MacDon M100 2009 Operator'S Manual Download

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MAINTENANCE/SERVICE

Form 169304

Model Year - 2009

7.3.2

Recommended Torques

•

Tighten all bolts to the torques specified in

chart unless otherwise noted throughout this

manual.

•

Check tightness of bolts periodically, using

bolt torque chart as a guide.

•

Replace hardware with the same strength

bolt.

•

Torque figures are valid for non-greased or

non-oiled threads and heads unless

otherwise specified. Do not grease or oil

bolts or capscrews unless specified in this

manual. When using locking elements,

increase torque values by 5%.

7.3.2.1 SAE Bolts

BOLT

DIA. "A"

in.

NC BOLT TORQUE*

SAE 5

SAE 8

lbf∙ft

N·m

lbf∙ft

N·m

1/4

5/16

3/8

7/16

1/2

102

105

142

9/16

110

149

202

5/8

150

203

200

271

3/4

265

359

365

495

7/8

420

569

600

813

640

867

890

1205

* Torque categories for bolts and capscrews are identified by their

head markings.

7.3.2.2 Metric Bolts

BOLT

DIA.

"A"

NC BOLT TORQUE*

8.8

10.9

lbf∙ft

N·m

lbf∙ft

N·m

0.4

0.5

1.3

1.8

2.2

3.3

4.5

M10

M12

125

M14

103

140

148

200

M16

166

225

229

310

M20

321

435

450

610

M24

553

750

774

1050

M30

1103

1495

1550

2100

M36

1917

2600

2710

3675

* Torque categories for bolts and capscrews are identified by their

head markings.

SAE-5 SAE-8

Summary of Contents for M100 2009

Page 1: ...ormation about the machine If you follow the instructions given in this manual your M100 Windrower will work well for many years If you require more detailed service information check with your dealer Use the Table of Contents and the Index to guide you to specific areas Study the Table of Contents to familiarize yourself with how the material is organized Keep this manual handy for frequent refer...

Page 2: ...WINDSHIELD WIPERS 21 5 9 REAR VIEW MIRRORS 21 5 10 CAB TEMPERATURE 22 5 10 1 Controls 22 5 10 2 Air Distribution 22 5 10 3 Heater Shut Off Valve 22 5 10 4 A C Compressor Protection 23 5 11 INTERIOR LIGHTS 23 5 12 OPERATOR AMENITIES 23 5 13 RADIOS 24 5 13 1 AM FM Radio 24 5 13 2 Antenna Mounting 24 5 14 HORN 24 5 15 ENGINE CONTROLS GAUGES 25 5 16 WINDROWER CONTROLS 26 5 17 HEADER CONTROLS 27 5 17 1...

Page 3: ...r Detachment A Series 84 6 6 3 Auger Speed 86 6 6 4 Knife Speed 87 7 MAINTENANCE SERVICE 89 7 1 PREPARATION FOR SERVICING 89 7 1 1 Welding Precautions 89 7 2 RECOMMENDED SAFETY PROCEDURES 89 7 3 MAINTENANCE SPECIFICATIONS 90 7 3 1 Recommended Fluids Fuel and Lubricants 90 7 3 2 Recommended Torques 91 7 3 3 Conversion Chart 93 7 4 ENGINE COMPARTMENT HOOD 94 7 5 MAINTENANCE PLATFORM 95 7 5 1 Opening...

Page 4: ...AINTENANCE SCHEDULE 155 7 13 1 Break In Inspection 155 7 13 2 Interval Maintenance 156 8 TROUBLESHOOTING 159 8 1 ENGINE 159 8 2 ELECTRICAL 161 8 3 HYDRAULICS 162 8 4 HEADER DRIVE 162 8 5 TRACTION DRIVE 163 8 6 STEERING AND GROUND SPEED CONTROL 164 8 7 CAB AIR 165 8 8 OPERATOR S STATION 167 9 OPTIONS 168 9 1 REEL DRIVE LIFT PLUMBING 168 9 2 TRACTOR HYDRAULIC COMPLETION FOR DRAPER HEADER REEL FORE A...

Page 5: ...actices CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It is also used as a reminder of good safety practices 2 3 SAFETY SIGNS 2 3 1 Safety Sign Installation Refer to the illustration on this and following pages and proceed as follows a Be sure the installation area is clean and dry b Decide on the exact location before you remove the...

Page 6: ...SAFETY Form 169304 6 Model Year 2009 Safety Sign Locations continued LIFT LINKAGES 163561 FRONT OF PLATFORM 134070 BEHIND DOOR 109843 BELOW DOOR HANDLE 32744 IN CAB 32744 ...

Page 7: ...SAFETY Form 169304 7 Model Year 2009 Safety Sign Locations continued IN CAB 109844 IN CAB 109868 ...

Page 8: ...SAFETY Form 169304 8 Model Year 2009 Safety Sign Locations continued ON FRAME 42130 ON FAN SHROUD 134068 ON FRAME 110986 ...

Page 9: ...SAFETY Form 169304 9 Model Year 2009 Safety Sign Locations continued INSIDE FRAME 32743 ON FRAME 110986 ON LIFT LINKAGE 163562 ...

Page 10: ...mpairment or loss of hearing Wearing a suitable hearing protective device such as ear muffs A or ear plugs B protects against objectionable or loud noises A B Provide a first aid kit for use in case of emergencies Keep a fire extinguisher on the machine Be sure the extinguisher is properly maintained and be familiar with its proper use Keep young children away from machinery at all times Be aware ...

Page 11: ...t for any reason A child or even a pet could engage an idling machine Keep the area used for servicing machinery clean and dry Wet or oily floors are slippery Wet spots can be dangerous when working with electrical equipment Be sure all electrical outlets and tools are properly grounded Use adequate light for the job at hand Keep machinery clean Straw and chaff on a hot engine are a fire hazard Do...

Page 12: ...Lever hp horsepower in inches in3 cubic inches kg kilograms kPa kilopascals lbf pounds force lbf ft or ft lbf pound feet or foot pounds lbf in or in lbf pound inches or inch pounds L min liters per minute mm millimeters mph miles per hour N Newtons N m newton meters N DETENT The slot opposite the neutral position on operator s console oz ounces psi pounds per square inch rpm Revolutions Per Minute...

Page 13: ...h mm FWD REV DRIVE TIRE Inner Outer 138 7 3522 142 9 3630 158 3 4021 120 7 3066 Outer Outer 134 2 3410 146 1 3712 157 1 3990 Inner Inner 120 1 3050 131 6 3342 150 0 3810 CASTER TIRE Minimum 93 2 2367 115 4 2932 Maximum 135 8 3448 158 0 4013 NOTE Above dimensions are with 18 4 26 drive tires and forked casters TREAD CASTERS 45 7 in 1160 TREAD HUBS TIRES WHEEL BASE 133 in 3378 mm WHEEL BASE ...

Page 14: ...Reverse 6 mph 9 6 km h Transport High Range 0 16 mph 25 6 km h Transmission Type 2 Piston Pumps 1 per Drive Wheel Displacement 3 0 cu in 49 cc Flow 33 U S gpm 129 L min Final Drive Type Planetary Gearbox Ratio 41 42 1 Wheel Motor Displ Lo Range 2 8 cu in 46 cc Hi Range 1 7 cu in 27 cc SYSTEM CAPACITIES Fuel Tank 97 U S Gallons 378 liters Cooling 5 1 U S Gallons 20 liters Hydraulic Reservoir 11 5 U...

Page 15: ...e One On Ignition One Live Keyed Mirrors Two Outside Radio Two Speakers and Antenna Factory Installed Dealer Installed Radio SYSTEM MONITORING Speeds Ground mph or km h Engine rpm Knife spm Optional Reel rpm Optional Conveyor Ref No Header Height Angle Optional TIRE OPTIONS Size Drive 18 4 26 Bar 18 4 26 Turf Rear 7 5 16SL Single Rib Formed Caster 10 x 16 Formed Forked Caster 16 5L 16 1 Rib Implem...

Page 16: ...UMBAR SUPPORT Adjusts Stiffness of Seat Back INCREASE Rotate Knob Upward DECREASE Rotate Knob Downward ARM REST ANGLE Adjusts Angle of Arm Rest INCREASE Rotate Knob Clockwise DECREASE Rotate Knob Counter Clockwise SEAT FORE AFT POSITION Adjusts Fore Aft Position Pull Lever Up To Release Move Seat Forward or Rearward Release Lever SEAT BACK ANGLE Pull Lever Up To Release Position Seat Back As Desir...

Page 17: ...ine securely fasten your seat belt and ensure trainer s seat belt is fastened if occupied The seat belt can help insure your safety if it is used and maintained Never wear a seat belt loosely or with slack in the belt system Never wear the belt in a twisted condition or pinched between the seat structural members a To fasten seat belt pull belt completely across your body Push the metal eye into t...

Page 18: ...r shuts down If the seat switch is open for more than 5 seconds and the seat switch is closed again it requires the operator to move the header engage switch to OFF position and back to the ON position again to restart the header 5 6 2 Transmission If the operator leaves the seat and the transmission is not locked in neutral after 2 seconds the lower display will flash NOT IN NEUTRAL accompanied b...

Page 19: ...iner Refer to illustrations on following pages for location of lights 5 7 1 Field Lighting HI LO LIGHTS Controls Hi Lo Beam For Road Lights On Cab Roof LIGHTS SWITCH Controls Field and Transport Lights FIELD OFF ROAD BEACON Controls Beacons On Cab Standard for Export Optional for N A On Off REAR FIELD LIGHTS SWATH LIGHTS FRONT FIELD LIGHTS ...

Page 20: ... 7 3 Beacon Lighting Export The beacon lights are functional when the ignition and the beacon switches are on The beacons must be used when driving on the road REAR TAIL LIGHTS RED TURN SIGNALS HAZARDS AMBER FRONT TURN SIGNALS HAZARDS AMBER HI LO LIGHTS BEACON LIGHTS AMBER ...

Page 21: ...Year 2009 5 8 WINDSHIELD WIPERS The windshield wiper control is located in the cab headliner 5 9 REAR VIEW MIRRORS Two adjustable outside mounted mirrors provide rear view vision REAR VIEW MIRRORS WIPER SWITCH Controls Windshield Wiper ON OFF ...

Page 22: ... 2 Start engine and operate at low idle until engine is warm 3 Click A C switch from OFF to ON for one second then back to OFF for 5 to 10 seconds Repeat this step ten times 5 10 2 Air Distribution Cab air distribution is controlled through adjustable air vents They are located in the cab posts to provide window and operator ventilation as shown in illustration 5 10 3 Heater Shut Off Valve A shut ...

Page 23: ...r to run The Windrower Control Module WCM gives a warning when it senses rapid pressure changes that cause the compressor to rapidly engage and disengage If the air conditioning system is shut down by either switch locate the source of the problem and correct it before operating the system 5 11 INTERIOR LIGHTS Two interior lights are installed in the cab headliner A low intensity LED light A is lo...

Page 24: ... 2 Antenna Mounting A roof mounted antenna base for installing a magnetic antenna is available as an option from your dealer Order part 160288 or see illustration for part dimensions for a homemade version It accommodates most CB 2 way radio and satellite radio antennas Refer to M100 Self Propelled Windrower Unloading and Assembly Instruction for installation procedures IMPORTANT Antenna base can ...

Page 25: ...ration for the location and a description of each THROTTLE Controls Engine RPM FULL Push Lever Forward OPERATING See Section 6 3 5 IDLE Pull Lever Back IGNITION SWITCH ACC Fully Counter Clockwise OFF All Electrical Systems Off RUN Clockwise START Fully Clockwise To Crank Engine Release and Switch Returns to RUN REMOVE KEY WHEN WINDROWER NOT IN USE KEY ALSO LOCKS DOORS FULL IDLE ...

Page 26: ...eader Momentary Switch On Monitor FAST SLOW GROUND SPEED LEVER GSL Controls Speed and Direction of Movement F Forward N Neutral N DETENT Engages Neutral Interlock and Applies Park Brake When Steering Locked In Center R Reverse N DETENT TURN SIGNALS Activates Turn Signals On Windrower Tractor and Header Momentary Switches On Monitor REVERSE ...

Page 27: ... disengages header drive IMPORTANT Always move throttle lever back to idle before engaging header drive Do not engage header with engine at full RPM 5 17 2 GSL Header Switches The GSL A contains switches for the following header functions that are most often adjusted while in operation to suit changing crop conditions All are momentary type switches A decal that identifies the switch functions is ...

Page 28: ...l Release switch at desired position 5 17 2 3 Header Position Switches Press and hold switch at location shown to move header Release switch at desired position 5 17 2 4 Reel Speed Switches Press and hold switch at location shown to change reel or disc speed Release switch at desired speed Auger Header Auger speed automatically adjusts when reel speed is changed Draper Header Reel speed is limited...

Page 29: ...e contains switches for the following header functions that are most often used while the windrower is stationary 5 17 3 1 Deck Shift Float Preset Switch Draper Header with Deck Shift Option Controls deck shifting for double windrowing options with a draper header CENTER DELIVERY R I LEFT SIDE DELIVERY ...

Page 30: ...eat Water In Fuel Do not Operate Stop Engine SELECT SWITCH Allows Operator To Select Display Item On Lower Line See Table Push To Select AUGER DRAPER SPEED ADJUST Changes Auger Draper Speed INDEX with INDEX SWITCH on Changes Auger Draper SPEED with INDEX SWITCH off Push Upper Switch to Increase Push Lower Switch to Decrease DISPLAY Header Functions HEADER INDEX SWITCH OPTION Links Reel and Conveyo...

Page 31: ...ower or Upper Line DESCRIPTION ENGINE HRS Total Engine Operating Time HEADER HRS Total Header Operating Time SUB ACRES SUB HECTARES If Metric Area Cut Since Last Reset To Reset Display SUB ACRES On Lower Line And Hold Down Program Switch Until Display Resets 5 7 Seconds TOTAL ACRES TOTAL HECT If Metric Total Area Cut By Machine HEADER HEIGHT Distance Setting 00 0 10 0 Between Cutterbar Ground HEAD...

Page 32: ...d AUGER SPEED Auger Rotational Speed 0 0 10 0 KNIFE SPEED Optional KNIFE SENSOR If Sensor Disabled Knife Speed In Strokes Per Minute HEADER HEIGHT HEADER SENSOR If Sensor Disabled Distance Setting 00 0 10 0 Between Cutterbar Ground HEADER ANGLE Optional HEADER SENSOR If Sensor Disabled Angle Setting 00 0 10 0 Header Relative To Ground FUEL LEVEL Level of Fuel In Tank ENGINE TEMP F ENGINE TEMP C If...

Page 33: ...EED Draper Speed 0 0 10 0 KNIFE SPEED Optional KNIFE SENSOR If Sensor Disabled Knife Speed In Strokes Per Minute HEADER HEIGHT HEADER SENSOR If Sensor Disabled Distance Setting 00 0 10 0 Between Cutterbar Ground HEADER ANGLE Optional HEADER SENSOR If Sensor Disabled Angle Setting 00 0 10 0 Header Relative To Ground FUEL LEVEL Level of Fuel In Tank ENGINE TEMP F ENGINE TEMP C If Metric Engine Coola...

Page 34: ... With Ground Speed In MPH Or KPH KNIFE SPEED Optional KNIFE SENSOR If Sensor Disabled Knife Speed In Strokes Per Minute HEADER HEIGHT HEADER SENSOR If Sensor Disabled Distance Setting 00 0 10 0 Between Cutterbar Ground HEADER ANGLE Optional HEADER SENSOR If Sensor Disabled Angle Setting 00 0 10 0 Header Relative To Ground FUEL LEVEL Level of Fuel In Tank ENGINE TEMP F ENGINE TEMP C If Metric Engin...

Page 35: ...SPLAY Upper Line DESCRIPTION LEFT TURN Indicates Left Turn When Is Pressed On CDM RIGHT TURN Indicates Left Turn When Is Pressed On CDM HAZARD Indicates Hazard Warning Lights Are On When Is Pressed On CDM ROAD GEAR With Hi Range Selected On Console Switch HEADER ENGAGED Header Drive Engaged ...

Page 36: ... ignition is turned on and at engine operating speeds above 500 rpm 5 18 4 1 Engine Warning Lights WATER IN FUEL Illuminates Yellow Service Recommended CAUTION Illuminates Yellow Do Not Operate Engine Refer to Display Code DISPLAY Displays Malfunction Code Refer to Technical Service Manual ENGINE PREHEAT Illuminates Yellow Wait To Start Engine STOP Illuminates Red Stop Engine Immediately Refer to ...

Page 37: ... Seconds Voltage Below 11 5 HIGH VOLTS Single Loud Tone For 10 Seconds Voltage Above 16 IN PARK One Short Beep Steering Wheel Centered And Brakes Are Engaged PLACE GSL INTO N Beeps At 2 Per Second Until Corrected Interlock Switch Not Closed With Key On Engine Off SLOW DOWN Short Beep With Each Flash Ground Speed Greater Than or Equal to 25 mph 40 km h TRANS OIL PRESS Continuous Loud Tone Until Oil...

Page 38: ...d Then To On Position To Restart The Header HYDRAULIC FILTER Single Loud Tone For 10 Seconds Repeats Every 15 Minutes Until Condition Is Corrected Excessive Pressure Drop Across Hydraulic Oil Filter KNIFE OVERLOAD Ongoing Intermittent Moderate Tone Until Condition Is Corrected Machine Overload Knife Or Disc Speed Drops Below Programmed Value LOW HYDRAULIC OIL Continuous Loud Tone For 5 Seconds If ...

Page 39: ...n upper line d Press and then SELECT e HEADER TYPE is displayed DRAPER is flashing on lower line f Press or to change value on lower line g Press SELECT h TILT CYL INSTALLED is displayed i Press or to change value on lower line j Press SELECT to advance to the next L1 item and press arrow keys to change values k Press PROGRAM to exit programming mode when finished entering desired values Refer to ...

Page 40: ... E L S P E E D L2 M x x x E N A B L E D L O C K E D L1 C x x x R E E L F O R E A F T L2 M x x x E N A B L E D L O C K E D L1 C x x x H E A D E R T I L T L2 M x x x E N A B L E D L O C K E D L1 C x x x E X I T C O N T R O L L O C K S L2 M x x x N O Y E S D R A P E R S P E E D E N A B L E D L O C K E D Programming Menu Flow Chart If NO then jump to Use the arrow keys to set the header cut width If t...

Page 41: ... S E N S O R C A L L2 M x x x R A I S E H D R T O S T A R T L1 C x x x C A L I B R A T I N G H E I G H T L2 M x x x R A I S E H E A D E R H O L D L2 M x x x R A I S E H E A D E R D O N E L1 C x x x H E I G H T S E N S O R C A L L2 M x x x P R E S S L O W E R H E A D E R L1 M x x x C A L I B R A T I N G H E I G H T L2 M x x x L O W E R H E A D E R H O L D L2 M x x x H T S E N S O R C O M P L E T E ...

Page 42: ...R A U L I C O I L L1 C x x x E X I T T R A C T O R C O D E S L2 M x x x N O Y E S V I E W T R A C T O R C O D E S L1 C x x x E N T E R S E N S O R S E T U P L2 M x x x N O Y E S R E A D S E N S O R I N P U T S L1 C x x x H E A D E R H T S E N S O R L2 M x x x E N A B L E D I S A B L E L1 C x x x H E A D E R T I L T S E N S O R L2 M x x x E N A B L E D I S A B L E L1 C x x x K N I F E S P E E D S E...

Page 43: ...Y E S L1 C x x x T O A C T I V A T E P U R G E L2 M x x x P R E S S A N D H O L D L1 C x x x P U R G E C Y C L E S T A R T E D L2 M x x x P R E S S A N D H O L D L1 C x x x P U R G E C Y C L E E N D E D L2 M x x x L1 C x x x P U R G E C Y C L E E N D E D L2 M x x x N O E X I T Y E S L1 C x x x E X I T F U N C T I O N M E N U L2 M x x x N O Y E S H E A D E R D O W N U P L1 C x x x E X I T D I A G N...

Page 44: ...ist the operator or technician in locating a specific problem with engine operation Refer to the Appendix for the Error Codes 5 18 7 CDM WCM Fault Codes The CDM displays Fault Codes when there is a fault with one of the several sensors that monitor and control windrower operation to assist the operator or technician in locating a specific problem with the windrower Refer to the Appendix for the Fa...

Page 45: ...urs Do not modify the machine Unauthorized modifications may impair the function and or safety and affect machine life The safety information given in this manual does not replace safety codes insurance needs or laws governing your area Be sure your machine meets the standards set by these regulations 6 2 SYMBOL DEFINITIONS The following symbols are used to depict functions or reactions at the var...

Page 46: ...Air Blower 6 2 3 Header Functions Program Header Tilt Up Header Index Header Down Return To Cut Header Up Conveyor Speed Header Tilt Down Increase Decrease Reel Speed Deck Shift Reel Down Header Engage Reel Forward Header Disengage Reel Up Push Down Header Disengage Reel Rearward Pull Up Header Engage Display Select ...

Page 47: ...xcessive vibration and unusual noises If there is any indication of trouble shut down and inspect the machine Follow proper shutdown procedure Refer to Section 6 3 5 3 Shutdown Procedure Operate only in daylight or good artificial light 6 3 2 Break In Period The windrower is ready for normal operation However there are several items to check and watch out for during the first 150 hours 6 3 2 1 Eng...

Page 48: ...ed fire extinguisher on the windrower b Perform the following checks 1 Drain off excess hydraulic oil added for storage Refer to Section 7 12 2 Changing Hydraulic Oil 2 Remove plastic bags and or tape from all sealed openings air cleaner intake exhaust pipe fuel tank 3 Charge battery and install Be sure terminals are clean and cables are connected securely 4 Adjust tension on A C compressor belt S...

Page 49: ...e is plenty of ventilation to avoid asphyxiation IMPORTANT Do not tow machine to start engine Damage to hydrostatic drives will result WARNING Before starting engine securely fasten your seat belt and ensure trainer s seat belt is fastened if occupied The seat belt can help insure your safety if it is used and maintained a Move GSL A into N DETENT b Turn steering wheel until it locks c Fasten seat...

Page 50: ...ng and wait two minutes to allow the starting motor to cool before attempting to re start the engine 5 If engine fails to start repeat steps 1 to 4 6 Engine will cycle through a period where it appears to labour NOTE Throttle is non responsive during this time as engine is in WARM UP mode This mode will last from 30 seconds to 3 minutes depending on temperature After engine has stabilized and idli...

Page 51: ...BRI CITY Diesel Grade No 2 ASTM D 975 As Per Spec As Per Spec As Per Spec As Per Spec Diesel Grade No 1 2 mix n a 1 Max 0 5 Max Preferred 0 1 Max 45 55 Cold Weather High Alt 460 HFRR f Replace fuel tank cap A and turn cap handle B clockwise until snug NOTE Fill fuel tank daily preferably at the end of the day s operation to help prevent condensation in the tank Tank Capacity is 97 U S Gallons 378 ...

Page 52: ...ttery and alternator Refer to table IGNITION ENGINE READING INDICATED CONDITION On Running 13 8 15 0 Normal 16 0 See Note Regulator Out of Adjustment 12 5 See Note Alternator Not Working or Regulator Out of Adjustment Shutdown 12 0 Battery Normal Note Display flashes voltage reading with single loud tone Repeats every 30 minutes until condition fixed 6 3 5 8 Engine Warning Lights There are four en...

Page 53: ...d hydrostatically that is turning the steering wheel varies the hydraulic flow to one drive wheel relative to the other drive wheel The reaction of this type of steering is different than conventional steering mechanisms IMPORTANT With the engine running moving the ground speed lever out of N DETENT unlocks steering Any movement of steering wheel will then cause the machine to move even if the gro...

Page 54: ...o Be sure ground speed lever is in N DETENT and steering wheel is locked in the straight ahead position o Fully lower header and reel o Disengage header drives o Stop engine and remove key from ignition A child or even a pet could engage an idling machine o Turn off wiper o Turn off lights unless required for inspection purposes o Release seat belt o Raise armrest and steering wheel for easier exi...

Page 55: ... speed which will be displayed at F CAUTION Operate both steering wheel and ground speed lever slowly for familiarization Avoid the common tendency of new operators to over steer 6 3 6 2 1 Reverse WARNING Back up slowly Steering is opposite to normal when reversing Hold steering wheel at the bottom and turn wheel in direction you want the rear cab forward of the machine to travel a Set ground spee...

Page 56: ...increase ground speed as well e To stop the turn return the steering wheel to center 6 3 6 2 3 Stopping WARNING Do not move ground speed lever rapidly back to neutral Operator may be thrown forward by sudden stop Always wear seat belt when operating windrower tractor a SLOWLY return the GSL A to neutral and into N DETENT b Turn steering wheel until it locks c Move throttle lever D to low idle posi...

Page 57: ...ving operator s seat for any reason A child or even a pet could engage an idling machine a Raise rear of tractor slightly so that most of the weight is off the casters using a jack or other lifting device under the frame where shown NOTE Lifting device should have lifting capacity of at least 5000 lb 2270 kg b Remove bolts and washers A and B from left and right sides of the walking beam c Slide w...

Page 58: ... fully raised and reel fully lowered Maintain adequate visibility and be aware of roadside obstructions oncoming traffic and bridges When travelling down hill reduce speed and keep header at a minimum height This provides maximum stability if forward motion is stopped for any reason Raise header completely at bottom of grade to avoid contacting ground Travel speed should be such that complete cont...

Page 59: ...ng to other vehicles Do not use field lamps on roads other drivers may be confused by them d Push ground speed range switch A for road speed CDM will display ROAD GEAR at B and LED over 2 will light up e Slowly push throttle C to full forward operating rpm CDM should display 2600 2650 at D f Slowly move the GSL E forward to desired ground speed which will be displayed also at D C B E D ROAD SPEED ...

Page 60: ...ould attach to tow bar at same height as towing vehicle hitch Towing apparatus should be removed for field operation to avoid interference with windrow WARNING With final drives disengaged the windrower may roll on a sloped surface Before disengaging final drives attach windrower tractor to towing vehicle After towing engage drives and ensure GSL is in N DETENT before detaching from towing vehicle...

Page 61: ...rotect the switches instruments tires etc from inclement weather e If no cover is available seal air cleaner intake and exhaust pipe with plastic bags and or waterproof tape f If possible block up windrower to take weight off tires If it is not possible to block up the machine increase tire pressure by 25 for storage Adjust to recommended operating pressure before next use g Repaint all worn or ch...

Page 62: ...der always engage cylinder stops before going under header for any reason Engage cylinder stops as follows a Press HEADER UP switch to raise header to maximum height NOTE If one end of the header does not raise fully the lift cylinders require re phasing Proceed as follows 1 Hold the up switch until both cylinders stop moving 2 Press HEADER DOWN switch to lower the header all the way down and cont...

Page 63: ...hen working with the cutterbar on the ground Set center link to mid range position Refer to Section 6 4 4 Header Angle In rocky fields adjust skid shoes down to raise guards when operating at flattest header angle to minimize scooping rocks Adjust header height or adjust header angle to minimize pushing soil 6 4 2 2 Float Adjustment The float adjustment uses drawbolts to change the tension on the ...

Page 64: ...b If necessary adjust the float with the drawbolts as follows CAUTION Check to be sure all bystanders have cleared the area 1 Start engine 2 Using HEADER UP switch on GSL Raise the header fully shut down the engine and remove the key 3 Turn drawbolt D clockwise to increase float makes header lighter or counterclockwise to decrease float makes header heavier 4 Recheck the float as described on prev...

Page 65: ... link B Note high and low end of header 3 Place wooden blocks under header cutterbar and legs and lower header onto blocks so that members A lift off links B Stop engine DANGER Stop engine and remove key from ignition before leaving operator s seat for any reason A child or even a pet could engage an idling machine 4 On high side remove nut washer and bolt C that attaches shims D to link 5 Remove ...

Page 66: ...een the ground and the drapers cutterbar and is adjustable to accommodate crop conditions and or soil type Refer to the appropriate operator s manual for range of adjustment and recommended settings for your particular header IMPORTANT Changing header angle will affect flotation slightly because it has the effect of making the header lighter or heavier IMPORTANT To prevent excessive guard breakage...

Page 67: ...ader height control switches 1 To deactivate press and hold PROGRAM switch and momentarily press either HEADER TILT UP or HEADER TILT DOWN NOTE If either of the header tilt switches are pressed while deactivated the lower display line will indicate TILT DISABLED for five seconds along with a tone 2 To reactivate repeat above procedure MECHANICAL CENTER LINK a Loosen plate nut C b To increase steep...

Page 68: ...ollows IMPORTANT The windrower must be running with the header engaged 1 RETURN TO CUT switch must be off indicator light is off 2 Adjust the header to the desired height with the HEADER UP or HEADER DOWN switches on the GSL CDM displays between 00 0 and 10 0 3 Adjust the header angle with the HEADER TILT UP or HEADER TILT DOWN switches on the GSL CDM displays between 0 and 10 0 This step is not r...

Page 69: ...r rises past the pre set height 3 If the header angle is changed double click two clicks within 0 5 seconds the HEADER TILT UP or HEADER TILT DOWN switch and the header will return to the pre set angle NOTE If the header cannot return to the pre set height or angle within 30 seconds the RETURN TO CUT feature will deactivate to prevent the hydraulic oil from overheating Push the RETURN TO CUT switc...

Page 70: ...posite side b Remove hairpin on pins D and remove pins from header legs CAUTION Check to be sure all bystanders have cleared the area c Start the engine and activate header down button on the GSL to fully retract header lift cylinders d Slowly drive tractor forward so that boots B enter header legs E Continue to drive slowly forward until linkages contact support plates in the lower header legs an...

Page 71: ...that it can connect to header 2 Push down on rod end of link cylinder K until hook engages pin on header and is locked g Raise the header fully with the header up switch on the GSL Stop engine and remove key DANGER To avoid bodily injury from fall of raised header always engage header lift cylinder stops when working on or around raised header h Engage lift cylinder stops on both lift cylinders i ...

Page 72: ...with hairpin l Disengage lift cylinder stops m Start engine and activate header lift cylinders switch on GSL to lower header fully n Stop engine and remove key o Connect header drive P and electrical harness Q to header Refer to the Draper Header Operator s Manual p Connect reel hydraulics R at RH side of tractor Q P HEADER DRIVE HOSES R REEL HYDRAULICS O N ...

Page 73: ... header stand B by pulling spring loaded pin C Release pin to lock stand e Remove pin D from linkage to disengage float springs and insert in storage hole E Secure with lynch pin f Disengage lift cylinder stops g Start engine choose a level area and lower header to the ground Stop engine and remove key h Disconnect header drive hydraulics L and electrical harness M from header Refer to the Draper ...

Page 74: ...ULIC LINK OPTION 1 Start engine and activate header tilt cylinder switch on GSL to release load on center link cylinder 2 Disconnect center link by lifting release J and lift hook K off header NOTE If optional center link self alignment kit is installed lift release J and then operate the link lift cylinder from the cab to disengage the center link from the header k Slowly back tractor away from h...

Page 75: ...b Ground cutting speed can be maintained using this feature IMPORTANT Windrower must be moving CAUTION Check to be sure all bystanders have cleared the area Example Windrower is operating at 8 mph with Header Index on and set at 5 5 Display shows 13 5 5 5 REEL IND where 13 5 8 5 5 is the reel speed in mph and 5 5 is the header index setting Windrower speed drops to 7 5 mph at same Header Index set...

Page 76: ...t 6 5 3 3 Reel Only Speed Set the speed of the reel independently of ground speed as follows CAUTION Check to be sure all bystanders have cleared the area NOTE This procedure can also be used to change the draper speed on the go These changes become the new set points MPH or KPH HEADER ENGAGED OR DISENGAGED HEADER INDEX SWITCH ON ON GSL PRESS REEL SPEED SWITCH FAST OR SLOW DISPLAY SHOWS MIN REEL D...

Page 77: ...oise in the cab Ground cutting speed can be maintained using this feature NOTE This procedure can also be used to change the draper speed on the go These changes become the new set points IMPORTANT Windrower must be moving Example Windrower is operating at 8 mph with Header Index on and set at 1 5 Display shows 9 5 1 5 DRAP INDX where 9 5 8 1 5 is the draper speed in mph and 1 5 is the header inde...

Page 78: ...lus Index is less than the Minimum Draper Speed Set Point 6 5 4 3 Draper Speed Independent of Ground Speed Set the speed of the draper independently of ground speed as follows NOTE This procedure can also be used to change the draper speed on the go CAUTION Check to be sure all bystanders have cleared the area MPH or KPH ENGAGE HEADER ON CDM PRESS FAST OR SLOW DISPLAY SHOWS DRAPER MIN DONE SPEED O...

Page 79: ...eed Header All 1400 1950 If the machine is equipped with the appropriate sensor the CDM will notify the operator when the knife speed reaches an overload pre set usually 75 of knife speed The pre set can be changed on the CDM Refer to Section 5 18 5 CDM Programming Use the following procedure to set the knife speed See chart on next page for settings CAUTION Check to be sure all bystanders have cl...

Page 80: ...15 2 49 40 8 83 1 27 2 103 0 25 1 95 0 4 0 55 14 2 34 38 3 78 1 25 6 96 9 23 6 89 3 5 0 51 13 2 20 36 1 73 4 24 0 90 8 22 2 84 0 6 0 47 12 2 07 33 9 69 0 22 6 85 6 20 9 79 1 7 0 43 11 1 95 32 0 64 8 21 2 80 2 19 6 74 2 8 0 39 10 1 83 30 0 61 0 20 0 75 7 18 4 69 7 9 0 35 9 1 72 28 2 57 3 18 8 71 2 17 3 65 5 10 0 31 8 1 62 26 6 53 9 17 6 66 6 16 3 61 7 11 0 24 6 1 52 24 9 50 6 16 6 62 8 15 3 57 9 12...

Page 81: ...t enables crop delivery from left side center or right side of the header Shift decks as follows CAUTION Check to be sure all bystanders have cleared the area a Engage header by pulling up on header engage switch A b Push rocker switch B to desired delivery position Deck s will move and direction of drapers will change accordingly c Operate windrower CENTER DELIVERY RIGHT SIDE DELIVERY LEFT SIDE D...

Page 82: ...e tractor forward so that feet C on tractor enter boots B on the header Continue to drive slowly forward until feet engage the boots and header nudges forward d Connect center link as follows MECHANICAL LINK 1 Loosen nut E and rotate barrel F to adjust length so that other end lines up with header bracket 2 Install pin G and secure with cotter pins 3 Adjust link to required length for proper heade...

Page 83: ...ng on or around raised header f Engage lift cylinder stops on both lift cylinders g Install pin A through each boot and foot and secure with hairpin IMPORTANT Ensure pin A is fully inserted and hairpin is installed behind bracket h Remove lynch pin from pin K in stand L i Hold stand and remove pin K j Reposition stand to storage position by inverting stand and re locating on bracket as shown Reins...

Page 84: ...s on both lift cylinders c Remove hairpin from pin A and remove pin from left and right header boots B on header d Lower stand C by pulling pin D inverting stand and re locating on bracket Reinsert pin D and secure with hairpin e Remove pin E from linkage to disengage float springs and insert in storage hole F Secure with lynch pin Repeat for opposite linkage f Disengage lift cylinder stops g Star...

Page 85: ...der tilt cylinder switch on GSL to release load on center link cylinder K 2 Lift hook release L and lift hook M off header pin NOTE If optional center link lift cylinder is installed lift release L and then operate the link lift cylinder from the cab to disengage the center link from the header i Disconnect header drive hydraulics N and electrical harness O Refer to the Auger Header Operator s Man...

Page 86: ...n A40 D double knife headers an optional 30 tooth sprocket can be installed to change the reel speed independently of the auger speed CAUTION Check to be sure all bystanders have cleared the area ENGAGE HEADER HEADER INDEX SWITCH OFF ON GSL PRESS SELECTOR BUTTON OR SELECT SWITCH ON CDM FOR AUGER SPEED 00 0 99 0 00 0 150 rpm 99 0 320 rpm Auger Speed Not To Exceed 320 rpm ENGAGE HEADER ON CDM PRESS ...

Page 87: ...ming NOTE The knife speed cannot be programmed outside the range specified for each header NOTE The speed can be adjusted without shutting down the machine although it is recommended that the windrower be stopped to enable the operator to re program the WCM Use the following procedure to set the knife speed See chart on next page for settings CAUTION Check to be sure all bystanders have cleared th...

Page 88: ...15 2 49 40 8 83 1 27 2 103 0 25 1 95 0 4 0 55 14 2 34 38 3 78 1 25 6 96 9 23 6 89 3 5 0 51 13 2 20 36 1 73 4 24 0 90 8 22 2 84 0 6 0 47 12 2 07 33 9 69 0 22 6 85 6 20 9 79 1 7 0 43 11 1 95 32 0 64 8 21 2 80 2 19 6 74 2 8 0 39 10 1 83 30 0 61 0 20 0 75 7 18 4 69 7 9 0 35 9 1 72 28 2 57 3 18 8 71 2 17 3 65 5 10 0 31 8 1 62 26 6 53 9 17 6 66 6 16 3 61 7 11 0 24 6 1 52 24 9 50 6 16 6 62 8 15 3 57 9 12...

Page 89: ...and cover long hair Never wear dangling items such as scarves or bracelets Wear protective shoes with slip resistant soles a hard hat protective glasses or goggles and heavy gloves If more than one person is servicing the machine at the same time be aware that rotating a driveline or other mechanically driven component by hand for example accessing a lube fitting will cause drive components in oth...

Page 90: ...r Conditioning System Compressor Oil SP 15 Compressor Oil Cab Air Conditioning Compressor Lubricant Mix with equal parts of high quality soft de ionized or distilled water 7 3 1 3 Lubricants LUBRICANT SPEC DESCRIPTION USE Grease SAE Multi Purpose High Temp Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base As Required Unless Otherwise Specified Engine Oil S...

Page 91: ...ts BOLT DIA A in NC BOLT TORQUE SAE 5 SAE 8 lbf ft N m lbf ft N m 1 4 9 12 11 15 5 16 18 24 25 34 3 8 32 43 41 56 7 16 50 68 70 95 1 2 75 102 105 142 9 16 110 149 149 202 5 8 150 203 200 271 3 4 265 359 365 495 7 8 420 569 600 813 1 640 867 890 1205 Torque categories for bolts and capscrews are identified by their head markings 7 3 2 2 Metric Bolts BOLT DIA A NC BOLT TORQUE 8 8 10 9 lbf ft N m lbf...

Page 92: ... Fittings a Inspect O ring and seat for dirt or obvious defects b On angle fittings back off the lock nut until washer A bottoms out at top of groove B in fitting c Hand tighten fitting until back up washer A or washer face if straight fitting bottoms on part face C and O ring is seated d Position angle fittings by unscrewing no more than one turn e Tighten straight fittings to torque shown f Tigh...

Page 93: ...ds per square inch psi x 6 8948 kilopascals kPa x 00689 megapascals MPa Torque pound feet or foot pounds lbf ft or ft lbf x 1 3558 newton meters N m pound inches or inch pounds lbf in or in lbf x 0 1129 newton meters N m Temperature degrees Fahrenheit F F 32 x 0 56 Celsius C Velocity feet per minute ft min x 0 3048 meters per min m min feet per second ft s x 0 3048 meters per sec m s miles per hou...

Page 94: ...d D stops it at approximately a 40 degree angle b To close hood 1 Pull down on strap B grasp the hood when within reach and lower until hood engages latch A c Open the hood at the highest position as follows 1 Open hood to lowest position 2 Remove strap from hooks C and D and allow hood to raise fully to approximately 65 degrees d To close hood 1 Grasp the strap at B and loop under upper hook C 2 ...

Page 95: ...n b To move platform back to closed position release latch A and move platform forward until it stops and latch re engages 7 5 2 Opening Closing Platform for Major Servicing To improve access to the hydraulics plumbing the platform can be swung away from the tractor To Open a Open engine compartment hood to lowest position IMPORTANT Failure to open hood will result in damage to the hood when the p...

Page 96: ...bricant LUBRICANT SPEC DESCRIPTION USE Grease SAE Multi Purpose High Temp Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base As Required Unless Otherwise Specified The greasing points are marked on the machine by decals showing a grease gun and grease interval in hours of operation See illustration below Log hours of operation and use the Maintenance Checkl...

Page 97: ...fying the various locations that require lubrication TOP LINK TWO FITTINGS BOTH SIDES CASTER PIVOT BOTH SIDES High Temp Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base WALKING BEAM PIVOT FORKED CASTER SPINDLE BEARINGS TWO PLACES BOTH WHEELS FORMED CASTER WHEEL BEARING 1 PLACE BOTH WHEELS 200 ...

Page 98: ...l flash NOT IN NEUTRAL accompanied by a continuous loud tone Move the GSL into N DETENT to cancel the alarm 2 If there is no warning the operator presence system requires adjustment See your MacDon dealer d With the windrower in forward motion at approximately 2 3 mph 1 Stand up out of the seat 2 The CDM will flash NO OPERATOR on the upper line and ENGINE SHUTS DOWN 5 4 3 2 1 0 accompanied by a st...

Page 99: ...roperly functioning system should operate as follows The starter should engage ONLY when the GSL is in N DETENT steering wheel locked in the CENTER position and the header drive switch is in the OFF position Under the above conditions the brake should engage and the machine should not move after engine start up The steering wheel should not lock with the engine running and the GSL is out of the N ...

Page 100: ... neutral but neutral start switch does not compress Neutral Start Switch 7 7 3 6 Neutral Lock Adjust Bolts 7 7 3 7 Cable Tension 7 7 3 4 GSL Position 7 7 3 3 Neutral Lock 7 7 3 5 Perform Neutral Set up Procedure 7 7 4 Machine growls severely or moves after engine start up Neutral Start Switch 7 7 3 6 Neutral Lock Adjust Bolts 7 7 3 7 Cable Tension 7 7 3 4 GSL Fore Aft Movement 7 7 3 1 GSL Position...

Page 101: ...lbf 108 122 Nm 7 7 3 4 Cable Tension The GSL D should easily move into the N DETENT E by itself and the cable F should be tight when the GSL is at the right hand side of the neutral detent on side console The neutral start switch should also be fully compressed If the cable is too tight it will prevent the neutral start switch from fully compressing and prevent proper engagement of adjustment bolt...

Page 102: ...hten outer nut E against inner nut F 7 Torque outer nuts C E to 60 70 ft lbf 80 90 Nm 8 Reconnect spring A 7 7 3 6 Neutral Start Switch The neutral start switch G must be closed before the engine can be started The switch is closed when the neutral interlock on the pump is activated by positioning the GSL into N DETENT and locking the steering wheel in centre position When the switch closes and ma...

Page 103: ...0 inch 1 5 mm d If required adjust the interlock release cable C as follows 1 Loosen jam nut D and turn nut E counterclockwise to increase the gap and clockwise to decrease 2 Tighten jam nut D against nut E 3 Check neutral start switch plunger is fully depressed 7 7 3 8 Loose Hardware Check all hardware not included in the previous checks is properly tightened to torque specifications on ground sp...

Page 104: ...urn Failure to raise front wheels will result in machine runaway causing severe personal injury or death a Detach header and remove hay conditioner forming shields from under tractor b Raise front of machine high enough to allow both wheels to turn freely and support with jack stands See Jacking Procedure under Wheel Tire Maintenance in this section c Open maintenance platform d Disconnect electri...

Page 105: ...ts the pintle arm 9 Move the pintle arm firmly against the rear adjusting bolt to check the setting it s acceptable for the LH wheel to just begin to creep backward Hand tighten the jam nut D at the rear adjusting bolt 10 Verify the adjusting bolt setting by again moving the pintle arm forward then rearward to check that the LH wheel just begins to creep in both cases 11 Fully tighten jam nuts on ...

Page 106: ... d Wash filter as required 1 Soak 15 minutes in warm water not over 100 F 40 C with Filter Element Cleaner Donaldson D 1400 or equivalent 2 Rinse thoroughly with clean water maximum pressure 40 psi 275 kPa 3 Shake excessive water from filter and allow element to dry Do not use compressed air to dry filter it may rupture the wet element Protect element from freezing until dry e Inspect filter befor...

Page 107: ...and position on cab wall over opening e Secure to cab wall with knobs A 7 7 5 3 A C Condenser The air conditioning condenser should be cleaned daily with compressed air and more frequent cleaning may be necessary in severe conditions Cleaning the condenser can be done at the same time as the radiator oil cooler and charge air cooler Refer to Section 7 9 2 Cooling Box Maintenance 7 7 5 4 A C Evapor...

Page 108: ... C Compressor Protection The compressor is protected from excessively low and high pressures by two switches that shut down the compressor to prevent damage to the system These switches do not require any regular servicing or maintenance so if problems occur and the switches are suspect contact your dealer 7 7 5 6 Refrigerant and Oil IMPORTANT Perform the following steps whenever the machine is fi...

Page 109: ...ine oil level frequently and watch for any signs of leakage NOTE During the break in period a higher than usual oil consumption should be considered normal a Stop the engine and remove the key Wait about 5 minutes b Open engine compartment hood to lowest position c Remove dipstick by turning it counterclockwise to unlock and remove d Wipe clean reinsert in engine and remove e Oil level should be b...

Page 110: ...e filter h Clean gasket mating surface i Apply a thin film of clean oil to the gasket on the new filter j Screw the new filter onto the filter mount until the gasket contacts the filter head k Tighten the filter an additional to turn by hand IMPORTANT Do not use a filter wrench to install the oil filter Over tightening can damage the gasket and filter l Install the oil pan drain plug m Remove oil ...

Page 111: ...r is equipped with a restriction gauge which signals red when the primary filter element requires cleaning Check restriction gauge daily Never clean filter element unless restriction gauge signals red Excessive cleaning will shorten element life After cleaning re set restriction gauge by pushing button on top of gauge 7 8 4 2 Air Filter Servicing DANGER Stop engine and remove key from ignition bef...

Page 112: ...T The secondary inner element should be replaced every third time the primary element is changed h Clean inside of canister and cover with a damp cloth IMPORTANT Leave secondary element in place to prevent ingress of dirt into engine intake i Pat sides of primary element gently to loosen dirt Do not tap element against a hard surface j Using a Dry Element Cleaner Gun clean element with compressed ...

Page 113: ... place t Close engine compartment hood 7 8 4 3 Charge Air Cooling After the intake air passes through the air filter it passes through the turbocharger which boosts the pressure This process heats the air so it is passed through a cooler before entering the engine intake The cooler is located in the cooling box behind the radiator and should be cleaned daily with compressed air Refer to Section 7 ...

Page 114: ...ling machine WARNING To avoid personal injury or death from explosion or fire do not smoke or allow flame or sparks near windrower when servicing a Open engine compartment hood to highest position b Locate filter A on vent line against hydraulic oil reservoir c Release hose tension clamps B and slide away from filter Pull hoses off filter d Position new filter through hole in frame and attach top ...

Page 115: ...alve E under fuel tank c Change primary filter C as follows 1 Clean around the filter head F 2 Disconnect Water in Fuel WIF sensor G from bottom of filter 3 Remove filter C with a filter wrench 4 Clean gasket mating surface 5 Fill new filter with clean fuel and apply a thin film of clean oil to the gasket on the new filter 6 Screw the new filter C onto the filter mount until the gasket contacts th...

Page 116: ...tening can damage the gasket and filter e Open fuel valve E under fuel tank f Use priming pump on primary filter to fill new filter g Close engine compartment hood 7 8 5 3 Draining Fuel Tank Draining the fuel tank is necessary to remove old or contaminated fuel To drain the tank refer to following illustrations and proceed as follows a Stop the engine and remove the key b Open engine compartment h...

Page 117: ...l water separator is incorporated into the primary fuel filter The separator is equipped with a sensor G that detects water in the fuel and alerts the operator on the CDM Drain the water and sediment as follows from the separator daily or at any time the CDM Water in Fuel WIF light illuminates a Stop engine and remove key b Turn drain valve M by hand 1 to 2 turns counterclockwise until draining oc...

Page 118: ... any fittings Personal injury and property damage can result IMPORTANT Bleeding the fuel system is not recommended nor required a Manual priming may be required if The fuel filter is not filled prior to installation Injection pump is replaced High pressure fuel lines are replaced Engine is run until fuel tank is empty b Prime the fuel system as follows 1 Stop the engine and remove the key 2 Open e...

Page 119: ... system perform the following DANGER Stop engine and remove key from ignition before leaving operator s seat for any reason A child or even a pet could engage an idling machine a Stop engine and remove key b Move the maintenance platform to the open position for access to the coolant tank and radiator Ensure the platform latch is engaged in open position c Raise engine compartment hood to lowest p...

Page 120: ...ing is stuck c Close engine compartment hood and move maintenance platform to working position 7 8 6 3 Changing Coolant Coolant should be drained and the system flushed and filled with new coolant every 2000 hours or 2 years Change coolant and flush the system as follows CAUTION To avoid personal injury from hot coolant do not turn radiator cap until engine cools DANGER Stop engine and remove key ...

Page 121: ...with a solution of clean water and a heavy duty radiator cleaner Follow instructions provided with cleaner n After using cleaner solution again flush system with clean water Inspect radiator hoses and fittings for leaks o Close drain valves and fill system through radiator with an equal part mix of anti freeze and clean soft water Use Ethylene Glycol with SCA and equal parts of high quality soft d...

Page 122: ...haust gases to escape to the cab c Dents or crushed portions of any tubing create exhaust flow restriction and increase back pressure significantly Even relatively small dents will cause decreased fuel economy and increased turbo wear If dents are relatively large increased bearing and cylinder wear will occur due to increased exhaust temperature d The exhaust system should be secured to eliminate...

Page 123: ...ator s seat for any reason A child or even a pet could engage an idling machine a Shutdown the engine and open engine compartment access hood to highest position b Loosen compressor mounting hardware C and push compressor towards engine to release belt D tension c Remove belt D d Loosen alternator mounting hardware A and push alternator towards engine to release belt B tension e Remove belt B f In...

Page 124: ...re and factory set See Section 4 Specifications If specified speeds cannot be maintained see your Windrower dealer 7 8 9 1 Alternate Engine Speeds The engine operating speed can be programmed to enable the windrower to operate at reduced engine rpm without significantly affecting the ground or header speeds Intermediate Speed Control ISC is useful in where operating loads are reduced such as in li...

Page 125: ...emove key b Raise engine compartment hood fully c If rotors A are plugged clean as follows 1 Remove nut B 2 Pivot rotor assembly C away from screen 3 Blow out debris from rotors A with compressed air d Push latch D and open screen assembly access door E Secure with rod F stored inside screen door e If duct G is plugged blow out debris with compressed air f Clean screen with compressed air g Reposi...

Page 126: ... 08 0 24 in 2 6 mm from screen near the center 3 Re tighten nut B 4 Loosen the two motor mount bolts H 5 Move motor duct assembly J to obtain 0 04 0 32 in 1 8 mm gap to screen at full rotation of the duct 6 Re tighten nuts H on motor mount j Close screen access door E and engage latch D k Lower engine compartment hood B C 0 08 0 24 in 2 6 mm D E H J 0 04 0 32 in 1 8 mm ...

Page 127: ... or even a pet could engage an idling machine a Stop engine and remove key b Raise engine compartment hood fully c Push latch A and open screen assembly access door B Secure with rod C stored inside the screen door d Rotate retainer D pull open condenser E and secure with support rod at F e Lift lever G and pull open access door J f Slide out the oil cooler assembly K with handle If movement is re...

Page 128: ... K back into cooling box j Close side access door J and lock with lever G k Close side door N and secure with latch M l Remove support rod at F swing condenser E back into position and secure with retainer D m Unhook support rod C in screen door and store at base of cooling box n Close door until latch engages pin A o Lower hood and hood latch will lock hood E O P Q K K J G A C N M D E F ...

Page 129: ... with alternator or battery disconnected With battery cables disconnected and engine running a high voltage can be built up if terminals touch the frame Anyone touching the frame under these conditions would be severely shocked When working around storage batteries remember that all of the exposed metal parts are live Never lay a metal object across the terminals because a spark or short circuit w...

Page 130: ...e must not exceed 125 F 52 C Follow all instructions and precautions furnished by the battery charger manufacturer Charge at recommended rates and times 7 10 1 3 Boosting A twelve volt battery can be connected in parallel to with the windrower tractor battery Use heavy duty battery cables CAUTION Gas given off by batteries is explosive Keep sparks and flames away from batteries Make last connectio...

Page 131: ... flames away from electrolyte container and battery as gas given off by electrolyte is explosive Battery electrolyte causes severe burns Avoid contact with skin eyes or clothing Wear protective eyewear and heavy gloves WARNING If electrolyte is spilled or splashed on clothing or on the body neutralize it immediately with a solution of baking soda and water then rinse with clean water Electrolyte s...

Page 132: ...inal and remove cable from battery e Remove bolt C securing strap D to frame and remove strap f Lift battery off holder RATING GROUP CCA VOLT MAX DIMENSION Heavy Duty Off Road Vibration Resistant BCI 29H or 31A 950 12 12 5x7x10 in 317x178x254 mm g Position new battery on holder h Install strap D with bolt C IMPORTANT BATTERY IS NEGATIVE GROUNDED Always connect starter cable to the positive termina...

Page 133: ...ine disconnect battery cables and alternator wire e Always disconnect battery ground cable when working with the alternator or regulator f Never attempt to polarize alternator or regulator g If wires are disconnected from the alternator use the illustration below to ensure proper reconnection h Never ground the alternator field terminal or field circuit i Never connect or disconnect alternator or ...

Page 134: ...at a distance of 25 ft 7 5 m from the headlight a Hold onto the hand holds A on the cab front corners and stand on the header anti slip strips b Adjust the lights with screws B 7 10 2 2 Bulb Replacement a Remove the two screws C and remove light assembly b Pull wiring harness connector off the headlight assembly and remove rubber insulator boot D c Pinch the wire retainer E and lift away from hook...

Page 135: ...d not be necessary 7 10 3 Flood Lights Forward The forward floodlights are not adjustable Replace bulbs as follows a Shutdown engine and remove the key Turn off the lights b Hold onto the hand holds H on the cab front corners and stand on the header anti slip strips when removing the forward field lights c Remove the two screws J and remove light bezel K d Remove light from receptacle e Pinch the ...

Page 136: ...d right side up j Position light into light receptacle ensuring top is up and secure with bezel K and screws J 7 10 4 Flood Lights Rear 7 10 4 1 Adjustment The rear floodlights are best adjusted with the machine in the field or the equivalent to suit operator preference a Shutdown engine and remove the key Turn on lights b Loosen bolts A and B c Position light to desired position d Tighten bolts A...

Page 137: ... optical unit and insert bulb into unit g Secure bulb with wire retainer E h Push wire into connector G i Position light into light receptacle ensuring top is up and secure with bezel D and screws C 7 10 5 Swath Lights DANGER Stop engine and remove key from ignition before leaving operator s seat for any reason A child or even a pet could engage an idling machine The swath lights are not adjustabl...

Page 138: ...ugs O in optical unit and insert bulb into unit f Secure bulb with wire retainer J g Push wire into connector L IMPORTANT For proper lighting pattern be sure lights are installed right side up h Position light into light receptacle ensuring top is up and secure with bezel B and screws A 7 10 5 1 Red Tail Lights a Shutdown engine and remove the key Turn off the lights a Remove two screws C from lig...

Page 139: ...g that bulb base is properly engaged in socket Use Bulb Trade 1156 e Reinstall lens with screws B 7 10 5 3 Dome Light a Shutdown engine b Remove two screws C from plastic lens and remove lens c Replace bulb d Reinstall plastic lens with screws C 7 10 6 Ambient Light a Shutdown engine b Push against tabs D with a screwdriver and pull ambient light fixture out of cab roof c Remove connectors E d Con...

Page 140: ...ine and remove key b Remove wing nut A and remove fuse box cover B c Refer to decal on inside of cover for identification of fuses and circuit breakers See illustration next page SEE BG 7 10 8 1 Checking Replacing Fuses a To check fuse pull fuse C out of receptacle and visually examine b To replace fuse insert new fuse into receptacle IMPORTANT Replacement fuses should match rating on decal shown ...

Page 141: ...er a Stop engine and remove key b To check condition of fuse pull tab A and open cover B c Visually examine fuse C for indications of melting d To remove fuse C remove two nuts D and pull fuse free from holder Existing wiring may need to be pulled off the stud first e Install new fuse on studs and any existing wiring that was removed f Secure with nuts D g Close cover B and secure with tab A A B B...

Page 142: ... Before installing any replacement hose flush the inside of it with unused diesel fuel or unused commercial petroleum cleaning solvent for ten seconds minimum Do not use water water soluble cleaners or compressed air IMPORTANT The components in this system are built to very close tolerances and have been adjusted at the factory Do not attempt to service these components except to maintain proper o...

Page 143: ... Cooling Box Maintenance 7 11 4 Hydraulic Oil Filters NOTE Change hydraulic oil filters after the first 50 hours of operation and every 500 hours thereafter Filter A part 112420 and filter B part 151975 can be obtained from your dealer The hydraulic system contains two filters Change hydraulic oil filters as follows DANGER Stop engine and remove key from ignition before leaving operator s seat for...

Page 144: ...equire adjusting Contact your Windrower Dealer or refer to the Technical Service Manual for your Windrower HEADER MODEL APPLICATION SYSTEM SUGGESTED OVERLOAD WARNING SETTING psi kPa TRACTOR PRESSURE COMP SETTING psi kPa D60 A40D Reel Draper Pressure 3000 20684 3200 22063 D60 A40D Knife Conditioner Pressure 4000 27579 4200 28958 7 11 5 2 Reel Conveyor Flow Control Block Two hydraulic valve blocks c...

Page 145: ...emove key from ignition before leaving operator s seat for any reason A child or even a pet could engage an idling machine a Lower header to ground stop engine and remove key b Move maintenance platform rearward c Loosen jam nut A on needle valve and turn screw B clockwise to decrease the drop rate and counter clockwise to increase the drop rate d Tighten jam nut A e Close platform and engine comp...

Page 146: ...c Check the charge pressure relief valve Refer to following section d If charge pressure still cannot be maintained do not operate the windrower Contact your windrower dealer 7 11 6 2 Charge Pump Pressure Incorrect charge pressure settings may result in the inability to build required system pressure and or inadequate loop flushing flows Correct charge pressure must be maintained under all conditi...

Page 147: ...re g Remove pressure gauge hose and reinstall cap A to fitting 7 11 7 Hoses and Lines Check hydraulic hoses and lines daily for signs of leaks WARNING Avoid high pressure fluids Escaping fluid can penetrate the skin causing serious injury Relieve pressure before disconnecting hydraulic lines Tighten all connections before applying pressure Keep hands and body away from pin holes and nozzles which ...

Page 148: ... is correctly seated before inflating to operating pressure Do not remove install or make repairs to a tire on a rim unless you have the proper equipment and experience to perform the job Take the tire and rim to a qualified tire repair shop If the tire is not in correct position on the rim or if too full of air the tire bead can loosen on one side causing air to leak at high speed and with great ...

Page 149: ...Class GL 5 Extreme Pressure Gear Lubricant After first change use SAE 75W 90 API Service Class GL 5 Fully Synthetic Transmission Lubricant SAE J2360 preferred c Replace plugs and tighten d Change the lubricant as follows 1 Rotate the wheel so that plug A is located at the bottom 2 Place a large enough container about 2 quarts U S 2 litres under the drain plug A 3 Remove plugs A and B and drain lub...

Page 150: ...n a 5000 lb 2270 kg jack under leg jack point and raise windrower tractor wheel slightly off ground e Undo wheel nuts C and remove wheel f To install new tire ensure that air valves are on outside and tire tread point forward For Turf tires diamond tread be sure arrow on sidewall points in forward rotation g Position wheel on hub and install wheel nuts C h Tighten nuts C to 175 200 ft lbf 237 271 ...

Page 151: ...rim Never weld a wheel rim Make sure all the air is removed from a tire before removing the tire from the rim Never use force on an inflated or partially inflated tire Make sure the tire is correctly seated before inflating to operating pressure Do not remove install or make repairs to a tire on a rim unless you have the proper equipment and experience to perform the job Take the tire and rim to a...

Page 152: ...U S Gal Liters TOTAL WEIGHT OF BOTH TIRES lb kg 7 5X16 A 10 38 200 91 10X16 B 18 69 380 170 16 5X16 1 C 41 158 830 377 Weights are given for typical calcium chloride and water mixtures Weight is reduced by 20 if only water is used for areas that do not require anti freeze protection HEADER DESCRIPTION RECOMMENDED BALLAST RECOMMENDED TIRE SIZE LEVEL GROUND HILLS TYPE SIZE PER TIRE BOTH TIRES PER TI...

Page 153: ...eath caused by machine runaway shut off engine and remove key before performing any of the following checks and or adjustments a Remove the caster wheel as follows 1 Park windrower on level ground and block all wheels 2 Place GSL in N DETENT shutdown engine and remove key 3 Raise end of walking beam using a 2000 lb 908 kg capacity jack or other suitable lifting device until the wheel is slightly o...

Page 154: ...908 kg capacity jack or other suitable lifting device until the wheel is slightly off the ground 4 Undo the six wheel bolts E and remove wheel from hub b Install the caster wheel as follows 1 Position wheel on hub and install wheel bolts E 2 Torque bolts E to 100 ft lbf 135 N m using the tightening sequence as shown on previous page 3 Lower windrower tractor and remove jack 7 12 2 6 Caster Wheels ...

Page 155: ...OMMENDED SAFETY PROCEDURES 7 13 1 Break In Inspection HRS ITEM CHECK REF 25 Road or 1 in Field Drive Wheel Nuts Torque 175 200 ft lbf 237 271 N m Repeat Checks Until Torque Stabilizes 7 12 1 5 A C Belt Tension 7 8 8 3 Caster Wheel Nuts Torque 115 127 ft lbf 156 172 N m 7 12 2 Caster Wheel Anti Shimmy Dampener Bolts Optional Inboard Bolt Torque 100 ft lbf 135 N m Outboard Bolt Torque 100 ft lbf 135...

Page 156: ...uel Filter Water Trap 7 Fill Fuel Tank 8 Check Hydraulic Hoses And Lines For Leaks 50 HOURS 1 Grease Caster Pivots 2 Grease Walking Beam Center Pivot 3 Grease Top Lift Link Pivots 4 Grease Forked Caster Spindle Bearings 5 Clean Cab Fresh Air Intake Filter 100 HOURS OR ANNUALLY 1 Clean Cab Air Return Filter 200 HOURS OR ANNUALLY 1 Check Drive Wheel Lubricant Level 2 Grease Formed Caster Wheel Hub B...

Page 157: ...OT NORMALLY REQUIRED BUT IS AT THE OWNER OPERATOR S DISCRETION A C Condenser Charge Air Cooler Engine Oil Level Engine Coolant Level Fuel Tank Fuel Filter Water Trap Hydraulic Hoses And Lines Hydraulic Oil Cooler Hydraulic Oil Level Radiator Tire Inflation ANNUALLY A C Blower Anti Freeze Concentration Battery Charge Battery Fluid Level Fuel Tank Vent Line Filter Safety Systems or 500 hours 50 HOUR...

Page 158: ... Hour Meter Reading Date Serviced By 500 HOURS Engine Oil And Filter Fuel Filters Engine Valve Tappet Clearance 1st Engine Air Cleaner Filter Element Crankcase Breather Hydraulic Oil Filters 1000 HOURS Drive Wheel Lubricant Engine Valve Tappet Clearance 2000 HOURS Engine Coolant General Inspection Hydraulic Oil ...

Page 159: ...ity of wiring and breaker manual reset 7 10 8 1 Loose connection at fuel pump Ensure connector at pump is fully pushed in ECM fuse 1 of 2 blown Replace 7 10 8 2 ECM Ignition relay faulty Neutral Logic relay faulty Faulty injectors Contact MacDon dealer Engine Knocks Insufficient oil Add oil 7 8 2 Engine out of time Contact MacDon dealer Low or high coolant temperature Remove and check thermostat S...

Page 160: ... Engine Overheats Low coolant level Fill reserve tank to proper level Check system for leaks 7 8 6 1 Engine overloaded Reduce ground speed 6 3 6 2 Defective radiator cap Replace cap 7 8 6 2 Defective fan belt Replace belt 7 8 8 3 Dirty radiator screen Rotors turning Check for obstructions in ducting from screen to fan shroud 7 10 1 Rotors not turning Check connections to rotor electric motor Dirty...

Page 161: ...l Move GSL to neutral Move steering wheel to center position Disengage header clutch 6 3 6 6 3 5 1 5 16 1 Relay not functioning Check relay and wire connections 7 10 8 1 Loose or corroded battery connections Clean and tighten loose connections 7 10 1 4 Key switch worn or terminals loose Contact MacDon dealer Crankcase oil too high viscosity Use recommended oil 7 3 3 Main fuse defective blown Repla...

Page 162: ...ing energized by activating switch Contact MacDon dealer Header Or Reel Lifts But Lacks Power Relief pressure too low or contaminant in relief valve Check adjust clean relief valve at cylinder control valve Reel And Or Conveyor Not Turning Header drive switch not engaged Engage switch 5 16 1 Flow controls adjusted too low Toggle speed controls on CDM to increase flow 6 5 3 6 5 4 6 6 4 Appropriate ...

Page 163: ...oil level Check oil reservoir level 7 12 1 Power hubs disengaged Engage power hubs 6 3 9 4 Damaged hydraulic lines preventing proper oil flow Replace damaged lines Steering controls worn or defective Check GSL and steering for loose worn or dam aged ball joints and connecting rods 7 8 3 7 8 4 Speed range control not working Contact MacDon dealer Pump arms have broken shaft or loose hardware Repair...

Page 164: ...r replace 7 8 3 7 8 4 Brakes binding or not releasing fully Check pressure min 200 psi on brake release valve Faulty pump or motor Contact MacDon dealer Air in system Check lines for leakage Hydraulic Oil Filter Leaks At Seal Not properly tightened Tighten filter element 7 12 4 Damaged seal or threads Replace filter or filter head 7 12 4 8 6 STEERING AND GROUND SPEED CONTROL SYMPTOM PROBLEM SOLUTI...

Page 165: ... Odour From Air Louvers Plugged drainage hose Blow out hose with compressed air Dirty filters Clean filters 7 7 5 1 7 7 5 2 Air Conditioning Not Cooling Low refrigerant level Add refrigerant Switch contacts in thermostat burned excessively or sensing element defective Replace thermostat Clutch coil burned out or disconnected Contact MacDon dealer Condenser fins plugged Clean condenser 7 9 2 Blower...

Page 166: ...ondenser 7 9 7 3 Evaporator fins clogged Clean evaporator fins under cab floor 7 7 5 4 Too little refrigerant in system Contact MacDon dealer Clogged expansion valve Clogged receiver drier Excessive moisture in system Air in system Thermostat defective or improperly adjusted Replace thermostat Blower motor sluggish in operation Contact MacDon dealer Air Conditioning System Too Noisy Defective wind...

Page 167: ...m Contact MacDon dealer Incorrect super heat adjustment in expansion valve Thermostat defective Defective blower switch or blower motor Partially open improper ground or loose connection in compressor clutch coil Windows Fog Up High humidity Run A C to dehumidify air and heater to control temperature 5 10 1 1 8 8 OPERATOR S STATION SYMPTOM PROBLEM SOLUTION SECTION Rough Ride Seat suspension not ad...

Page 168: ...st the header angle from the cab Installation instructions are included 9 8 TRAINING SEAT A wall mounted fold up training seat complete with seat belt is available to assist in training a new operator Installation instructions are included 9 9 KNIFE SPEED REEL SPEED INDEX AND TILT SENSOR MODULE To allow the electronic monitoring of header knife speed reel speed and header angle Also enables the in...

Page 169: ...Disc Header disc speed switch 28 Display set up 42 Display Warnings 37 Draper Header attachment 70 deck shift 81 detaching 73 draper minimum speed 78 draper speed 77 knife speed 79 reel minimum speed 76 reel speed 75 Drive Wheels 148 bolt torque 148 lubricant 149 removal installation 150 Driving spin turn 56 stopping 56 windrower 53 Electrical System circuit breakers 140 fuses 140 main fuses 141 t...

Page 170: ...ive 146 transmission oil pressure 146 troubleshooting 162 valve block 144 Hydraulics hoses and lines 147 leaks 147 Ignition Switch 25 Interior Lights 139 Jacking 150 Knife Drive valve block 144 Knife Speed auger header 87 draper header 79 Levelling the Header 65 Lift Cylinder Stops 62 Lighting engine forward 20 Lights 19 floodlight bulb replace 135 headlight adjustment 134 headlight bulb 134 rear ...

Page 171: ...ments 99 cable tension 101 GSL fore aft 99 GSL position 101 hub locks 61 neutral interlock 99 neutral lock 102 neutral set up procedure 104 troubleshooting 163 164 Tractor break in 48 dimensions 13 monitoring 30 specifications 14 Training Seat 17 Transporting 58 Troubleshooting air conditioning 165 electrical 161 engine 159 header drive 162 hydraulics 162 operator s Station 167 traction drive 163 ...

Page 172: ... A I N D R I V E V 1 0 Main header drive solenoid V10 fault detected E 39 E 40 H I G H R A N G E V 5 A High range solenoid V5A fault detected E 41 R E E L A F T V 2 B Reel aft solenoid V2B fault detected E 42 R E E L F O R E V 4 D Reel fore solenoid V4D fault detected E 43 R E E L U P D O W N V 4 B Reel up down solenoid V4B fault detected E 44 E 45 E 46 S E N S O R V O L T S H I G H Sensor voltage...

Page 173: ...c Intermittent or Incorrect 3 Red 131 91 Accelerator Pedal or Lever Position Sensor Circuit Voltage Above Normal or Shorted to High Source 4 Red 132 91 Accelerator Pedal or Lever Position Sensor Circuit Voltage Below Normal or Shorted to Low Source 8 154 91 Abnormal frequency pulse width or period 12 154 91 Bad Device or component 19 Red 287 SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor...

Page 174: ...Manifold Air Temperature Sensor Circuit Voltage Above Normal or Shorted to High Source 4 Amber 154 172 Intake Manifold Air Temperature Sensor Circuit Voltage Below Normal or Shorted to Low Source 15 None 2964 539 Intake Manifold Temperature High Data Valid but Above Normal Operational Range Least Severe Level 16 Amber 488 539 Intake Manifold 1 Temperature Data Valid but Above Normal Operational Ra...

Page 175: ... Severe Level 18 Amber 441 Battery 1 Voltage Low Data Valid but Below Normal Operational Range Moderately Severe Level Ambient Air Temperature 171 3 Amber 249 Ambient Air Temperature Sensor Circuit Voltage Above Normal or Shorted to High Source 4 Amber 256 Ambient Air Temperature Sensor Circuit Voltage Below Normal or Shorted to Low Source Fuel Temperature 174 3 Amber 263 Engine Fuel Temperature S...

Page 176: ...Lost without Ignition Off Data Erratic Intermittent or Incorrect Controller 1 629 12 Red 111 Engine Control Module Critical internal failure Bad intelligent Device or Component Calibration Memory 630 2 Amber 341 268 Engine Control Module data lost Data Erratic Intermittent or Incorrect 13 Red 342 Electronic Calibration Code Incompatibility Out of Calibration 31 Amber 2217 ECM Program Memory RAM Co...

Page 177: ...Out of Adjustment 8 142 342 Abnormal signal frequency Intake Air Heater 1 729 3 Amber 2555 Intake Air Heater 1 Circuit Voltage Above Normal or Shorted to High Source 4 Amber 2556 Intake Air Heater 1 Circuit Voltage Below Normal or Shorted to Low Source Internal Sensor Voltage Supply 1043 3 Amber 387 Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit Voltage Above Normal or Shorted t...

Page 178: ...211 Additional Auxiliary Diagnostic Codes logged Condition Exists Control Module Identification Input State 1563 2 Amber 1256 Control Module Identification Input State Error Data Erratic Intermittent or Incorrect Accelerator Pedal Position 2623 3 Amber 1239 Accelerator Pedal or Lever Position Sensor 2 Circuit Voltage Above Normal or Shorted to High Source 4 Amber 1241 Accelerator Pedal or Lever Po...

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MacDon M100 2009, Operator'S Manual

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