4 Connect the hydraulic fittings to the hydraulic hoses as follows NOTE The two quick couplers and two elbow fittings are supplied in the Quick Coupler kit MD B6277 a Attach 90 elbow fitting A and 1 in female coupler fitting B to disc pressure hose C b Attach 90 elbow fitting A and 1 in male coupler fitting D to disc return hose E ATTACHING A HEADER TO THE WIND...

Page 223: ...nal four hoses supplied with the grass seed version of the header as follows a Connect the hose with the green cable tie with female quick coupler A to coupler B on the windrower frame b Connect the hose with the yellow cable tie with male quick coupler C to coupler D on the windrower frame c Remove the cap not shown from inboard bulkhead fitting E Connect hose F red cable tie to inboard bulkhead ...

Page 224: ...ter harness B 9 If you are connecting the standard configuration R2 header equipped with the optional electric baffle control kit Connect electric baffle control harness C to adapter harness D 10 If you are connecting an R2 header configured for grass seed harvesting Connect actuator harness C to adapter harness D Figure 5 212 Left Cab Forward Platform 11 Push latch A to unlock platform B ATTACHIN...

Page 225: ...sensors whenever you are Attaching the header to the windrower for the first time Changing the speed sensor or hydraulic drive motor on the header Changing the header drive pump associated with the knife drive Harvest Performance Tracker HPT or the master controller on the windrower For instructions refer to 5 7 1 Calibrating Knife Drive on Harvest Performance Tracker Display page 230 and 5 7 2 Ca...

Page 226: ...nough slack to pass by the multicoupler bracket without contacting it To adjust the slack in the hoses loosen the clamps below pin B adjust the hoses then retighten the hose holder Figure 5 216 Hard Plumbed Connections on R216 Rotary Disc Header Ready Windrower 3 Connect the hydraulic hoses to the windrower as follows a Connect disc pressure hose A fitted with red cable tie B to hard plumb fitting...

Page 227: ...ss seed module s drum on the right side of the header b Remove the plug not shown from drive manifold port CP2 Install 45 fitting B in port CP2 Connect hose D red cable tie to fitting B NOTE The other end of hose D connects to the grass seed module s drum on the left side of the header c Connect hose green cable tie with female quick coupler E to coupler F as shown d Connect hose yellow cable tie ...

Page 228: ...c baffle control kit Connect electric baffle control harness C to adapter harness D 8 If you are connecting an R2 header configured for grass seed harvesting Connect actuator harness C to adapter harness D Figure 5 220 Left Cab Forward Platform 9 Push latch A to unlock platform B Figure 5 221 Left Cab Forward Platform 10 Pull platform A towards the cab until it stops and the latch is engaged ATTAC...

Page 229: ...e 230 and 5 7 2 Calibrating Header Position Sensors on Harvest Performance Tracker Display page 233 Rotary Disc Only Configuration Quick Coupler Connections The rotary disc configuration allows the windrower to operate with compatible rotary disc headers Attaching the header s hydraulic connections to the windrower s ports using quick couplers does not require any additional tools or hardware IMPO...

Page 230: ...o disc return hose E Figure 5 225 Hydraulics and Electrical Rotary Disc Configuration with Quick Couplers Installed 4 Connect the header s hydraulic hoses to the windrower as follows a Connect disc pressure hose A with coupler B as shown b Connect disc return hose C with coupler D as shown c Connect case drain hose E to fitting F ensuring that the connection is oriented so that the relief valve po...

Page 231: ... grass seed module s drum on the right side of the header b Remove the plug not shown from drive manifold port CP2 Install 45 fitting B in port CP2 Connect hose D red cable tie to fitting B NOTE The other end of hose D connects to the grass seed module s drum on the left side of the header c Connect the hose green cable tie with female quick coupler E to coupler F on the windrower d Connect the ho...

Page 232: ... sensors whenever you are Attaching the header to the windrower for the first time Changing the speed sensor or hydraulic drive motor on the header Changing the header drive pump associated with the knife drive Harvest Performance Tracker HPT or the master controller on the windrower For instructions refer to 5 7 1 Calibrating Knife Drive on Harvest Performance Tracker Display page 230 and 5 7 2 C...

Page 233: ...emove the key from the ignition Figure 5 231 Left Cab Forward Platform 3 Approach platform A on the left cab forward side of the windrower and ensure the cab door is closed 4 Push latch B and pull platform A toward the walking beam until it stops and the latch engages Figure 5 232 Header Drive Hydraulics All M1 Configurations using Quick Couplers 5 Disconnect hydraulic hoses A B and C from the win...

Page 234: ...ics M1240 Rotary Disc Configuration with Hard Plumbed Fittings Figure 5 234 Grass Seed Hydraulic Connections M1240 Draper Disc ReadyM1170 Draper Auger Ready 6 Grass seed header Disconnect additional four hoses A B C and D ATTACHING A HEADER TO THE WINDROWER ...

Page 235: ...20 223 Revision A Figure 5 235 Grass Seed Hydraulic Connections M1240 Rotary Disc Configuration Figure 5 236 Left Cab Forward Platform 7 Push latch A to unlock platform B ATTACHING A HEADER TO THE WINDROWER ...

Page 236: ...the cab until it stops and the latch is engaged Figure 5 238 Header Hoses on Windrower 9 Remove hose support A and hose bundle from windrower frame Figure 5 239 Hose Bundle Storage Position 10 Rest hydraulic hose bundle A on header for storage as shown ATTACHING A HEADER TO THE WINDROWER ...

Page 237: ...kit Disconnect electric baffle control harness C from adapter harness D 13 Grass seed Disconnect actuator harness C from adapter harness D Figure 5 241 Adapter Harness 14 Secure adapter harness A on the center link with an adjustable strap B Figure 5 242 Header Supports 15 Remove hairpin B from clevis pin A Remove clevis pin from header support C on both sides of header ATTACHING A HEADER TO THE W...

Page 238: ...r float when prompted by the Harvest Performance Tracker HPT NOTE If not prompted by the HPT to remove float remove float manually Figure 5 244 GSL 19 Use HEADER TILT cylinder switches A on GSL to release load on center link cylinder 20 Windrowers WITH center link self alignment kit Operate the link lift cylinder with REEL UP switch B to disengage the center link from the header Proceed to Step 24...

Page 239: ...the engine and remove the key from the ignition 26 Reinstall clevis pin A through support C and secure with hairpin B Repeat for the opposite side of the header Figure 5 247 Shield Mount Plates on Forming Shield IMPORTANT When detaching an R216 SP Rotary Disc Header from an M1 Series Windrower that will be configured for a D1X Series Draper Header ensure the two shield mount plates A MD 307045 are...

Page 240: ...om straight pin C 2 Pull rubber strap D away from straight pin C 3 Lower rear end of forming shield 4 Reinstall washer B and hairpin A on straight pin C for storage 5 Repeat Step 1 page 228 to Step 4 page 228 at the opposite side 6 Reattach clevis pin and lynch pin to the forming shield for storage 7 Remove the forming shield ATTACHING A HEADER TO THE WINDROWER ...

Page 241: ...roll knob For instructions refer to Navigating the Harvest Performance Tracker page 113 2 Scroll to SET UP HEADER option A and press the scroll knob to select it NOTE The settings displayed will vary depending on the type of header attached to the windrower 3 Scroll to highlight the appropriate option and press the scroll knob to select it For example if a draper header is attached and ATTACHMENTS...

Page 242: ... Drive on Harvest Performance Tracker Display When a header is attached to a windrower the Harvest Performance Tracker HPT will recognize the header ID and configure the windrower accordingly The header must be calibrated to ensure that the knife drive pump output is accurate DANGER Never start or move the machine until you are sure that all bystanders have cleared the area 1 Start the engine Figu...

Page 243: ...hortcut button on the operator s console will also open the WINDROWER SETTINGS menu Figure 5 252 Calibration Selection Screen 7 In the Calibration Selection screen scroll to KNIFE DRIVE A and press SELECT 8 Engage the header Figure 5 253 Engage Header Warning NOTE If calibration is selected while the header is disengaged WARNING A will appear Engage the header PLAY icon B appears after you engage ...

Page 244: ...press PLAY icon A on the screen to continue with Stage 2 of the calibration process NOTE Knife drive calibration consists of nine stages Figure 5 256 Calibration Page 12 Press the PLAY icon to begin the calibration process NOTE During the calibration procedure the windrower s computer will vary the engine rpm and header speed NOTE Press X icon A on the screen or use the HEADER DISENGAGE switch at ...

Page 245: ...ectors for an intermittent connection Replace the sensor 5 7 2 Calibrating Header Position Sensors on Harvest Performance Tracker Display The header position sensors need to be recalibrated whenever the Harvest Performance Tracker HPT is replaced a position sensor is replaced sensor readouts are erratic a pump has been replaced or when a new header type or attachment is connected to the windrower ...

Page 246: ...n scroll to POSITION SENSORS A and press SELECT Figure 5 261 Calibration Screen NOTE Pressing X icon A on the screen or pressing the HOME BACK or any GSL button buttons not shown at any time during the calibration process will EXIT the calibration procedure without saving your progress The engine speed will also return to the original rpm prior to starting the calibration process NOTE If a sensor ...

Page 247: ...OAT setting or press HOME or BACK button not shown to exit NOTE The engine speed returns to the speed prior to calibration when stage two calibration is complete Figure 5 264 Sample of Failed Calibration Display Message NOTE If the voltage of any sensor falls below its acceptable range during calibration a message appears after completing the calibration with a list of sensors reporting out of ran...

Page 248: ......

Page 249: ...ion 518 liters 137 U S gallons Hydraulic oil Hydraulic reservoir Single grade transmission hydraulic fluid THF Recommend Viscosity 60 1 cSt 40 C 9 5 cSt 100 C 60 liters 15 8 U S gallons 2 Gear lubricant Gearbox SAE 75W 140 or 80W 140 API service class GL 5 fully synthetic gear lubricant SAE J2360 preferred 2 3 liters 2 4 U S quarts Gear lubricant Standard wheel drive SAE 75W 140 or 80W 140 API ser...

Page 250: ...inder cavitation protection according to a fleet study run at or above 60 load capacity Protects the cooling system metals cast iron aluminum alloys and copper alloys such as brass from corrosion Coolant MUST be nitrite free and MUST be free of 2 Ethylhexanoic 2 EH acid NOTE M1 Series windrowers have Peak Final Charge Global coolant installed at the factory The additive package must be part of one...

Page 251: ... mix6 n a 1 maximum 0 5 maximum preferred 0 1 maximum 45 55 113 130 cold weather high altitude 460 Microns In extreme situations when available fuels are of poor quality or problems exist which are particular to certain operations additives can be used however the engine manufacturer recommends consultation with the fuel supplier or engine manufacturer before using fuel additives Situations where ...

Page 252: ... applied to regular nuts by 0 65 to obtain the modified torque value Self tapping screws Use the standard torque values when installing self tapping screws Do NOT install self tapping screws on structural or otherwise critical joints 6 3 1 Metric Bolt Specifications The torque values provided in the following metric bolt torque tables apply to hardware installed dry that is hardware with no grease...

Page 253: ...5 65 72 48 53 14 2 0 104 115 77 85 16 2 0 161 178 119 132 20 2 5 314 347 233 257 24 3 0 543 600 402 444 Figure 6 3 Bolt Grades Table 6 5 Metric Class 10 9 Bolts and Class 10 Free Spinning Nut Nominal Size A Torque Nm Torque lbf ft lbf in Min Max Min Max 3 0 5 1 8 2 18 19 3 5 0 6 2 8 3 1 27 30 4 0 7 4 2 4 6 41 45 5 0 8 8 4 9 3 82 91 6 1 0 14 3 15 8 140 154 8 1 25 38 42 28 31 10 1 5 75 83 56 62 12 1...

Page 254: ...356 24 3 0 750 829 556 614 6 3 2 Metric Bolt Specifications Bolting into Cast Aluminum The torque values provided in the following metric bolt torque tables apply to hardware installed dry that is hardware with no grease oil or threadlocker on the threads or heads Do NOT grease or oil bolts or cap screws unless directed to do so in this manual Figure 6 5 Bolt Grades Table 6 7 Metric Bolt Bolting i...

Page 255: ... C as far as possible Ensure that washer D is loose and is pushed toward lock nut C as far as possible 3 Check that O ring A is NOT on the threads Adjust O ring A if necessary 4 Apply hydraulic system oil to O ring A Figure 6 7 Hydraulic Fitting 5 Install fitting B into the port until backup washer D and O ring A contact part face E 6 Position the angle fittings by unscrewing no more than one turn...

Page 256: ...rque values are provided for non adjustable hydraulic fittings If a procedure specifies a different torque value for the same type and size of fitting found in this topic use the value specified in the procedure instead Torque values are shown in following table below Figure 6 8 Hydraulic Fitting 1 Inspect O ring A and seat B for dirt or obvious defects 2 Check that O ring A is NOT on the threads ...

Page 257: ...298 199 220 32 2 1 2 12 332 365 245 269 6 3 5 O Ring Face Seal Hydraulic Fittings The standard torque values are provided for O ring face seal hydraulic fittings If a procedure specifies a different torque value for the same type and size of fitting found in this topic use the value specified in the procedure instead Torque values are shown in following table below Figure 6 9 Hydraulic Fitting 1 C...

Page 258: ...5 28 18 21 5 Note10 5 16 6 11 16 3 8 40 44 29 32 8 13 16 1 2 55 61 41 45 10 1 5 8 80 88 59 65 12 1 3 16 3 4 115 127 85 94 14 Note10 7 8 16 1 7 16 1 150 165 111 122 20 1 11 16 1 1 4 205 226 151 167 24 1 2 1 1 2 315 347 232 256 32 2 1 2 2 510 561 376 414 6 3 6 Tapered Pipe Thread Fittings The standard torque values are provided for tapered pipe thread fittings If a procedure specifies a different to...

Page 259: ... excess thread conditioner with an appropriate cleaner 6 Assess the final condition of the fitting Pay special attention to the possibility of cracks in the port opening 7 Mark the final position of the fitting If a fitting leaks disassemble the fitting and check it for damage NOTE The failure of fittings due to overtorquing may not be evident until the fittings are disassembled and inspected Tabl...

Page 260: ...ter m x 3 2808 foot ft Power kilowatt kW x 1 341 horsepower hp Pressure kilopascal kPa x 0 145 pounds per square inch psi Pressure megapascal MPa x 145 038 pounds per square inch psi Pressure bar Non SI bar x 14 5038 pounds per square inch psi Torque Newton meter Nm x 0 7376 pound feet or foot pounds lbf ft Torque Newton meter Nm x 8 8507 pound inches or inch pounds lbf in Temperature degrees Cels...

Page 261: ...ftertreatment decomposition tube DWA Double Windrow Attachment ECM Engine control module EEC Eco engine control Engine forward Windrower operation with Operator and engine facing in direction of travel FFFT Flats from finger tight Finger tight Finger tight is a reference position in which the given sealing surfaces or components are making contact with each other and the fitting has been tightened...

Page 262: ...tive Engineers SCR Selective catalytic reduction Screw A headed and externally threaded fastener that threads into preformed threads or forms its own thread when inserted into a mating part SDD Single draper drive SK Single knife SKD Single knife drive Soft joint A flexible joint made by use of a fastener in which the joining materials compress or relax over a period of time spm Strokes per minute...

Page 263: ...page 97 Check fuel separator for water and foreign material drain and clean as necessary and add fuel 4 1 4 Checking Fuel Separator page 98 Check gearbox lubricant level 4 1 7 Checking Engine Gearbox Lubricant Level and Adding Lubricant M1170 page 101 or 4 1 8 Checking Engine Gearbox Lubricant Level and Adding Lubricant M1240 page 102 Check tension of A C compressor belt 4 1 9 Checking Air Conditi...

Page 264: ...acons are functioning properly if installed 4 2 5 Checking Exterior Lights page 120 Complete the header s Predelivery Checklist if applicable Check that manuals are in the windrower manual case 4 3 Checking Manuals page 128 Remove plastic coverings and windshield decal from cab interior 4 4 Performing Final Steps page 129 Date Checked Checked by REFERENCE ...

Page 265: ......

Page 266: ...CUSTOMERS MacDon com DEALERS Portal MacDon com Trademarks of products are the marks of their respective manufacturers and or distributors Printed in Canada ...

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