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MacDon M105 2011, Operator'S Manual

The MacDon M105 2011 Operator's Manual is a comprehensive guide for users of this remarkable agricultural machine. Available for free download at manualshive.com, this manual equips operators with essential knowledge and instructions to maximize productivity. Don't miss this opportunity to obtain the manual and enhance your MacDon M105 experience.

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OPERATOR’S STATION 

Form 169552 / 169554 / 169555

 

44

 

Revision A

 

(continued next page) 

L1

C x x x || S E T   C O N T R O L   L O C K S ?

L2

M x x x ||

N O  /  Y E S

V I E W   C O N T R O L   L O C K S ?

L1

C x x x || D R A P E R   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 || A U G E R   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   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    

L1

C x x x || V I E W   C O N T R O L   L O C K S ?

L2

M x x x ||

N O  /  Y E S

E X I T   T R A C T O R   S E T U P ? 

L1

C x x x || D R A P E R   S P E E D

         

L2

M x x x ||     5 7 5 . 1

H R S

E N A B L E D

L2

M x x x ||     6 4 8 . 6

H R S

L O C K E D

L1

C x x x || A U G E R   S P E E D

     

L2

M x x x ||     5 7 5 . 1

H R S

E N A B L E D

L2

M x x x ||     6 4 8 . 6

H R S

L O C K E D

L1

C x x x || R E E L   S P E E D

L2

M x x x ||     5 7 5 . 1

H R S

E N A B L E D

L2

M x x x ||     6 4 8 . 6

H R S

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 ||     5 7 5 . 1

H R S

E N A B L E D

L2

M x x x ||     6 4 8 . 6

H R S

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 ||     5 7 5 . 1

H R S

E N A B L E D

L2

M x x x ||     6 4 8 . 6

H R S

L O C K E D

L1

C x x x || E X I T   V I E W   L O C K O U T S ?

L2

M x x x ||      

    N O  /  Y E S        

D R A P E R   S P E E D

         

L1

C x x x || E X I T   T R A C T O R   S E T U P ? 

L2

M x x x ||      

    N O  /  Y E S        

T I L T   C Y L   I N S T A L L E D ?

L1

C x x x

||

C A B   D I S P L A Y   S E T U P ?

L2

M x x x

||

     

    N O  /  Y E S        

C A L I B R A T E   S E N S O R S ?

L1

C x x x || D I S P L A Y   L A N G U A G E ?  

L2

M x x x ||             E N G L I S H      

 

L2

M x x x ||             E S P A N O L      

 

L2

M x x x ||             R U S S I A N          

L1

C x x x || D I S P L A Y   U N I T S ?        

L2

M x x x ||           I M P E R I A L      

 

L2

M x x x ||             M E T R I C            

Use the "arrow" keys to change the default 

language. Pressing "SELECT" goes to the next L1 

menu selection.

If "NO" then jump to:

If "NO" then jump to:

If "NO" then jump to:

Using the "arrow" keys allows the operator to select 

the various functions. Pressing "SELECT" will go to 

the EXIT VIEW LOCKOUTS?  menu selection.

If "NO" then jump to:

If "NO" then jump to:

Tilt to be suppressed if not "installed" in the tractor 

setup menu.

If any of the HDR ANGLE / KNIFE SPEED or REEL 

SPEED sensors are not "installed" (no expansion 

module or A30 Auger header selected, they should 

be suppressed.

The "arrow" keys are used to select between 

IMPERIAL or METRIC. The default value will be 

displayed first.

If "NO" then jump to:

This menu allows the operator to selectably "lock 

out" the control functions for the various header 

functions. The default or selected "status" for each 

item will flash.

When the control lock outs are viewed, the lower 

display line (L2) will show the engine hours and 

either ENABLED or LOCKED to indicate the 

present status along with the engine hours at which 

time the function was either ENABLED or LOCKED.

If the expansion module is not installed the 

corresponding menu items should be suppressed.

The "arrow" keys are used to ENABLE or LOCK 

OUT each function. Pressing "SELECT" will go to 

the next L1 menu item.

Summary of Contents for M105 2011

Page 1: ...M105 Self Propelled Windrower OPERATOR S MANUAL Part 169552 Rev A 25 ...

Page 2: ...nd MAINTENANCE SERVICE for your new MacDon Model M105 Self Propelled Windrower CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ...

Page 3: ...n conjunction with your Header Operator s Manual CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD ASSEMBLE OR USE THE MACHINE Use this manual as your first source of information about the machine If you follow the instructions given in this manual your M105 windrower will work well for many years If you require more detailed service information check with your MacDon Dealer Use...

Page 4: ...ar of the Windrower and Engine on the lines below WINDROWER SERIAL NO _________________YEAR______ Serial Number Plate is located on the left side of the main frame near the walking beam ENGINE SERIAL NO _____________________YEAR_______ Serial Number Plate is located on the top face of the engine cylinder head cover ...

Page 5: ... OPERATOR PRESENCE 22 5 6 1 Header Drive 22 5 6 2 Transmission 22 5 6 3 Engine 22 5 7 LIGHTS 23 5 7 1 Field Lighting 23 5 7 2 Road Lighting 24 5 7 3 Beacon Lighting Export N A Optional 24 5 8 WINDSHIELD WIPER 25 5 9 REAR VIEW MIRRORS 25 5 10 CAB TEMPERATURE 26 5 10 1 Controls 26 5 10 2 Air Distribution 26 5 10 3 Heater Shut Off Valve 26 5 10 4 A C Compressor Protection 27 5 11 INTERIOR LIGHTS 27 5...

Page 6: ...rage 73 6 4 HEADER OPERATION 74 6 4 1 Header Lift Cylinder Stops 74 6 4 2 Header Flotation 75 6 4 3 Levelling 77 6 4 4 Header Drive 78 6 4 5 Header Angle 78 6 4 6 Cutting Height 80 6 4 7 Swath Roller Operation 81 6 5 D SERIES HEADER OPERATION 82 6 5 1 Header Attachment Error Bookmark not defined 6 5 2 Header Detachment Error Bookmark not defined 6 5 3 Header Position 89 6 5 4 Reel Fore Aft Positio...

Page 7: ...7 8 8 Gearbox 140 7 8 9 Exhaust System 142 7 8 10 Belts 143 7 8 11 Engine Speed 144 7 9 COOLING BOX 145 7 9 1 Cooling Box Screen 145 7 9 2 Rotor To Screen Clearance 146 7 9 3 Cooling Box Maintenance 147 7 10 ELECTRICAL SYSTEM 150 7 10 1 Batteries 150 7 10 2 Headlights 156 7 10 3 Field Lights Forward 157 7 10 4 Flood Lights Forward 158 7 10 5 Flood Lights Rear 159 7 10 6 Swath Lights 160 7 10 7 Amb...

Page 8: ...ROWER HYDRAULIC COMPLETION FOR DRAPER HEADER REEL FORE AFT 193 9 3 BOOSTER SPRING KIT 193 9 4 INTERNAL BOOSTER SPRING KIT 193 9 5 LIGHT HEADER FLOTATION KIT 193 9 6 AM FM RADIO 193 9 7 HYDRAULIC CENTER LINK 193 9 8 FAN AIR BAFFLE KIT 193 9 9 TRAINING SEAT 193 9 10 KNIFE SPEED REEL SPEED INDEX AND TILT SENSOR MODULE 193 9 11 ANTI SHIMMY KIT FOR CASTERS 193 9 12 SWATH ROLLER 193 9 13 WARNING BEACONS...

Page 9: ...It is also used to alert against unsafe practices CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It is also used as a reminder of good safety practices 3 3 SAFETY SIGNS 3 3 1 SAFETY SIGN INSTALLATION Proceed as follows a Be sure the installation area is clean and dry b Decide on the exact location before you remove the decal backing p...

Page 10: ...SAFETY Form 169552 169554 169555 8 Revision A Safety Sign Locations cont d IN CAB 109868 IN CAB 109844 IN CAB 160422 BEL0W DOOR HANDLE 32744 ON SEAT 115148 ON OIL RESERVOIR UNDER HOOD BOTH SIDES 44944 ...

Page 11: ...Form 169552 169554 169555 9 Revision A Safety Sign Locations cont d BEHIND DOOR ON SILL LH SIDE ONLY 160396 BEHIND DOOR ON SILL 109843 LIFT LINKAGES 163561 IN CAB 32744 BELOW DOOR HANDLE 32744 ON FRAME 110989 ...

Page 12: ...SAFETY Form 169552 169554 169555 10 Revision A Safety Sign Locations cont d ON FRAME 32743 ON FRAME 110986 ON FRAME 42130 ON FAN SHROUD 134068 EXHAUST COVER 139668 ...

Page 13: ...SAFETY Form 169552 169554 169555 11 Revision A Safety Sign Locations cont d ON DRINK COOLER 160429 ON FRAME 110986 ON TRACTION PUMP 32743 ON LIFT LINKAGE 163562 ...

Page 14: ...ide 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 that accidents often happen when the Operator is tired or in a hurry to get finished Take the time to consider the safest way Never ignore warning signs of fatigue...

Page 15: ...e 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 not allow oil or grease to accumulate on service platforms ladders or controls Clean machines before storage Never use gasoline naphtha or any vola...

Page 16: ...ader and the machine that tilts the header ECM Engine Control Module GSL Ground Speed Lever Header A machine that cuts and lays crop into a windrow and is attached to a self propelled windrower ISC Intermediate Speed Control Mower Conditioner A machine that cuts and conditions hay and is pulled by an Ag tractor PTO Power Take Off SAE Society Of Automotive Engineers Self Propelled Windrower SP Self...

Page 17: ...ange 0 11 mph 18 km h Reverse Cab Forward 6 mph 9 6 km h Transport Cab Forward High Range 0 16 mph 26 km h Transmission Type 2 Piston Pumps 1 per Drive Wheel Displacement 3 0 cu in 50 cc Flow 33 U S gpm 125 L min Pressure 5000 psi 345 bar Final Drive Type Planetary Gearbox Ratio 41 42 1 Wheel Motor Displacement Low Range 2 80 cu in 46 cc High Range 1 65 cu in 27 cc SYSTEM CAPACITIES Fuel Tank 97 U...

Page 18: ...Two Outside Radio Two Speakers and Antenna Factory Installed Radio Dealer Installed SYSTEM MONITORING Speeds Ground mph or km h Engine rpm Knife spm Optional Reel rpm or mph km h Optional Conveyor Ref No Header Height Angle Optional TIRE OPTIONS Drive Tires 18 4 26 600 65 R28 18 4 26 23 1 26 580 70 R26 Bar Bar Turf Turf Turf 32 psi 26 psi 35 psi 20 psi 24 psi 221 kPa 179 kPa 241 kPa 138 kPa 165 kP...

Page 19: ... 3712 156 3 3970 Inner Inner 123 3124 131 9 3352 142 1 3610 600 65R28 Radial Tire Inner Outer 130 1 3305 139 1 3532 153 7 3904 142 9 3630 158 3 4020 120 6 3064 Outer Outer 137 2 3484 146 1 3712 160 9 4084 Inner Inner 123 3124 131 9 3352 146 6 3724 23 1 26 and 580 70R26 Turf Tires Inner Outer 127 2 3230 139 1 3532 150 3810 142 9 3630 158 3 4020 120 6 3064 Outer Outer 134 2 3410 146 1 3712 157 1 399...

Page 20: ...DESCRIPTION Form 169552 169554 169555 18 Revision A WINDROWER DIMENSIONS cont d FORWARD 45 7 in 1160 TREAD HUBS TIRES WHEEL BASE 133 in 3378 mm REVERSE TREAD CASTERS WHEEL BASE ...

Page 21: ...D ROAD LIGHTS OPERATOR S STATION HEADER FLOAT SPRINGS DOOR WINDSHIELD WIPER MIRROR MAINTENANCE PLATFORM CENTER LINK TURN SIGNAL HAZARD LIGHTS HAND RAILS FLOOD LIGHTS REAR SWATH LIGHTS DRIVE WHEEL TURN SIGNAL HAZARD LIGHTS MIRROR WALKING BEAM DOOR ENGINE COMPARTMENT HOOD CASTER WHEEL HORN RED TAIL LIGHTS ...

Page 22: ...OTTLE HEADER CONTROLS SECTION 5 17 ENGINE WINDROWER CAB DISPLAY MODULE CDM SECTION 5 18 GROUND SPEED CONTROLS SECTION 5 16 LUMBAR 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...

Page 23: ...ine securely fasten your seat belt and ensure Trainer s seat belt is fastened if occupied The seat belt can help ensure 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 24: ...header 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 DRIVE 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 accompani...

Page 25: ...ner Refer to illustrations that follow for location of lights 5 7 1 FIELD LIGHTING HIGH LOW LIGHTS Controls High Low 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 FRONT HIGH LOW FIELD LIGHTS FLOOD LIGHTS SWATH LIGHTS HIGH LOW REAR ...

Page 26: ...e activated with the switch on the CDM when driving on the road 5 7 3 BEACON LIGHTING EXPORT N A OPTIONAL The beacon lights are functional when the ignition and the beacon switches are ON The beacons must be used when driving on the road where required by law BEACON LIGHTS AMBER FRONT HIGH LOW ROAD TURN SIGNALS HAZARDS AMBER REAR TURN SIGNALS HAZARDS AMBER SMV SIGN RED TAIL LIGHTS ...

Page 27: ... 5 9 REAR VIEW MIRRORS Two adjustable outside mounted mirrors provide rear view vision The mirror light assembly is designed to fold backwards if accidentally struck either during normal operation or by another machine A detent type lock keeps it in place WIPER SWITCH Controls Windshield Wiper ON OFF REAR VIEW MIRRORS WIPER IN PARK POSITION ...

Page 28: ...itch to maximum heating and A C control to OFF c Start engine and operate at low idle until engine is warm d 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 located in the cab posts as shown above The vents provide window and Operator ventilation 5 ...

Page 29: ...falls to 220 280 psi 1517 1930 kPa the switch closes and allows the compressor to run 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 located directly overhead to provide ambient lighting if desired and f...

Page 30: ...th the radio 5 13 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 next illustration for part dimensions for a homemade version It accommodates most CB 2 way radio and satellite radio antennas Refer to Form 169558 M105 Self Propelled Windrower Unloading and Assembly Instruction for installation proc...

Page 31: ...tration 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 32: ...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 and Header Push ON Push OFF REVERSE AUTO STEER ENGAGEMENT SWITCH Engages Auto Steer System If compatible system is installed ENGAGE Click To Engage DISENGAGE Turn Steering Wheel Or Click To D...

Page 33: ...ng header drive Do not engage header with engine at full RPM 5 17 2 DECK SHIFT Draper Header with Deck Shift Option Controls deck shifting for double windrowing options with a draper header 5 17 3 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...

Page 34: ...l Release switch at desired position 5 17 3 3 Header Position Switches Press and hold the switch at location shown to move header Release the switch at desired position 5 17 3 4 Reel Speed Switches Press and hold the switch at location shown to change reel speed Release the switch at desired speed NOTE Auger speed adjusts proportionately when reel speed is changed For further details see Section 6...

Page 35: ...eat Water In Fuel Caution Stop Engine ENGINE RPM DISPLAY Header Functions HEADER INDEX SWITCH OPTION Links Reel and Conveyor Speed to Ground Speed Push ON Push OFF Illuminates In ON Position SELECT SWITCH Allows Operator To Select Display Item On Bottom Line See Table Push to SELECT RETURN TO CUT HEIGHT SWITCH Allows Cutting Height Pre Set Push ON Push OFF Illuminates In ON Position NOTE HEADER MU...

Page 36: ...N 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 00 0 10 0 Distance Between Cutterbar and Ground HEADER ANGLE 00 0 10 0 Header Angle R...

Page 37: ...eed 0 0 10 0 KNIFE SPEED SPEED SENSOR Flashing Knife Speed In Strokes Per Minute Optional Sensor Disabled HEADER HEIGHT HEIGHT SENSOR Flashing 00 0 10 0 Distance Between Cutterbar and Ground Sensor Disabled HEADER ANGLE ANGLE SENSOR Flashing 00 0 10 0 Header Angle Relative To Ground Opt Sensor Disabled FUEL LEVEL Level of Fuel In Tank ENGINE TEMP F ENGINE TEMP C If Metric Engine Coolant Temperatur...

Page 38: ...E SENSOR If Sensor Disabled Knife Speed In Strokes Per Minute SPEED and SENSOR flash alternately HEADER HEIGHT HEADER SENSOR If Sensor Disabled Distance Setting 00 0 10 0 Between Cutterbar and Ground If sensor disabled HEIGHT and SENSOR flash alternately HEADER ANGLE Optional HEADER SENSOR If Sensor Disabled Angle Setting 00 0 10 0 Header Relative To Ground If sensor disabled ANGLE and SENSOR flas...

Page 39: ...nsor Disabled Knife Speed In Strokes Per Minute SPEED and SENSOR flash alternately HEADER HEIGHT HEADER SENSOR If Sensor Disabled Distance Setting 00 0 10 0 Between Cutterbar and Ground If sensor disabled HEIGHT and SENSOR flash alternately HEADER ANGLE Optional HEADER SENSOR If Sensor Disabled Angle Setting 00 0 10 0 Header Relative To Ground If sensor disabled ANGLE and SENSOR flash alternately ...

Page 40: ...N DISPLAY 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 High Range Selected On Console Switch HEADER ENGAGED Header Drive Engaged ...

Page 41: ...tion 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 Prompt Attention is Required Refer to Display Code DISPLAY Displays Malfunction Code Refer to Appendix and Technical Service Manual ENGINE PREHEAT Illuminates Yellow Wait To Start Engine STOP Illuminates Red Stop Engine Immedi...

Page 42: ...Short Beep Every 2 seconds Flashes every second Voltage Below 11 5 HIGH VOLTS Short Beep Every 2 seconds Flashes every second Voltage Above 15 4 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 TRANS OIL PRESS Continuous Loud Tone Until Oil Pressure Is Regained Low Transmi...

Page 43: ...ate Tone Until Condition Is Corrected Machine Overload Knife Speed Drops Below Programmed Value LOW HYDRAULIC OIL Continuous Loud Tone For 5 Seconds If Condition Not Rectified Single Loud Tone Every 5 Minutes Low Hydraulic Oil Level Header Shuts Down Automatically If Engaged Header On Switch Must Be Moved To OFF Position And Then To ON Position To Restart The Header NO OPERATOR Continuous Tone Ope...

Page 44: ...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 Detailed Prog...

Page 45: ...L2 M x x x R P M K P H L1 C x x x S E T T I R E S I Z E L2 M x x x 1 8 4 X 2 6 T U R F L2 M x x x 1 8 4 X 2 6 B A R L2 M x x x 2 3 1 X 2 6 T U R F L2 M x x x 6 0 0 6 5 R 2 8 L1 C x x x S E T E N G I N E I S C R P M L2 M x x x O F F O N S E T C O N T R O L L O C K S Pressing SELECT will go to the next line 1 L1 menu selection The turn signal arrow keys are used to change the values Pressing SELECT ...

Page 46: ... Y E S T I L T C Y L I N S T A L L E D L1 C x x x C A B D I S P L A Y S E T U P L2 M x x x N O Y E S C A L I B R A T E S E N S O R S L1 C x x x D I S P L A Y L A N G U A G E L2 M x x x E N G L I S H L2 M x x x E S P A N O L L2 M x x x R U S S I A N L1 C x x x D I S P L A Y U N I T S L2 M x x x I M P E R I A L L2 M x x x M E T R I C Use the arrow keys to change the default language Pressing SELECT ...

Page 47: ... L T T O S T A R T L1 C x x x C A L I B R A T I N G T I L T L2 M x x x E X T E N D T I L T H O L D L2 M x x x E X T E N D T I L T D O N E L1 M x x x H D R T I L T S E N S O R C A L L2 M x x x P R E S S R E T R A C T T I L T L1 C x x x C A L I B R A T I N G T I L T L2 M x x x R E T R A C T T I L T H O L D L2 M x x x H D R T I L T C O M P L E T E L1 C x x x T O C A L I B R A T E S E L E C T L2 M x x...

Page 48: ... N P U T L2 M x x x H D R H E I G H T 3 5 9 V L1 C x x x S E N S O R I N P U T L2 M x x x H E A D E R A N G L E 1 8 4 V L1 C x x x S E N S O R I N P U T L2 M x x x K N I F E S P E E D 1 2 3 H Z L1 C x x x S E N S O R I N P U T L2 M x x x R E E L S P E E D 1 2 3 H Z L1 C x x x S E N S O R I N P U T L2 M x x x W H E E L S P E E D 1 2 3 H Z L1 C x x x E X I T R E A D S E N S O R S L2 M x x x N O Y E ...

Page 49: ...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 O S T I C S L2 M x x x N O Y E S D I A G N O S T I C M O D E If the HEADER TILT cylinder or the REEL FOR...

Page 50: ...RROR CODES The CDM displays Error Codes when there is a fault with one of the several sensors that monitor and control engine operation to assist the Operator or Technician in locating a specific problem with engine operation Refer to pages 194 200 for Engine Error Codes 5 18 8 CDM AND WCM FAULT CODES The CDM displays Fault Codes when there is a fault with one of the several sensors that monitor a...

Page 51: ...t for other Operators not using recommended procedures or not following safety precautions Correct these mistakes immediately before an accident occurs 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 ma...

Page 52: ... Road Lights Seat Ride Damping Work Light Cab Temperature Control Lighter Blower Air Conditioning Fresh Air Recirculate 6 2 3 HEADER FUNCTIONS Program Header Tilt Up Header Index Header Down Return To Cut Header Up Conveyor Auger Speed Header Tilt Down Float Left Increase Float Right Decrease Reel Speed Deck Shift Disc Speed Float Reel Down Header Engage Reel Forward Header Disengage Reel Up Push ...

Page 53: ...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 In addition to the following perform the items specified in to section 7 13 1 Break In Inspections DANGER Before investigating an unusual sound or attempting to correct a problem place GSL in N DETENT shut off engi...

Page 54: ...ibute A C refrigerant oil as follows IMPORTANT Perform the following steps whenever the machine is first started after storage for more than one week i Turn blower switch to first position turn temperature control switch to maximum heating and A C control to OFF ii Start engine and operate at low idle until engine is warm iii Click A C switch from OFF to ON for one second then back to OFF for 5 to...

Page 55: ...r near machine Before starting engine be sure there 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 ensure your safety if it is used and maintained a A battery main disconnect...

Page 56: ... ON after 2 seconds for a pre set length of time The operating period for the glow plug light will change depending engine temperature 4 When grid heater light goes out turn key to START and crank engine until it starts Leave throttle at IDLE 5 If engine fails to start repeat steps 1 to 4 6 Engine will cycle through a period where it appears to labor NOTE Throttle is non responsive during this tim...

Page 57: ...wise to OFF position 6 3 5 4 Fueling WARNING To avoid personal injury or death from explosion or fire do not smoke or allow flame or sparks near fuel tank when refueling Never refuel the windrower when the engine is hot or running a Stop windrower and remove key b Stand on platform to access fuel tank filler pipe c Clean the area around the filler cap A d Turn cap handle B counter clockwise until ...

Page 58: ...gate later but it is strongly advised to monitor the situation carefully 6 3 5 7 Electrical 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 Shut down 12 0 Battery Normal NOTE Display flashes voltage reading with single loud tone Repeats every 30 minutes until condit...

Page 59: ...lly 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 CAUTION 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 ground speed lever ...

Page 60: ...ngage header drives o Stop engine and remove key from ignition A child or even a pet could engage an idling machine o Turn off windshield wiper o Turn off lights unless required for inspection purposes o Release seat belt o Raise armrest and steering wheel for easier exit and re entry o Lock the cab door when leaving the windrower unattended When the door is locked it can still be opened from insi...

Page 61: ...ency of new Operators to over steer NOTE The windrower can be equipped with an automatic steering system for use in the field The Auto Steer is available as an option and can be installed by an Auto Steer Dealer The GSL has been pre wired at the factory with a switch Also see Section 9 14 AUTO STEER 6 3 6 2 1 Reverse WARNING Back up slowly Steering is opposite to normal when reversing Hold steerin...

Page 62: ...will increase ground speed as well h To stop the turn return the steering wheel to center 6 3 6 4 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 a SLOWLY return the GSL A to NEUTRAL and into N DETENT b Turn steering wheel until it locks c Move throttle lever B to low idle position ...

Page 63: ...d steering wheel locked 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 Raise rear of windrower 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 a lifting capacity of at least 5000 lb 2270 kg b Re...

Page 64: ... installed at the back inboard locations e Install bottom bolts C f Tighten bolts as follows 1 Snug bottom bolts C 2 Tighten and torque back bolts B to 330 ft lbf 447 N m 3 Tighten and torque bottom bolts C to 330 ft lbf 447 N m g Lower windrower to ground IMPORTANT Re torque bolts after first 5 and 10 hours of operation A B C ...

Page 65: ...the windrower may not be apparent under these conditions CAUTION Operate both steering wheel and ground speed lever slowly for familiarization Remember that steering is more sensitive when speed range control is in ROAD SPEED position Avoid the common tendency of new Operators to over steer a Ensure HEADER DRIVE switch is pushed to OFF position b Before driving windrower on a roadway 1 Clean flash...

Page 66: ... WARNING To avoid serious injury or death from loss of control Do not make abrupt changes in steering direction Anticipate turns and steep slopes by slowing down well in advance Do not rapidly accelerate or decelerate while turning When travelling on steep slopes i Move ground speed lever closer to NEUTRAL to reduce speed ii Lower header iii Move GROUND SPEED RANGE switch to low range With header ...

Page 67: ... appropriate equipment to comply with all local regulations Before each towing trip a pre trip inspection must be conducted to verify that all signal lighting and safety equipment is installed and functioning properly Do not connect any towed implement except for 30 35 FT D Series headers equipped with slow speed transport package or Header transport trailers for 20 25 FT D Series headers Tongue w...

Page 68: ... on weight box and install into rear hole A at the top of the lift arms for additional lift height for transport wheel deployment DANGER To avoid bodily injury from fall of raised header always engage header lift cylinder stops when working on or around raised header d Raise header to full height stop engine and engage safety locks on lift cylinders e Deploy header slow speed transport system See ...

Page 69: ...ft system when lowering header lift linkages without a header or weight box attached to windrower ensure that float engagement pin is installed in storage location C and not installed at hole location B 1 Drive windrower so that windrower lift arms are positioned into the weight box pockets 2 Raise lift arms slightly 3 Stop engine and remove key 4 Install locking pins D into pockets and through wi...

Page 70: ...gine and gently reverse the windrower until the drawbar support pivots down into transport position iii Stop engine and remove key iv Re install pin C to secure drawbar support and proceed to step n on next page IMPORTANT Ensure lynch pins are secure in all three pins and that the drawbar pin is also secured by a locking pin 4 If the tow bar A is too close to the windrower i Remove pin F lower the...

Page 71: ...w bar harness plug K to the receptacle on the windrower p At the LH float spring tower attach connector L on windrower harness to towing harness receptacle M q Confirm that the flashing amber and signal lights on header function properly r Before moving the machine double check that all pins are secure the drawbar and hitching components are not showing signs of damage and that all safety equipmen...

Page 72: ... in LH float spring tower c Disconnect electrical harness C from windrower and store harness on tow bar d Undo lock D remove safety chain E from drawbar and remove clevis pin F e Move tow bar off drawbar f At rear of windrower remove pins G lift drawbar support H to horizontal position and re install pins as shown g Alternate drawbar J is used for attaching a tow behind swath roller IMPORTANT Do n...

Page 73: ...ower j Start engine lower weight box onto blocks and back away k Attach header to windrower Refer to Section 6 5 1 Header Attachment l Convert header into field position See Header Operator s Manual for procedure m Start engine and lower header to ground Continue to retract lift cylinders so that member N lifts off link O n Remove temporary lift pins P from lift arms and install pins into storage ...

Page 74: ...he windrower may roll on a sloped surface Before disengaging final drives attach windrower to towing vehicle After towing engage drives and ensure GSL is in N DETENT before detaching from towing vehicle IMPORTANT Failure to disengage final drives before towing will result in serious transmission damage IMPORTANT Do not exceed 16 mph 26 km h when towing windrower IMPORTANT Do not use this towing me...

Page 75: ...r waterproof tape g 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 h Re paint all worn or chipped painted surfaces to prevent rust i Lubricate the windrower thoroughly leaving excess grease on fittings to keep moisture out of bearings Apply grease...

Page 76: ... or death from fall of raised header 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 Press and hold HEADER UP switch until both cylinders stop moving 2 Continue to hold switch ...

Page 77: ...rating Guidelines When working with the cutterbar on the ground Set center link to mid range position Refer to Section 6 4 5 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 ...

Page 78: ...pped 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 counter clockwise to decrease float makes header heavier 4 Re check the float as described ...

Page 79: ...ecks adjust as follows 1 Place float pins in storage location A 2 Park windrower on level ground 3 Set header approximately 6 inches 150 mm off ground and check that member B is on link C as shown Note high and low end of header 4 Place wooden blocks under header cutterbar and legs 5 Lower header onto blocks so that members B lift off links C Stop engine DANGER Stop engine and remove key from igni...

Page 80: ...witch c A slight delay between switch ON and operating speed is normal d Push yellow knob to disengage header drive 6 4 5 HEADER ANGLE Header angle is defined as the angle between the ground and the drapers cutterbar and is adjustable to accommodate crop conditions and or soil type Refer to the appropriate Header Operator s Manual for range of adjustment and recommended settings for your particula...

Page 81: ...advertent header angle changes when pressing the header height control switches Refer to paragraph 5 18 5 Cab Display Module CDM Programming 1 Switch to PROGRAM mode on CDM 2 Press SELECT until SET CONTROL LOCKS is displayed 3 Press to display HEADER TILT 4 Press to LOCK deactivate the control 5 Press PROGRAM to exit d Periodically check the operation of the hook locking mechanism and ensure that ...

Page 82: ...tting height and angle If desired the CDM can be programmed so that only the cutting height feature is active The unit is pre programmed to activate both cutting height and header angle a Program the RETURN TO CUT feature as follows 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 wit...

Page 83: ...ch to reactivate 6 4 6 2 Auto Raise Height c Program the AUTO RAISE HEIGHT feature as follows 1 RETURN TO CUT switch can be OFF or ON 2 PROGRAM and SELECT on CDM to enter Programming Mode 3 Press SELECT TRACTOR SETUP is displayed on upper line 4 Press then SELECT SET KNIFE SPEED is displayed 5 Press SELECT until AUTO RAISE HEIGHT is displayed 6 Press or to change value on lower line Range is 0 0 t...

Page 84: ...s from your MacDon Dealer and install them in accordance with the instructions supplied with the kits Base Kit B5577 6 5 2 ATTACH HEADER BOOTS IMPORTANT To prevent damage to the lift system when lowering header lift linkages without a header or weight box attached to windrower ensure that float engagement pin is installed in storage location A and not installed at hole location B If not installed ...

Page 85: ...n may be installed from either side of boot g Secure pin C with hairpin h Repeat for opposite side 6 5 3 HEADER ATTACHMENT a Remove hairpin on pins F and remove pins from header legs CAUTION Check to be sure all bystanders have cleared the area D E C F HEADER UP HEADER TILT UP HEADER TILT DOWN REEL UP REEL DOWN HEADER DOWN ...

Page 86: ...y retract header lift cylinders IMPORTANT If the center link is too low it may contact the header as the windrower approaches the header for hook up c If necessary re locate the pin J at the frame linkage as required to raise the center link G so that the hook H is above the attachment pin on the header continued next page G H G J ...

Page 87: ...NK 1 Activate HEADER TILT cylinder switches on GSL to extend or retract center link cylinder G so that the hook lines up with the header attachment pin 2 Stop engine and remove key from ignition 3 Push down on rod end of link cylinder G until hook engages pin on header and is locked IMPORTANT Hook release L must be down to enable self locking mechanism If the release is open up manually push it do...

Page 88: ...h a hammer is sufficient CAUTION Check to be sure all bystanders have cleared the area g If engine is not running start engine and press HEADER UP switch to raise header to maximum height NOTE If one end of the header does not raise fully the lift cylinders require re phasing re phasing is needed proceed as follows 1 Press and hold the HEADER UP switch until both cylinders stop moving 2 Continue t...

Page 89: ... both header lift cylinders on the windrower Engage lift cylinder stops on both lift cylinders as follows 1 Stop engine and remove key from ignition 2 Pull lever P and rotate toward header to release and lower cylinder stop Q onto cylinder 3 Repeat for opposite lift cylinder continued next page P Q ...

Page 90: ...g lever P downward to release and lower stop until lever locks into vertical position m Repeat for opposite lift cylinder stop CAUTION Check to be sure all bystanders have cleared the area n Start engine and activate HEADER DOWN switch on GSL to lower header fully Stop engine and remove key WARNING Stop windrower engine and remove key before making adjustments to machine A child or even a pet coul...

Page 91: ...oat 6 5 5 REEL FORE AFT POSITION Press and hold the switch for the desired fore or aft movement of the reel 6 5 6 REEL HEIGHT Press and hold the switch for the desired UP or DOWN movement of the reel IMPORTANT Under certain conditions with reel raised to full height the reel tines may contact the cab roof Exercise care to avoid damage to the machine REEL UP REEL DOWN REEL AFT REEL FORWARD ...

Page 92: ...y or at your MacDon Dealer To use this feature set the Minimum Reel Speed and set the Reel Index as follows a Set Reel Minimum Speed IMPORTANT Windrower can be moving but must be less than minimum reel speed CAUTION Check to be sure all bystanders have cleared the area NOTE DISPLAY will flash MIN REEL MPH or KPH to prompt the Operator to change the minimum set point or increase ground speed if Gro...

Page 93: ...el speed in mph and 5 5 is the HEADER INDEX setting Windrower speed drops to 7 5 mph at same HEADER INDEX setting Display shows 13 0 5 5 REEL IND where 13 0 7 5 5 5 is the reel speed in mph and 5 5 is the HEADER INDEX setting Windrower is operating at 8 mph with HEADER INDEX ON and set at 1 0 Display shows 9 0 1 0 REEL IND where 9 0 8 1 0 is the reel speed in mph and 1 0 is the HEADER INDEX settin...

Page 94: ...b Ground cutting speed can be maintained using this feature a Set Draper Minimum Speed IMPORTANT Windrower can be moving but must be less than minimum reel speed NOTE DISPLAY will flash MIN CONV MPH or KPH to prompt the Operator to change the minimum set point or increase ground speed if Ground Speed Plus Index is less than the Minimum Draper Speed Set Point b Set Draper Index while driving windro...

Page 95: ... is operating at 8 mph with HEADER INDEX ON and set at 0 9 Display shows 8 9 0 9 DRAP INDX where 8 9 8 0 9 is the draper speed in mph and 0 9 is the HEADER INDEX setting 6 5 8 2 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 bystander...

Page 96: ...speed should stay within the range specified for each header HEADER DESCRIPTION KNIFE SPEED TYPE SIZE FT MINIMUM MAXIMUM RPM SPM RPM SPM Draper DK 15 750 1500 950 1900 20 and 25 700 1400 850 1700 30 600 1200 800 1600 35 700 1400 Draper SK 20 and 25 750 1500 30 700 1400 35 550 1100 RPM speed of wobble box pulley SPM strokes per minute of knife RPM x 2 a Determine the knife speed as follows if the m...

Page 97: ...d by 58 revolutions per minute 4 Once adjustment has been made re torque jam nut A as shown d Start engine and re check knife speed 6 5 10 DECK SHIFT OPTIONAL The hydraulic deck shift option allows the Operator to control deck position and draper rotation from the Operator s station It enables crop delivery from left side center or right side of the header Shift decks as follows CAUTION Check to b...

Page 98: ...in C Release pin to lock stand h Remove pin from location D to disengage float springs and insert in storage hole E Secure with lynch pin IMPORTANT To prevent damage to the lift system when lowering header lift linkages without a header or weight box attached to windrower ensure that float engagement pin is installed in storage location E and not installed at hole location D i Disengage lift cylin...

Page 99: ...kit is installed lift release M and then operate the link lift cylinder with REEL UP switch on GSL to disengage the center link from the header n Slowly back windrower away from header NOTE If hay conditioner is installed watch clearances on both sides MECHANICAL LINK 1 Loosen nut J and rotate barrel K to relieve load on link 2 Remove cotter pin on pin L and remove pin to disconnect from windrower...

Page 100: ...HEADER OPERATION D SERIES Form 169552 169554 169555 98 Revision A Re install pin A into header leg and secure with hairpin ...

Page 101: ...ndrower ensure that float engagement pin is installed in storage location C and not installed at hole location D CAUTION Check to be sure all bystanders have cleared the area b Start the engine and activate HEADER DOWN button on the GSL to fully retract header lift cylinders c Slowly drive windrower forward so that feet E on windrower enter boots B on the header Continue to drive slowly forward un...

Page 102: ... GSL to extend or retract center link cylinder so that the hook lines up with the header attachment pin 3 Push down on rod end of link cylinder until hook engages pin on header and is locked IMPORTANT Hook release must be down to enable self locking mechanism If the release is open up manually push it down after hook engages header pin 4 Check that center link is locked onto header by pulling upwa...

Page 103: ...ove pin J j Re position stand to storage position by inverting stand and re locating on bracket as shown Re insert pin J and secure with lynch pin k Remove pin L from storage position in linkage and insert in hole M to engage float springs Secure with lynch pin l Disengage lift cylinder stops Refer to Section 6 4 1 Header Lift Cylinder Stops m Start engine and activate HEADER LIFT cylinder switch ...

Page 104: ...ots B on header d Lower stand C by pulling pin D inverting stand and re locating on bracket Re insert pin D and secure with hairpin e Remove pin from linkage E to disengage float springs and insert in storage hole F Secure with lynch pin Repeat for opposite linkage IMPORTANT To prevent damage to the lift system when lowering header lift linkages without a header or weight box attached to windrower...

Page 105: ...eader 3 Proceed to step i in the next column HYDRAULIC LINK OPTIONAL 1 Activate HEADER TILT cylinder switches on GSL to release load on center link cylinder K 2 Lift hook release L and lift hook M off header pin i Disconnect header drive hydraulics N and electrical harness O Refer to the Auger Header Operator s Manual j Slowly back windrower away from header k Re install pins A in header boots B H...

Page 106: ...ed can be independently changed from the knife speed by changing the drive sprocket Refer to A30 S A30 D and A40 D Self Propelled Windrower Headers Operator s Manual Display the auger speed as follows ENGAGE HEADER ON GSL PRESS FAST OR SLOW DISPLAY SHOWS AUGER SPEED DONE SPEED O K NO YES PRESS DISPLAY SELECTOR FOR AUGER SPEED HEADER INDEX SWITCH OFF 4 7 9 9 4 7 150 rpm 9 9 320 rpm Auger Speed Not ...

Page 107: ...m that is controlled with switches on the CDM and on the GSL at the Operator s station The hydraulic flows for the reel and auger are interconnected so that the auger and reel speeds are controlled using the GSL switches ENGAGE HEADER ON GSL PRESS FAST OR SLOW DISPLAY SHOWS AUGER SPEED DONE SPEED 99 0 NO YES PRESS DISPLAY SELECTOR FOR AUGER SPEED HEADER INDEX SWITCH OFF 0 00 9 9 00 0 150 rpm 9 9 3...

Page 108: ...ld stay within the range specified for each header HEADER DESCRIPTION KNIFE SPEED TYPE SIZE MINIMUM MAXIMUM RPM SPM RPM SPM Auger A40 D All 700 1400 950 1900 Auger A30 D 775 1550 Auger A30 S 625 1250 775 1550 RPM speed of wobble box pulley SPM strokes per minute of knife RPM x 2 a Determine the knife speed as follows if the machine is not equipped with the optional module CAUTION Check to be sure ...

Page 109: ...ling machine 1 Shut down engine 2 Loosen jam nut A 3 Turn adjuster screw B clockwise screw in to decrease knife speed and counter clockwise screw out to increase the knife speed NOTE One turn of the adjuster screw will change the knife speed by approximately 116 strokes per minute or the wobble box pulley speed by 58 revolutions per minute 4 Once adjustment has been made re torque jam nut A as sho...

Page 110: ...M 7 2 RECOMMENDED SAFETY PROCEDURES Wear close fitting clothing and cover long hair Never wear dangling items such as scarves or bracelets Use adequate light for the job at hand Replace all shields removed or opened for service Park on a level surface when possible Block wheels securely Wear protective shoes with slip resistant soles a hard hat protective glasses or goggles and heavy gloves If mor...

Page 111: ...MAINTENANCE AND SERVICING Form 169552 169554 169555 109 Revision A for cleaning purposes These materials may be toxic and or flammable ...

Page 112: ...locking elements increase torque values by 5 7 3 1 1 SAE Bolts 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 1 2 Me...

Page 113: ...sembly 7 3 1 4 O Ring Boss ORB Hydraulic Fittings a Inspect O ring and seat for dirt or obvious defects b On angle fittings back off the lock nut until washer A bottoms out at top of groove B in fitting c Hand tighten fitting until back up washer A or washer face if straight fitting bottoms on part face C and O ring is seated d Position angle fittings by unscrewing no more than one turn e Tighten ...

Page 114: ... Thread tube or hose nut until hand tight The nut should turn freely until it is bottomed out Torque fitting further to the specified number of F F F T Flats From Finger Tight or to a given torque value in the table shown in the opposite column NOTE If available always hold the hex on the fitting body to prevent unwanted rotation of fitting body and hose when tightening the fitting nut e When asse...

Page 115: ...ylene Glycol With SCA Equal Parts With Water Engine Coolant Air Conditioning Refrigerant R134A Refrigerant Cab Air Conditioning System Air Conditioning Compressor Oil SP 15 PAG Compressor Oil Cab Air Conditioning Compressor Lubricant High quality soft de ionized or distilled water as recommended by supplier 7 3 2 3 Lubricants LUBRICANT SPEC DESCRIPTION USE Grease SAE Multi Purpose High Temperature...

Page 116: ...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 Temperature degrees Fahrenheit F F 32 x 0 56 Celsius C Velocity feet per minute ft min x 0 3048 meters per minute m min feet per second ft s x 0 3048 meters per second m s miles per hour mph x 1 6063 kilo...

Page 117: ...tly further b To close hood 1 Grasp the strap at B and loop under upper hook C IMPORTANT Failure to hook strap may result in it becoming entangled with the screen cleaners or the latch 2 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 al...

Page 118: ... OPENING CLOSING PLATFORM FOR MAJOR SERVICING To improve access to the hydraulics plumbing the platform can be swung away from the windrower a Open engine compartment hood to lowest position IMPORTANT Failure to open hood will result in damage to the hood when the platform is re positioned b Unlock latch A and move platform C toward open position but do not lock in full aft position c Remove nut a...

Page 119: ...ANT SPEC DESCRIPTION USE Grease SAE Multi Purpose High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base As Required Unless Otherwise Specified Log hours of operation and use the Maintenance Checklist provided to keep a record of scheduled maintenance Refer to Section 7 13 MAINTENANCE SCHEDULE 7 6 1 PROCEDURE DANGER Stop engine and remove key f...

Page 120: ...t d WALKING BEAM PIVOT FORMED CASTER WHEEL BEARING 1 PLACE BOTH WHEELS CASTER PIVOT BOTH SIDES FORKED CASTER SPINDLE BEARINGS TWO PLACES BOTH WHEELS TOP LINK TWO FITTINGS BOTH SIDES High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base ...

Page 121: ... upper line and ENGINE SHUT DOWN 5 4 3 2 1 0 on the lower line accompanied by a steady tone At 0 the engine shuts down 3 If the engine does not shut down the Operator Presence System requires adjustment See your Dealer d With the windrower moving at more than 5 mph 8 km h 1 Stand up out of the seat 2 The CDM beeps once and displays NO OPERATOR on the lower line 3 If not the Operator Presence Syste...

Page 122: ...t of pintle arm Adjust the cable tension as follows a Hold nut D from turning and loosen jam nut E b To increase the tension turn the nut D clockwise c To decrease the cable tension turn the nut D counter clockwise d Hold nut D from turning and tighten jam nut E 7 7 3 2 GSL Fore Aft Movement The GSL should remain as positioned by the Operator and yet can be moved without excessive force The spring...

Page 123: ...he N DETENT slot when the steering wheel is centered and locked If necessary adjust as follows IMPORTANT Neutral Interlock must be properly adjusted before adjusting GSL position a Lock pintle arms b Loosen nuts B c Hold GSL in center of N DETENT slot to locate support C d Tighten nuts B and torque to 80 90 ft lbf 108 122 Nm A B C ...

Page 124: ... of moving parts with hoses tubes other linkages c Check steering rod bolts A for looseness and ball joints B for any perceptible play or movement d If steering rod bolts A are loose 1 Back off outer jam nut C 2 Tighten inside nut D to 70 80 ft lbf 95 108 N m 3 Hold inside nut D and tighten jam nut C to 60 70 ft lbf 81 95 N m e If steering rod ball joints B are loose they should be replaced See yo...

Page 125: ...e 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 CENTER position When the switch closes and the machine starts and runs the brakes continue to be applied to the drive wheels as park brake solenoid 3 is energized preventing brake release The Neutral Start Switch is located on the frame adjacent ...

Page 126: ...posite direction of air flow arrows 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 as it may rupture the wet element Protect element from fre...

Page 127: ...over C and position on cab wall over opening e Secure to cab wall with knobs A 7 7 6 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 3 Cooling Box Maintenance 7 7 6 4 A C...

Page 128: ...esent soak evaporator in water to loosen dirt and then blow out with compressed air g Straighten any bent fins h Re position cover J and attach with ten fasteners H i Re attach drain hoses to drain tubes and secure with hose clamps D 7 7 6 5 A C Compressor Protection The compressor is protected from excessively low and high pressures by two switches that shut down the compressor to prevent damage ...

Page 129: ...s Manually turn engine as follows IMPORTANT Ensure nothing falls into gearbox oil reservoir 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 Remove key from ignition b Move platform on right front side of machine to open position to allow access to the battery c Remove red plastic covers A from posi...

Page 130: ...g it counter clockwise to unlock and remove d Wipe clean re insert in engine and remove e Oil level should be between LOW and HIGH marks f Replace dipstick and turn it clockwise to lock g Add oil as follows if level is below the LOW mark One U S qt 1 liter is will raise the level from LOW to HIGH CAUTION Do not fill above the HIGH mark 1 Turn handle B counter clockwise to loosen bung and remove ca...

Page 131: ...Remove filter C 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 A m Re...

Page 132: ...ay and tone on the CDM when the filter system requires servicing IMPORTANT Filter servicing should only be performed when the CDM indicates ENGINE AIR FILTER or at the specified interval Refer to Section 7 13 MAINTENANCE SCHEDULE 7 8 5 1 Air Filter Servicing 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 ma...

Page 133: ...nto canister seal first and push until seal is seated inside canister IMPORTANT When replacing safety filter re insert new filter as soon as possible to prevent dirt from entering engine intake i Insert new primary filter element K into canister over safety element and push into place ensuring that element is firmly seated in canister j Position end cap F onto filter housing with aspirator pointin...

Page 134: ...ly wear a hole in the filter 3 Be sure filter gasket is in good condition If gasket is damaged or missing replace element 4 If element is coated with oil or soot replace the element 5 Check the safety element for cleanliness If there is visible dirt on the safety element replace both primary and safety elements IMPORTANT The air cleaner s primary outer filter element should be replaced after three...

Page 135: ...ervicing a Open engine compartment hood to highest position See Section 7 4 ENGINE COMPARTMENT HOOD 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 hose onto filter IN marking should face down NOTE If filter has an arrow instead of an IN marking...

Page 136: ...ect WIF Water In Fuel sensor G 8 Hand tighten the filter an additional to turn IMPORTANT Do not use a filter wrench to install the filter Over tightening can damage the gasket and filter c Change secondary filter D as follows 1 Clean around the filter head J 2 Place a container under the filter to catch spilled fluid 3 Remove filter D with a filter wrench 4 Clean gasket mating surface IMPORTANT Do...

Page 137: ...sion or fire do not smoke or allow flame or sparks near windrower when servicing a Stop engine and remove key b Open engine compartment hood to lowest position See Section 7 4 ENGINE COMPARTMENT HOOD c Close fuel supply valve A d Place a 5 U S gallon 20 liter drain pan under the fuel supply hose B at primary filter e Loosen clamp C and pull hose B off fitting f Route hose to drain pan and open val...

Page 138: ...rain manifold Small amounts of air introduced by changing filters or injection pump supply line will be vented automatically if the fuel filters are changed in accordance with instructions WARNING The fuel pump high pressure fuel lines and fuel rail contain extremely high pressure fuel Never loosen any fittings Personal injury and property damage can result IMPORTANT Bleeding the fuel system is no...

Page 139: ...damage from freezing could still result To service the cooling 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 Raise engine compartment hood to lowest position See Section 7 4 ENGINE COMPARTMENT HOOD 7 8 7 1 Coolant Level and Concentration a...

Page 140: ...nually preferably before off season storage Tester should indicate protection to temperatures of 30 F 34 C b Replace the cap if spring is stuck c Close engine compartment hood and move maintenance platform to working position 7 8 7 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 follo...

Page 141: ...ne until normal operating temperature is reached l Stop engine and drain water out before rust or sediment settles See steps d to h m Close drain valves and fill system 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 dra...

Page 142: ...ing machine a Check the lubricant level every 50 hours as follows 1 Park windrower on level ground shut down engine and remove key 2 Remove plug A The lubricant should be visible through the hole or slightly running out b Add lubricant as follows 1 Raise engine compartment hood to highest position See Section 7 4 ENGINE COMPARTMENT HOOD 2 Remove breather cap B and add lubricant until it runs out a...

Page 143: ... under the gearbox c Remove drain plug C and allow the oil to completely finish draining d Install the drain plug C and remove the check plug A e Unscrew breather cap B and add lubricant The gearbox will require 2 2 U S quarts 2 1 liters Add sufficient lubricant until it slightly runs out of hole A Use SAE 75W 90 API Service Class GL 5 Fully Synthetic Transmission Lubricant SAE J2360 preferred f I...

Page 144: ...aky exhaust system may allow exhaust 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...

Page 145: ... mounting hardware 5 Re check tension and re adjust as required 7 8 10 2 A C Compressor Belt Replacement a Shut down engine and open engine compartment access hood to lowest position Refer to illustration opposite b Loosen compressor mounting hardware B and push compressor towards engine to release tension c Remove belt A d Install new belt A on pulleys e Pry compressor away from engine so that a ...

Page 146: ... 12 lbf 35 55 N deflects the belt A 3 16 inch 5 mm at mid span n Tighten compressor mounting hardware B o Re check tension and re adjust as required p Move maintenance platform to working position and close engine compartment hood 7 8 11 ENGINE SPEED The maximum and idle engine speeds are factory set to the specifications See Section 4 2 SPECIFICATIONS If specified speeds cannot be maintained see ...

Page 147: ...gged Service rotors and screen as follows a Stop engine and remove key b Raise engine compartment hood fully See Section 7 4 ENGINE COMPARTMENT HOOD 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...

Page 148: ... b If necessary adjust clearance as follows 1 Loosen nut B on motor support C 2 Move support in or out until duct is 0 08 0 24 in 2 6 mm from screen near the center 3 Re tighten nut B 4 Loosen the two motor mount bolts D 5 Move motor duct assembly E to obtain 0 04 0 32 in 1 8 mm gap to screen at full rotation of the duct 6 Re tighten nuts D on motor mount c Close screen access door F and engage la...

Page 149: ...ese components proceed as follows 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 Raise engine compartment hood fully See Section 7 4 ENGINE COMPARTMENT HOOD c Push latch A and open screen assembly access door B Secure with rod C stored inside the screen door d Lift lev...

Page 150: ...rs can be very easily bent which may interfere with its function Exercise caution when cleaning h Clean radiator O through access holes in cooling box with compressed air i Clean oil cooler A C condenser P charge air cooler Q and cooling box S with compressed air j Inspect all lines and coolers for evidence of leaks and damage k Slide oil cooler AC condenser H back into cooling box continued next ...

Page 151: ... l Close side access door G and lock with lever F m Close top door N and secure with wing nut M n Unhook support rod C in screen door and store in screen door o Close screen door B until latch engages pin A p Lower hood and hood latch will lock the hood F G M N A B C ...

Page 152: ...ttery electrolyte causes severe burns Avoid contact with skin eyes or clothing Keep batteries out of reach of children If electrolyte is spilled or splashed on clothing or the body neutralize it immediately with a solution of baking soda and water then rinse with clean water Electrolyte splashed into the eyes is extremely dangerous Should this occur force the eye open and flood with cool clean wat...

Page 153: ... See Section 7 10 1 2 Charging Add electrolyte if necessary See Section 7 10 1 4 Adding Electrolyte b Keep batteries clean by wiping with a damp cloth c Keep all connections clean and tight Remove any corrosion and wash terminals with a solution of baking soda and water A light coating of grease on terminals after cables are attached will reduce corrosion d To prolong battery life store batteries ...

Page 154: ...erature 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 battery Use heavy duty battery cables CAUTION Gas given off by batteries is explosive Keep sparks and flames away from batteries Make last connection ...

Page 155: ... all smoking materials sparks and 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 rin...

Page 156: ...ion 7 4 ENGINE COMPARTMENT HOOD c Remove red plastic cover from positive cable clamps A Loosen clamps and remove cable from batteries d Loosen clamps B on negative terminals and remove cable from batteries e Remove bolts C securing strap D to frame and remove strap f Lift batteries off holder E g Position new batteries on holder E h Install strap D with bolts C IMPORTANT BATTERY IS NEGATIVE GROUND...

Page 157: ...lternator wire See also Section 7 1 1 Welding Precautions 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 altern...

Page 158: ...avel line from the headlights i e not skewed left or right Upper limit of the beam not higher than 105 inches 266 cm above ground at a distance of 25 FT 7 5 m from the headlight a Hold onto hand holds A on the cab front corners and stand on header anti slip strips b Adjust lights with screws B 7 10 2 2 Bulb Replacement a Remove two screws C and remove light assembly b Pull wiring harness connector...

Page 159: ...y 7 10 3 FIELD LIGHTS FORWARD 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 7 10 3 1 Adjustment Field lights are best adjusted with the machine in the field or equivalent to suit Operator preference a Hold onto hand holds A on cab front corners and stand on header anti slip strips b Adjust lights w...

Page 160: ... remove light bezel C d Remove light from receptacle e Pinch wire retainer D and lift away from hooks f Remove bulb E from body and pull wire from connector F IMPORTANT Do not touch the glass of the halogen bulb as the oils or other chemicals from your skin will cause the bulb to fail prematurely g Match slots on new bulb E with lugs G in optical unit and insert bulb into unit h Secure bulb with w...

Page 161: ... d Tighten bolts A and B 7 10 5 2 Bulb Replacement a Shut down engine and remove key Turn lights OFF b Remove two screws C and remove light bezel D c Remove light from receptacle d Pinch the wire retainer E and lift away from hooks e Remove bulb F from body and pull wire from connector G IMPORTANT Do not touch the glass of the halogen bulb as the oils or other chemicals from your skin will cause t...

Page 162: ...nch the wire retainer J and lift away from hooks d Remove bulb K from body and pull wire from connector L IMPORTANT Do not touch the glass of the halogen bulb as the oils or other chemicals from your skin will cause the bulb to fail prematurely e Match slots on new bulb K with lugs O in optical unit and insert bulb into unit f Secure bulb with wire retainer J g Push wire into connector L IMPORTANT...

Page 163: ...m lens and remove lens c Push and twist light bulb to remove from socket d Install new bulb ensuring that bulb base is properly engaged in socket Use Bulb Trade 1156 e Re install lens with screws B 7 10 8 BEACONS IF INSTALLED a Shut down engine and remove key Turn beacons OFF NOTE Hold onto hand holds on cab front corners and stand on header anti slip strips or stand on maintenance platform when a...

Page 164: ...bulb as the oils or other chemicals from your skin will cause the bulb to fail prematurely f Connect harness to new lamp place lamp in socket and line up flat side on lamp with recess in socket g Place retainer over lamp and pinch tabs to secure retainer to socket h Line up the three lugs one is longer in the base with slots in lens and seat the lens against the rubber seal i Turn the lens clockwi...

Page 165: ...with screws A 7 10 10 AMBIENT LIGHT a Shut down engine b Push against tabs B with a screwdriver and pull ambient light fixture out of cab roof c Remove wires from connectors C d Connect wires to new light fixture e Push into place in cab roof until tabs B hold fixture in place 7 10 11 TURN SIGNAL INDICATORS If the turn signal indicators on the CDM do not function contact your Windrower Dealer A B ...

Page 166: ...s follows a Stop engine 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 on next page 7 10 12 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 ratin...

Page 167: ...MAINTENANCE AND SERVICING Form 169552 169554 169555 165 Revision A 7 10 12 3 Fuse Box Decal ...

Page 168: ... windrower 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...

Page 169: ...acement 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 oil level change oil and fil...

Page 170: ...oil cooler is located inside the cooling box behind the radiator It should be cleaned daily with compressed air Refer to Section 7 9 3 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 ...

Page 171: ...operating pressure is very close to the compensator valve pressure setting If lift and drive capacity problems develop the pressure compensator valve may require adjusting Contact your Dealer or refer to the Technical Service Manual for your windrower HEADER MODEL APPLICATION SYSTEM SUGGESTED OVERLOAD WARNING SETTING psi kPa WINDROWER PRESSURE COMP SETTING psi kPa D60 and A40 D Reel Draper Pressur...

Page 172: ...ssed From full height to ground should take approximately 3 5 seconds Adjust as follows 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 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 th...

Page 173: ...n 7 11 1 Oil Level b Check the hoses and lines for leakage 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 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 cha...

Page 174: ... hands and body away from pin holes and nozzles which eject fluids under high pressure If ANY fluid is injected into the skin it must be surgically removed within a few hours by a Doctor familiar with this type of injury or gangrene may result Use a piece of cardboard or paper to search for leaks IMPORTANT Keep hydraulic coupler tips and connectors clean Dust dirt water and foreign material are th...

Page 175: ...re 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 force An air leak of this...

Page 176: ...me Pressure Gear Lubricant After first change use SAE 75W 90 API Service Class GL 5 Fully Synthetic Transmission Lubricant SAE J2360 preferred 4 Replace plugs and tighten b Change the lubricant as follows 1 Rotate the wheel so that one of the plugs A is located at the bottom 2 Place a large enough container about 2 quarts U S 2 liters under the drain plug A 3 Remove top plug B and drain lubricant ...

Page 177: ...e and remove key d Jack up windrower under leg jack point and raise windrower wheel slightly off ground e Undo wheel nuts and remove wheel f To install new tire ensure that air valves are on the outside and tire tread points forward For Turf tires diamond tread be sure arrow on sidewall points in forward rotation g Position wheel on hub and install wheel nuts h Tighten nuts to 220 ft lbf 300 N m u...

Page 178: ...in a cracked wheel 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 th...

Page 179: ...L WEIGHT OF BOTH TIRES lb kg 7 5X16 10 38 200 91 10X16 18 69 380 170 16 5X16 1 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 FT PER TIRE BOTH TIRES PER TIRE BOTH TIRES U S Gal ...

Page 180: ... 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 shut down engine and remove key 3 Raise end of walking beam using a jack 4000 lb 1816 kg capacity or other suitable lifting device until the wheel is slightly off the ground 4 Remove the eight bolts C att...

Page 181: ...g capacity or other suitable lifting device until the wheel is slightly off the ground 4 Undo the six wheel bolts A and remove wheel from hub b Install the caster wheel as follows 1 Position wheel on hub and install wheel bolts A 2 Torque bolts A to 120 ft lbf 163 N m using the tightening sequence as shown on previous page 3 Lower windrower and remove jack 7 12 2 6 Caster Wheels Anti Shimmy Dampen...

Page 182: ...es given under Sections 7 1 PREPARATION FOR SERVICING and 7 2 RECOMMENDED SAFETY PROCEDURES 7 13 1 BREAK IN INSPECTIONS BREAK IN INSPECTIONS HOURS ITEM CHECK Every 25 Road or 1 in Field Drive Wheel Nuts Torque 220 ft lbf 300 N m Repeat Checks Until Torque Stabilizes 5 A C Belt Tension Caster Wheel Nuts Torque 120 ft lbf 163 N m Caster Wheel Anti Shimmy Dampener Bolts Inboard Bolt Torque 100 ft lbf...

Page 183: ... 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 6 Check Gear Box Oil Level 100 HOURS OR ANNUALLY 1 Clean Cab Air Return Filter 250 HOURS OR ANNUALLY 1 Change Engine Oil and Filter 2 Change Engine Air Cleaner Primary Filter Element CDM displays ENGINE AIR FILTER 3 Check Drive Wheel L...

Page 184: ...EQUIRED 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 Steering Linkages 50 HOURS Cab Fresh Air Intake ...

Page 185: ...our Meter Reading Date Serviced By 500 HOURS Engine Oil and Filter or Annually Fuel Filters Gearbox Lubricant Charge System and Manifold Hydraulic Oil Filters Safety Systems or Annually 1000 HOURS Drive Wheel Lubricant 1500 HOURS Hydraulic Oil 2000 HOURS Engine Coolant General Inspection 5000 HOURS Engine Valve Tappet Clearance ...

Page 186: ...el 7 10 1 Poor battery connection Clean and tighten loose connections Loose electrical connection at fuel pump Ensure connector at pump is fully pushed in Wiring shorted circuit breaker open Check continuity of wiring and breaker manual reset 7 10 12 ECM fuse 1 of 2 blown Replace ECM Ignition relay faulty Neutral Logic relay faulty Neutral Interlock misadjusted Contact your Dealer Faulty starter F...

Page 187: ... engine temperature Remove and check thermostat See Engine Overheats in Technical Manual Engine Temperature Below Normal Defective thermostat Remove and check thermostat Warning Alarm Sounds Engine overheated Check coolant level 7 8 7 Check thermostat Low engine oil pressure Check oil level 7 8 3 Low transmission oil pressure 7 11 1 Engine Overheats Low coolant level Fill reserve tank to proper le...

Page 188: ...ne out of time Air in fuel system Engine Emits White Exhaust Engine out of time Improper type of fuel Consult your fuel supplier and use proper type fuel for conditions 7 3 2 1 Cool engine Warm engine up to normal operating temperature 6 3 5 1 Defective thermostat Remove and check thermostat Starter Cranks Slowly or Will Not Operate Low battery output Check battery charge 7 10 1 1 Controls not in ...

Page 189: ...n or defective circuit breaker Check circuit breaker 7 10 12 Defective relay Replace relay Defective light switch Contact your Dealer Turn Signals or Indicators Showing Wrong Direction Reversed wires No Current To Cab Broken or disconnected wire Circuit breaker tripped Breaker automatically resets Battery disconnect switch is OFF Turn switch ON 7 10 1 8 3 HYDRAULICS SYMPTOM PROBLEM SOLUTION SECTIO...

Page 190: ...ility On A Grade or Pulling Out Of A Ditch Internal pump or motor damage Insufficient torque at drive wheels Move ground speed range control to 1 field position and reduce ground speed 6 3 6 2 Loose or worn controls Check controls 7 7 3 Air in system Use proper oil 7 3 2 3 Check oil level and leaks 7 11 1 Check hydraulic oil filters 7 11 4 Brakes binding or not releasing fully Check pressure min 2...

Page 191: ...pump or motor Wheels not in same speed range Faulty relief valve Repair or replace valve 7 11 6 2 Excessive Noise From Drive System Hydraulic line clamps loose Tighten clamps Air in system Check lines for leakage Mechanical interference in steering or ground speed linkage Adjust repair replace 7 7 3 7 7 4 Brakes binding or not releasing fully Check pressure min 200 psi 1379 kPa on brake release va...

Page 192: ...manifold Install thermostat Odor From Air Louvers Dirty filters Clean fresh air and re circulation filters Plugged drainage hose Blow out hose with compressed air Air Conditioning Not Cooling Blower motor disconnected or burned out Contact your Dealer Switch contacts in thermostat burned excessively or sensing element defective Replace thermostat Low refrigerant level Add refrigerant Clutch coil b...

Page 193: ...place as necessary 7 7 6 1 7 7 6 2 Heater circuit is open Close heater valves 1 in cab and 1 at engine 5 10 1 5 10 3 Insufficient air circulation over condenser coil fins clogged with dirt or insects Clean condenser 7 9 3 Evaporator fins clogged Clean evaporator fins under cab floor 7 7 6 4 Thermostat defective or improperly adjusted Replace thermostat Air Conditioning System Too Noisy Defective w...

Page 194: ...em Contact your Dealer Incorrect super heat adjustment in the 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 de humidify air and heater to control temperature 5 10 1 8 8 OPERATOR S STATION SYMPTOM PROBLEM SOLUTION SECTION Rough Ride Seat suspension not ...

Page 195: ...tion instructions are included 9 8 FAN AIR BAFFLE KIT Provides a baffle to reduce windrow disturbance by air exiting the engine cooling fan 9 9 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 10 KNIFE SPEED REEL SPEED INDEX AND TILT SENSOR MODULE To allow the electronic monitoring ...

Page 196: ...wbar related parts and installation instructions 9 17 WEIGHT BOX The weight box allows engine forward transport in high range when the header is not attached 9 18 WINDSHIELD SHADES Retractable sun shades for front and rear windows 9 19 HID AUXILLIARY LIGHTING Provides additional field lighting The kit includes two cab mounted high intensity discharge lamps and installation instructions ...

Page 197: ...Displays 34 Center Link mechanical 83 standard 83 Circuit Breakers 158 Compressor Oil 107 Console 20 Cooler 27 Daily check 52 Definitions 14 Display Warnings 40 Draper Header attachment 82 deck shift 93 detaching 85 draper speed 90 knife speed 92 93 101 reel speed 88 Drawbar swath roller 70 Drive Wheels 167 bolt torque 167 lubricant 168 removal installation 169 Driving roads 63 spin turn 60 stoppi...

Page 198: ...er Controls 31 Heater controls 26 shut off valve 26 Height Control 80 Hub Locks 72 Hydraulic System 161 charge pump pressure 165 fitting types 105 hoses and lines 166 leaks 166 oil changing 162 oil cooler 162 oil filters 162 oil level 161 relief pressure 163 traction drive 165 transmission oil pressure 165 troubleshooting 181 valve block 163 Ignition Switch 29 Index Switch 88 Interior Lights 157 I...

Page 199: ...cants 107 windrower 73 Swath Lights 154 Swath Roller 81 Symbol Definitions 49 Tire Inflation caster wheels 170 drive wheels 167 Torques 104 Towing electrical 69 header 65 Towing Windrower 72 Traction Drive neutral start switch 117 Traction Drive System GSL adjustment 114 hub locks 72 steering links 116 troubleshooting 182 183 Training Seat 21 Transporting 63 Troubleshooting air conditioning 184 el...

Page 200: ... short circuit open circuit E 34 E134 R I G H T S T O P L A M P Right stop lamp output fault detected short circuit open circuit E 35 E135 L E F T S T O P L A M P Left stop lamp output fault detected short circuit open circuit E 36 E136 R I G H T T U R N L A M P Right turn lamp output fault detected short circuit open circuit E 37 E137 L E F T T U R N L A M P Left turn lamp output fault detected s...

Page 201: ... E H E A D E R Header engage switch on when ignition turned on x x x x S x x F x x C Engine code configuration Canbus C E N T E R S T E E R I N G GSL or Pintal switches not closed with the key on engine off N O T I N P A R K GSL or Pintal switches not closed with the key on engine off In the case of dual codes being shown for an item primarily the solenoid valves the first code indicates a SHORT C...

Page 202: ...celerator Pedal or Lever Position Sensor Circuit Voltage Below Normal or Shorted to Low Source 8 154 Abnormal frequency pulse width or period 12 154 Bad Device or component 19 Red 287 SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor System Error Received Network Data In Error 93 2 Amber 528 Switch Data Auxillary Alternate Torque Validation Switch Data Erratic Intermittant or Incorrect Swit...

Page 203: ...rature Sensor Circuit Voltage Below Normal or Shorted to Low Source 16 Amber 488 Intake Manifold 1 Temperature Data Valid but Above Normal Operational Range Moderately Severe Level 3 135 Voltage above normal or shorted high 4 135 Voltage below normal or shorted low 10 135 Inlet Manifold Pressure Sensor 5V supply connection open circuit 2 Amber 295 Barometric Pressure Sensor Circuit Data Erratic In...

Page 204: ...evel 18 Amber 597 Electrical Charging System Voltage Low Data Valid but Below Normal Operational Range Moderately Severe Level 0 Excessive battery power 1 Low battery power 2 Intermittent 16 Amber 442 Battery 1 Voltage High Data Valid but Above Normal Operational Range Moderately Severe Level 18 Amber 441 Battery 1 Voltage Low Data Valid but Below Normal Operational Range Moderately Severe Level 3...

Page 205: ...Driver Circuit Voltage Below Normal or Shorted to Low Source Red Stop Lamp 2 None 1117 Power Lost With Ignition On Data Erratic Intermittent or Incorrect 12 Amber 351 Injector Power Supply Bad Intelligent Device or Component 12 Red 111 Engine Control Module Critical internal failure Bad intelligent Device or Component 12 Amber 343 Engine Control Module Warning internal hardware failure Bad Intelli...

Page 206: ... Voltage Above Normal or Shorted to High Source Circuit Voltage 3 Amber 529 Auxillary Input Output 3 Circuit Voltage Above Normal or Shorted to High Source 11 Amber 779 Warning Auxillary Equipment Sensor Input 3 OEM Switch Root Cause Not Known 14 Amber 2195 Auxillary Equipment Sensor Input 3 OEM Switch Engine Protection Critical Special Instructions 2 Amber 778 Engine Speed Sensor Camshaft Erratic...

Page 207: ... Pressure Solenoid Valve Circuit Voltage Above Normal or Shorted to High Source 4 Amber 271 High Fuel Pressure Solenoid Valve Circuit Voltage Below Normal or Shorted to Low Source 5 162 Output current low 6 162 Output current high 7 Amber 281 High Fuel Pressure Solenoid Valve 1 Mechanical System Not Responding Properly or Out of Adjustment 1377 2 Amber 497 Switch Circuit Multiple Unit Syncronizati...

Page 208: ...e 1 Circuit Voltage Above Normal or Shorted to High Source 4 Amber 352 Sensor Supply Voltage 1 Circuit Voltage Below Normal or Shorted to Low Source 3 Amber 227 Sensor Supply Voltage 2 Circuit Voltage Above Normal or Shorted to High Source 4 Amber 187 Sensor Supply Voltage 2 Circuit Voltage Below Normal or Shorted to Low Source 3511 3 Amber 239 Sensor Supply Voltage 3 Circuit Voltage Above Normal ...

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