MacDon M105 Operator'S Manual Download Page 341

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TROUBLESHOOTING

6.5

Traction Drive Troubleshooting

Symptom

Problem

Solution

Section

Low hydraulic oil level

Stop engine, and add oil to hydraulic
system.

Checking and
Filling Hydraulic
Oil, page 288

Low hydraulic pressure

Foreign material shorting
sender

Short in alarm wiring

Warning alarm
sounds and trans
oil pressure is
displayed

Faulty sender

Contact Dealer.

Internal pump or motor
damage

Contact Dealer.

Insuf

cient torque at drive

wheels

Move ground speed range control to

eld position (1), and reduce ground

speed.

Driving Forward,
page 97

Loose or worn controls

Check controls.

5.7.3 Ground
Speed
Lever (GSL)
Adjustments, page
212

Use proper oil.

Lubricants, Fluids,
and System
Capacities, page
199

Check oil level and leaks.

Checking and
Filling Hydraulic
Oil, page 288

Air in system

Check hydraulic oil

lters.

5.7.9 Hydraulic
System, page 287

Brakes binding or not
releasing fully

Check pressure on brake release
valve (min. 200 psi [1379 kPa]).

Wheels lack pulling
ability on a grade
or pulling out of a
ditch

Relief valve in tandem pump
dirty or damaged

Replace relief valve.

Leakage at pump or motor

Wheels not in same speed
range

Contact Dealer.

With steering
wheel centered,
one wheel pulls
more than the
other

Faulty relief valve

Repair or replace valve. Contact
Dealer.

Contact Dealer.

169890

327

Revision A

Summary of Contents for M105

Page 1: ...The harvesting specialists worldwide M105 Self Propelled Windrower Operator s Manual 169890 Revision A Original Instruction ...

Page 2: ...Windrower Published July 2014 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 Battery posts terminals and related accessories contain lead and lead components Wash hands after handling ...

Page 3: ...Declaration of Conformity Figure 1 Declaration of Conformity Continued on next page 169890 i Revision A ...

Page 4: ... than 1 45 m s2 when analyzed in accordance with ISO 5349 These acceleration values depend on the roughness of the ground the speeds at which the windrower is operated the operator s experience weight and driving habits Noise Levels The A weighted sound pressure levels inside the operator s station ranged from 70 1 to 73 1 dB A as measured on several representative machines in accordance with ISO ...

Page 5: ...ble 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 If you follow the instructions given here your M105 Windrower will work well for many years Use this manual in conjunction with your header operator s manual A manual storage case is provided in the cab Keep this manual handy for frequent reference and...

Page 6: ...nts section No longer required with new design 5 6 2 Lubrication Points page 210 Replaced the missing Hydraulic Oil Maintenance instruction Checking and Filling Hydraulic Oil page 288 Modified the procedure for changing the new LED dome light assembly Dome Light page 281 Added the Adjusting Reel Drop Rate section Adjusting Reel Drop Rate page 295 Updated drive wheel images and references to repres...

Page 7: ...n the lines below The windrower serial number plate A is located on the left side of the main frame near the walking beam WINDROWER MODEL NUMBER WINDROWER SERIAL NUMBER YEAR OF MANUFACTURE Figure 2 Machine Serial Number Location The serial number plate A is located on top of the engine cylinder head cover ENGINE SERIAL NUMBER DATE OF MANUFACTURE Figure 3 Engine Serial Number Location 169890 v Revi...

Page 8: ......

Page 9: ...cifications 29 2 3 Windrower Dimensions 32 2 4 Component Location 34 3 Operator s Station 35 3 1 Operator Console 35 3 2 Operator Presence System 36 3 2 1 Header Drive 36 3 2 2 Engine and Transmission 36 3 3 Operator s Seat Adjustments 37 3 4 Training Seat Optional 38 3 5 Seat Belts 39 3 6 Steering Column Adjustment 40 3 7 Lighting 41 3 7 1 Field Lighting 41 3 7 2 Road Lighting 42 3 7 3 Beacon Lig...

Page 10: ...4 Cab Display Module CDM Warning Alarms 67 Engine Warning Lights 67 Display Warnings and Alarms 68 3 18 5 Cab Display Module CDM Programming 70 Programming Guidelines 71 Detailed Programming Menu Flow Chart 72 Operating Information Screens 78 3 18 6 Engine Error Codes 79 3 18 7 Cab Display Module CDM and Windrower Control Module WCM Fault Codes 79 4 Operation 81 4 1 Owner Operator Responsibilities...

Page 11: ...taching a D Series Header 131 Attaching a D Series Header Hydraulic Center Link 131 Attaching a D Series Header Mechanical Center Link 136 4 5 2 Detaching a D Series Header 141 Detaching a D Series Header Hydraulic Center Link 142 Detaching a D Series Header Mechanical Center Link 145 4 5 3 Attaching an A Series Header 148 Attaching an A Series Header Hydraulic Center Link 149 Attaching an A Serie...

Page 12: ...S Hydraulic Fittings 196 5 3 Maintenance Specifications 198 5 3 1 Recommended Fuel Fluids and Lubricants 198 Storing Lubricants and Fluids 198 Fuel Specifications 198 Lubricants Fluids and System Capacities 199 Filter Part Numbers 200 5 3 2 Conversion Chart 201 5 4 Engine Compartment Hood 202 5 4 1 Opening Hood Lower Position 202 5 4 2 Closing Hood Lower Position 203 5 4 3 Opening Hood Highest Pos...

Page 13: ...s 276 Red Tail Lights 277 Beacons if installed 277 Dome Light 281 Ambient Light 282 Turn Signal Indicators 282 Circuit Breakers and Fuses 282 5 7 9 Hydraulic System 287 Checking and Filling Hydraulic Oil 288 Hydraulic Oil Cooler 289 Draining Hydraulic Oil 290 Changing Hydraulic Oil Filters 290 Header and Reel Hydraulics 294 Traction Drive Hydraulics 296 Hoses and Lines 298 5 7 10 Wheels and Tires ...

Page 14: ...7 Draper Header Reel Drive and Lift Plumbing 338 7 1 8 Engine Block Heater 338 7 1 9 Engine Fan Air Baffle 338 7 1 10 Expansion Module 338 7 1 11 HID Auxiliary Lighting 338 7 1 12 Hydraulic Center Link 339 7 1 13 Light Header Flotation 339 7 1 14 Mechanical Center Link 339 7 1 15 Swath Roller 339 7 1 16 Towing Harness 339 7 1 17 Training Seat 339 7 1 18 Transport Drawbar 340 7 1 19 Warning Beacons...

Page 15: ...nd on safety signs on the windrower This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Carefully read and follow the safety message accompanying this symbol Why is safety important to you Accidents disable and kill Accidents cost Accidents can be avoided Figure 1 1 Safety Symbol 169890 1 Revision A ...

Page 16: ...mminently hazardous situation that if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation that if not avoided could result in death or serious injury It may also be used to alert against unsafe practices CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It may be used to alert against un...

Page 17: ...lter mask Hearing protection Be aware that exposure to loud noise can cause impairment or loss of hearing Wearing suitable hearing protection devices such as ear muffs or ear plugs These will help protect against objectionable or loud noises Figure 1 3 Safety Equipment Provide a first aid kit for use in case of emergencies Keep a fire extinguisher on the machine Be sure the fire extinguisher is pr...

Page 18: ...horten the machine s life Stop the engine and remove the key from ignition before leaving operator s seat for any reason A child or even a pet could engage an idling machine Figure 1 6 Safety around Equipment 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 t...

Page 19: ... sure all components are tight and that steel lines hoses and couplings are in good condition Keep hands feet clothing and hair away from all moving and or rotating parts Clear the area of bystanders especially children when carrying out any maintenance and repairs or when making any adjustments Install transport lock or place safety stands under the frame before working under the windrower If mor...

Page 20: ...ly and create a hazardous and unsafe condition Figure 1 11 Checking Hydraulic Leaks Wear proper hand and eye protection when searching for a high pressure hydraulic leak Use a piece of cardboard as a backstop instead of hands to isolate and identify a leak If injured by a concentrated high pressure stream of hydraulic fluid seek medical attention immediately Serious infection or toxic reaction can...

Page 21: ...an explosion that may result in serious injury or death Figure 1 14 Over Inflated Tire Do NOT attempt to mount a tire unless you have the proper training and equipment Have a qualified tire dealer or repair service perform required tire maintenance Figure 1 15 Safely Filling a Tire with Air 169890 7 Revision A ...

Page 22: ...on clothing or the body neutralize it immediately with a solution of baking soda and water then rinse with clear water Figure 1 17 Safety around Batteries WARNING To avoid injury from spark or short circuit disconnect battery ground cable before servicing and part of electrical system Do NOT operate the engine with alternator or battery disconnected With battery cables disconnected and engine runn...

Page 23: ... with welding can cause damage to electronic components Before welding on any part of the windrower or an attached header disconnect all electronic module harness connections as well as the battery cables Refer to your MacDon Dealer for proper procedures 169890 9 Revision A ...

Page 24: ...e or move the controls Consult with the person who attached the warning tag before the engine is started Start the engine from the operator s compartment Always start the engine according to the procedure that is described in the Starting the Engine section of the operator s manual Knowing the correct procedure will help to prevent major damage to the engine components and prevent personal injury ...

Page 25: ...hensive programmable engine monitoring system The ECM has the ability to monitor the engine operating conditions If conditions exceed the allowable range the ECM will initiate an immediate action The following actions are available for engine monitoring control Warning Derate Shutdown The following monitored engine operating conditions have the ability to limit engine speed and or the engine power...

Page 26: ...om your Dealer Parts Department Figure 1 19 Operator s Manual Decal 1 10 1 Installing Safety Decals To install a safety decal follow these steps 1 Clean and dry the installation area 2 Decide on the exact location before you remove the decal backing paper 3 Remove the smaller portion of the split backing paper 4 Place the sign in position and slowly peel back the remaining paper smoothing the sign...

Page 27: ... Fan Shroud Bottom B MD 166425 LH of Step B MD 166440 RH of Step C MD 166466 LH Frame D MD 166450 LH Close to the Exhaust D MD 166461 RH Close to Radiator Cap E MD 166438 LH Cab Door and Rim F MD 166438 LH Lift Linkage G MD 166456 LH Battery Bracket G MD 166455 RH Battery Bracket H MD 166233 LH Frame Behind Battery Bracket 169890 13 Revision A ...

Page 28: ...SAFETY Figure 1 21 Safety Signs LH Side 169890 14 Revision A ...

Page 29: ... Hydraulic Reservoir C MD 166425 Traction Pump Mount D MD 166457 Interior Post Above Vent D MD 166234 Interior Post Below Vent D MD 166462 Interior Post Bottom E MD 166464 Radio Panel F MD 166425 Front Frame Below Cab G MD 166439 RH Lift Linkage H MD 184372 RH Door Assembly I MD 166425 RH Frame J MD 166438 Rim 169890 15 Revision A ...

Page 30: ...SAFETY Figure 1 23 Safety Signs RH Side 169890 16 Revision A ...

Page 31: ...ss starter or starter relay terminals Machine will start with drive engaged and move if starting circuitry is bypassed Start engine only from operator s seat Do not try to start engine with someone under or near machine Figure 1 24 MD 166233 2 MD 166234 a Run over hazard b WARNING The training seat is provided for an experienced Operator of the machine when a new Operator is being trained The trai...

Page 32: ...ER Rest header on ground or engage safety props before going under unit Figure 1 26 MD 166438 4 MD 166439 a Crushing hazard b DANGER Rest header on ground or engage safety props before going under unit Figure 1 27 MD 166439 169890 18 Revision A ...

Page 33: ...h that weights are within the specified limits Figure 1 28 MD 166440 6 MD 166450 a Hot surface hazard b WARNING To avoid injury keep a safe distance from hot surface Figure 1 29 MD 166450 7 MD 166451 a Rotating fan hazard b WARNING To avoid injury stop the engine and remove the key before opening engine hood Figure 1 30 MD 166451 169890 19 Revision A ...

Page 34: ...elds in place and stay clear of moving parts viii Disengage header drive put transmission in Neutral and wait for all movement to stop before leaving operator s position ix Shut off the engine and remove the key from ignition before servicing adjusting lubricating cleaning or unplugging machine x Engage locks to prevent lowering of header or reel before servicing in the raised position xi Use slow...

Page 35: ...SAFETY 10 MD 166456 a Battery acid hazard b WARNING Corrosive and poisonous battery acid Acid can severely burn your body and clothing Figure 1 33 MD 166456 169890 21 Revision A ...

Page 36: ...for all movement to stop before leaving operator s position ix Shut off the engine and remove the key from ignition before servicing adjusting lubricating cleaning or unplugging machine x Engage locks to prevent lowering of header or reel before servicing in the raised position xi Use slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited by law c Run o...

Page 37: ...se slow moving vehicle emblem and flashing warning lights unless prohibited by law iii If width of attached header impedes other vehicle traffic remove header and install MacDon approved weight box Refer to operator s manual for safe procedure to tow header Figure 1 36 MD 166463 14 MD 166466 a High pressure oil hazard b WARNING Do not go near leaks High pressure oil easily punctures skin causing s...

Page 38: ...our Dealer Do not allow untrained persons to operate the machine Review safety instructions with all Operators annually Ensure that all safety signs are installed and legible Make certain everyone is clear of machine before starting engine and during operation Keep riders off the machine Keep all shields in place and stay clear of moving parts Disengage header drive put transmission in Neutral and...

Page 39: ...TY 17 MD 190546 a Slippery surface b WARNING Do not place foot Do not use this area as a step or platform Failure to comply could result in serious injury or death Figure 1 40 MD 190546 169890 25 Revision A ...

Page 40: ......

Page 41: ...finger tight GSL Ground speed lever GVW Gross vehicle weight Hard joint A joint made with the use of a fastener where the joining materials are highly incompressible Header A machine that cuts and lays crop into a windrow and is attached to a self propelled windrower Hex key A hex key or Allen key also known by various other synonyms is a tool of hexagonal cross section used to drive bolts and scr...

Page 42: ... are compressible or experience relaxation over a period of time spm Strokes per minute Tractor Agricultural type tractor Truck A four wheel highway road vehicle weighing no less than 7500 lbs 3400 kg Tension Axial load placed on a bolt or screw usually measured in pounds lb or Newtons N TFFT Turns from finger tight Torque The product of a force X lever arm length usually measured in foot pounds f...

Page 43: ...uty Off Road Vibration Resistant Alternator 130 amp Starter Wet Type as supplied Dry Type may be used Working Lights 11 TRACTION DRIVE E 1 Type Hydrostatic Two Speed Electric Shift Field Low Range 11 mph 0 18 km h Reverse 6 mph 9 6 km h Speed Transport High Range 0 16 mph 0 26 km h Type 2 Piston Pumps 1 per Drive Wheel Displacement 3 0 cu in 50 cc Flow 33 U S gpm 125 L min Transmission Pressure 50...

Page 44: ...Drive Conveyor Draper Reel Auger header dependent HEADER LIFT TILT Pump C 1 Type Hydraulic Double Acting Cylinders Tilt Optional Hydraulic Positioning Optional Hydraulic Center link Displacement 1 02 cu in 16 7 cc Flow 0 11 5 gpm 44 L min Gear Pump System Pressure Relief Max 2500 psi 17 237 kPa Function Lift Tilt Float HEADER FLOTATION Primary Adjustment Manual External Drawbolt With Springs 1 per...

Page 45: ... 17 750 lbs 8050 kg Weight Maximum CGVW 20 200 lbs 9160 kg HEADER COMPATIBILITY Auger Headers A30 D A40 D Compatible Draper Headers D50 D60 D65 up to 35 ft 3 Compatible NOTE Specifications and design are subject to change without notice or obligation to revise previously sold units 1 Pump Orientation a Gear pump center Draper control D Series Reel Auger control A Series b Gear pump inboard Reel co...

Page 46: ... 116 11 16 2964 133 1 2 3391 136 3 8 3464 Inner Outer Shipping 130 11 16 3319 140 9 16 3571 150 3 8 3819 Outer Outer 137 3 4 3499 147 11 16 3751 157 7 16 3999 18 4 x 26 Bar and Turf Wide Track Inner Inner 123 9 16 3139 133 1 2 3391 143 1 4 3639 Inner Outer Shipping 123 9 16 3139 140 9 16 3571 147 15 16 3758 Outer Outer 130 11 16 3319 147 11 16 3751 155 1 16 3938 600 65R28 Radial Tire Inner Inner 1...

Page 47: ...ead D in mm Casters E in mm Minimum 96 7 16 2448 118 15 16 3032 7 5 16SL Maximum 135 11 16 3448 158 3 4 4032 Minimum 96 7 16 2448 118 15 16 3032 10 16 Formed Caster Maximum 135 11 16 3448 158 3 4 4032 Minimum 96 7 16 2448 118 11 16 3014 10 16 Forked Caster Maximum 135 11 16 3448 158 4014 Minimum 96 7 16 2448 118 11 16 3014 16 5 x 16 1 Maximum 135 11 16 3448 158 4014 169890 33 Revision A ...

Page 48: ...hield Wiper E Turn Signal Hazard Lights F Field Road Lights G Handholds H Mirror J Door K Maintenance Platform L Center Link Figure 2 5 Rear View A Caster Wheel B Walking Beam C Red Tail Lights D Engine Compartment Hood E Flood Lights F Horn G Turn Signal Hazard Lights H Mirror J Drive Wheel K Swath Lights 169890 34 Revision A ...

Page 49: ...menities 3 1 Operator Console The console contains controls to operate the windrower as well as amenities for the Operator Figure 3 1 Operator Console A Ignition B Engine Windrower Cab Display Module CDM C Header Controls GSL Header Drive Switch Deck Shift D Ground Speed Controls E Throttle 169890 35 Revision A ...

Page 50: ...y the HEADER DRIVE switch must be moved to OFF position and back to the ON position again to restart the header 3 2 2 Engine and Transmission The engine will not start when the HEADER DRIVE switch is engaged The engine will not start when the transmission is NOT locked in NEUTRAL The engine will shut down when the windrower is moving at 5 mph 8 km h or less and the Operator leaves the seat The CDM...

Page 51: ...crease stiffness C Angle of Armrest Rotate knob C clockwise to increase armrest angle Rotate knob C counterclockwise to decrease angle of the armrest D Angle of Seat Back Pull lever D up to release the seat back Position seat back as desired Release lever D to lock the seat back in position E Seat Fore Aft Position Pull lever E up to release the seat for adjustment Move the seat forward or backwar...

Page 52: ...machine when a new Operator is being trained The training seat is NOT intended as a PASSENGER SEAT or FOR USE BY CHILDREN USE THE SEAT BELT whenever operating the machine or riding as a Trainer KEEP ALL OTHER RIDERS OFF THE MACHINE For storage lift seat B and secure with latch A Figure 3 3 Training Seat To lower seat lift latch A and lower seat B Figure 3 4 Training Seat 169890 38 Revision A ...

Page 53: ...ar 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 To fasten seat belt A 1 Pull belt at right side completely across your body 2 Push the metal eye B into the buckle C until it locks 3 Adjust the position of the belt as low on your body as possible To release seat belt A 4 Push the red button D in the en...

Page 54: ... particular Operator and for easier entry to and exit from the seat To adjust the steering column 1 Hold onto steering wheel step on lever A and move steering wheel up or down to desired position 2 Release lever A to lock steering wheel position Figure 3 6 Adjust Steering Column 169890 40 Revision A ...

Page 55: ... OFF ROAD B Low or High Beams for Road Transport Lights LOW HIGH C Beacons on Cab Roof If Installed OFF ON 3 7 1 Field Lighting The following lights are ON functional when the switch is in the FIELD position field lights forward flood lights rear swath lights rear select HIGH LOW optional HID auxiliary lighting if installed Figure 3 8 Field Light Switch 169890 41 Revision A ...

Page 56: ...ing The following lights are ON functional when the switch is in the ROAD position road lights front turn signals hazards amber front turn signals hazards amber rear red tail lights NOTE The hazard lights MUST be activated with the switch on the cab display module CDM when driving on the road Figure 3 11 Road Lighting Switch 169890 42 Revision A ...

Page 57: ...s Hazards Amber Figure 3 13 Rear View A Turn Signals Hazards Amber B SMV Sign C Red Tail Lights 3 7 3 Beacon Lighting MD B5582 Beacon lighting is an optional feature inside North America but comes standard on windrowers exported outside North America 169890 43 Revision A ...

Page 58: ...the road where required by law Figure 3 15 Optional Beacon Lights 3 7 4 Optional HID Auxiliary Lighting If installed Two optional High Intensity Discharge HID lights MD B5596 provide additional lighting during field operation If installed they are located on the mirror supports and are activated with the light switch in the FIELD position Figure 3 16 Field Light Switch 169890 44 Revision A ...

Page 59: ...OPERATOR S STATION 3 8 Windshield Wiper The ON OFF windshield wiper control is located in the cab headliner Figure 3 17 Switch in Cab Headliner Figure 3 18 Wiper in Park Position 169890 45 Revision A ...

Page 60: ...utside mounted mirrors A 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 Figure 3 19 Mirrors 169890 46 Revision A ...

Page 61: ...1 Heater Shut Off A shut off valve A at the engine allows the cab heater to be isolated from the engine coolant The valve must be OPEN to provide heat to the cab but for maximum cooling the valve can be CLOSED Figure 3 20 Heater Shut Off Valve 3 10 2 Air Distribution Cab air distribution is controlled through adjustable air vents A located in the cab posts The vents provide window and Operator ven...

Page 62: ...nd A C control to OFF 3 Start engine and operate at low idle until engine is warm 4 Click A C switch from OFF to ON for 1 second then back to OFF for 5 to 10 seconds Repeat this step ten times 3 10 4 Air Conditioning 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 The LOW PRESSUR...

Page 63: ...verhead to provide ambient lighting if desired and functions only when the ROAD FIELD light switch is ON An ON OFF switch is located on the light Figure 3 23 Interior Lights The other interior light B is located on the headliner switch panel and the push ON push OFF button is located on the light Figure 3 24 Interior Lights 169890 49 Revision A ...

Page 64: ...station includes the following amenities Operator s Console A Cigarette Lighter B Ashtray Cupholders C Utility Tray D Auxiliary Power E Data Link Receptacle F Live Switchable Ground 20 A G Manual Storage Case Figure 3 25 Operator Amenities 169890 50 Revision A ...

Page 65: ...nd Speakers A Speakers B Radio Mounting Location 3 13 2 Antenna Mounting A roof mounted antenna base for installing a magnetic antenna is available as an option from your Dealer Order antenna mount MD 160288 or refer to 3 28 Template for Antenna Mount page 52 for dimensions IMPORTANT Antenna base can only be installed on the left and right hand rear cab roof bolts It accommodates most CB satellite...

Page 66: ...OPERATOR S STATION To make your own mount refer to dimensions template Use 11 GA or 3 0 mm steel sheet Figure 3 28 Template for Antenna Mount 169890 52 Revision A ...

Page 67: ...utton A located beside the ignition key Sound the horn three times prior to starting the engine Figure 3 29 Operator Console The horn A is located outside the cab on the rear right hand corner of the cab under the roof Figure 3 30 Horn Location 169890 53 Revision A ...

Page 68: ... Switch ACC Fully counterclockwise 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 B Throttle controls engine speed FULL Push lever forward OPERATING Refer to 4 3 6 Windrower Operation page 94 CLOSED Pull lever back Figure 3 31 Engine Controls A Ignition Switch B Throttle ...

Page 69: ... locked in center R Reverse C HAZARD WARNING LIGHTS activate signals on windrower and header Push ON Push OFF E N Detent F Horn Figure 3 32 Console Controls A Turn Signals B Ground Speed Lever GSL C Hazard Warning Lights E N Detent Position F Horn Autosteer Control A AUTOSTEER ENGAGEMENT SWITCH engages disengages the automated steering system if compatible system is installed ENGAGE Click to engag...

Page 70: ...gages the header drive To engage the header drive push the switch to center and pull up To disengage the header drive push the switch down IMPORTANT Always move throttle lever back to IDLE before engaging header drive Do NOT engage header with engine at full rpm Figure 3 34 Header Drive Switch 3 17 2 Deck Shift Switch Draper Header Option The deck shift switch selects the crop delivery options whe...

Page 71: ...ted while in operation to suit changing crop conditions All are momentary type switches Figure 3 36 GSL NOTE A decal B identifying switch functions is located on the cab post above the operator s console Figure 3 37 GSL Function Groups A Reel Speed B Reel Position C Autosteer Engagement D Display Selector E Header Position 169890 57 Revision A ...

Page 72: ... each of the header controls Press switch B to scroll through settings Figure 3 38 GSL Reel Position Switches NOTE Reel position switches work on draper headers only To move reel press and hold the switch at the location shown Release switch at desired position Figure 3 39 Ground Speed Lever A Reel Down B Reel Forward C Reel Up D Reel Aft 169890 58 Revision A ...

Page 73: ...es Figure 3 40 Ground Speed Lever A Header Down B Header Tilt Down C Header Up D Header Tilt Up Reel Speed Switches Press and hold switch A to increase the reel speed Press and hold switch B to decrease the reel speed Release switch at desired speed NOTE Auger speed is adjusted proportionately when reel speed is changed For further details refer to 4 6 6 Reel Speed page 169 for D Series headers or...

Page 74: ...ons D HAZARD WARNING LIGHTS switch Activates hazard warning lights cancels turn signal E SELECT switch Allows operator to select display item on lower line Push to SELECT F TURN SIGNAL switches Activates turn signals on windrower and header Push ON Push OFF G IGNITION switch positions Accessory Stop Run Start H Engine warning lights Engine Pre Heat Water In Fuel CAUTION Stop Engine 169890 60 Revis...

Page 75: ... DRAPER SPEED CONTROL DRAPER HEADER controls draper speed Push UPPER switch to increase draper speed Push LOWER switch to decrease draper speed With optional expansion module controls Draper Speed INDEX with INDEX SWITCH ON and controls Draper Speed with INDEX SWITCH OFF HEADER INDEX SWITCH Links Reel and Conveyor Speed to Ground Speed Push ON Push OFF Illuminates in ON position NOTE Expansion mod...

Page 76: ...4 CDM Operating Screen A Display Selector for Upper Line B Display C CDM Upper Line D CDM Lower Line E Display Selector for Lower Line Ignition ON Engine Not Running Display upper line 2 3 seconds Description HEADER DISENGAGED Indicates HEADER DRIVE switch is OFF OK to start Engine Running At Initial Start Up Display upper line 2 3 seconds Description HEADER TYPE AND SIZE Ignition start engine run...

Page 77: ...el of fuel in tank NOTE When fuel level is low menu selections will be disrupted ENGINE TEMP F ENGINE TEMP C if metric Engine coolant temperature SCROLL SUB MENU Lower Line Only HEADER HEIGHT FUEL ENGINE TEMP F ENGINE TEMP C Displays above items after 2 3 seconds press SELECT to cancel ROAD GEAR upper line Ground speed range switch in HIGH range Only if 2 selected Engine Running Header Engaged Aug...

Page 78: ...menu display with CDM switch Knife speed is optional7 Reel rpm is optional7 Engine Running Header Engaged Draper Header Index Switch OFF Scroll through display with cab display module CDM switch or ground speed lever GSL switch Display lower or upper line Description ENGINE HRS Total engine operating time UNIT HRS Total windrower operating time HEADER HRS Total header operating time ACRES HOUR HEC...

Page 79: ...Draper Header Index Switch ON Scroll through display with cab display module CDM switch or ground speed lever GSL switch Display lower or upper line Description ENGINE HRS Total engine operating time UNIT HRS Total windrower operating time HEADER HRS Total header operating time ACRES HOUR HECTARES HOUR if metric Actual cutting rate in acres hectares hour SUB ACRES SUB HECTARES if metric Area cut s...

Page 80: ...DM switch Optional9 REEL MIN RPM lower line Reel speed drops below programmed set point MINIMUM lower line Optional9 Miscellaneous Operational Information Scroll through display with cab display module CDM switch or ground speed lever GSL switch Display upper line Description LEFT TURN Indicates left turn when left arrow is pressed on CDM RIGHT TURN Indicates right turn when right arrow is pressed...

Page 81: ... Figure 3 45 CDM Engine Warning Lights A Engine Pre Heat B Water in Fuel C Caution D Stop E Display ENGINE PRE HEAT Illuminates yellow Wait to start engine WATER IN FUEL Illuminates yellow Service recommended CAUTION Illuminates yellow Prompt attention is required Refer to display code STOP Illuminates red Stop engine immediately Refer to display code DISPLAY Displays malfunction code Refer to 8 E...

Page 82: ...tion switch turned ON ENGINE OIL PRESSURE X Continuous loud tone until oil pressure is regained Low engine oil pressure accompanied by warning lights ENGINE TEMPERATURE X Ongoing intermittent moderate tone until temperature is below 215 F 102 C Engine temperature over 230 F 110 C accompanied by warning lights HEADER DISENGAGED None Normal IN PARK X One short beep GSL in N DETENT steering wheel cen...

Page 83: ...ith header engaged or out of N DETENT engine shutdown after 5 seconds NOT IN PARK X Short beep with each flash GSL or interlock switches not closed with key ON engine OFF TRANS OIL PRESS X Continuous loud tone until oil pressure is regained Low transmission charge oil pressure TRANS OIL TEMP X Ongoing intermittent moderate tone until temperature is below acceptable level Transmission oil temperatu...

Page 84: ...Lower Line Selection SELECT SWITCH places monitor into Program Mode with PROGRAM switch Press to accept menu item and advance to next item MENU ITEM SCROLL FORWARD displays value under menu item Push to scroll forward Hold down for fast scroll10 MENU ITEM SCROLL BACKWARD displays value under menu item Push to scroll backward Hold down for fast scroll10 PROGRAM SWITCH places monitor into program mo...

Page 85: ... following functions NOTE The following can be set by the Dealer provided that the header is installed and other information needed is available TILT CYL INSTALLED DISC BLK INSTALLED HDR CUT WIDT HAY CONDITIONER SET TIRE SIZE 7 Press PROGRAM to exit programming mode when finished entering values Programming Guidelines Use the following guidelines when programming the cab display module CDM 1 The m...

Page 86: ...Flow Chart page 72 for a listing of all the menus with user information for each menu item NOTE Contact your MacDon dealer for information about software updates to the electronic modules Your Dealer will have the necessary interface tools and access to the latest software upgrades Detailed Programming Menu Flow Chart The programming menu flow chart is current for cab display module CDM software C...

Page 87: ...OPERATOR S STATION 169890 73 Revision A ...

Page 88: ...OPERATOR S STATION 169890 74 Revision A ...

Page 89: ...OPERATOR S STATION 169890 75 Revision A ...

Page 90: ...OPERATOR S STATION 169890 76 Revision A ...

Page 91: ...OPERATOR S STATION 169890 77 Revision A ...

Page 92: ...OPERATOR S STATION Operating Information Screens 169890 78 Revision A ...

Page 93: ...pecific problem with engine operation Refer to 8 Engine Error Codes page 341 3 18 7 Cab Display Module CDM and Windrower Control Module 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 9 Cab Display Module CDM...

Page 94: ......

Page 95: ...owever short a time or distance make sure they have been instructed in its safe and proper use Review the manual and all safety related items with all Operators annually Be alert 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 fun...

Page 96: ... operating the windrower 4 2 1 Engine Functions These are the symbols that are used on the console Figure 4 1 Engine Function Symbols A Electrical Power Accessories B Engine Coolant Temperature C Engine Glow Plugs D Engine Malfunction E Engine rpm F Engine Run G Engine Start H Engine Stop J Engine Throttle K Engine Urgent Stop L Fast M Slow N Water in Fuel 169890 82 Revision A ...

Page 97: ...ing Lights C Forward D Neutral E Reverse F Headlights Low Beam Road Lights G Headlights High Beam Road Lights H Work Light J Lighter K Fresh Air L Blower M Windshield Wiper N Seat Height Up O Seat Height Down P Seat Fore and Aft Q Seat Fore Aft Isolator R Seat Back Fore and Aft S Seat Ride Damping T Cab Temperature Control U Air Conditioning V Recirculate 169890 83 Revision A ...

Page 98: ...eader Index D Reel Speed E Return to Cut F Reel Rearward G Reel Forward H Header Tilt Up J Header Tilt Down K Conveyor Auger Speed L Header Down M Header Up N Reel Up O Reel Down P Deck Shift Q Header Disengage R Header Engage S Pull Up Header Engage T Push Down Header Disengage 169890 84 Revision A ...

Page 99: ...hearing protective device such as ear muffs or ear plugs to protect against objectionable or uncomfortable loud noises Follow all safety and operational instructions given in your operator s manuals If you do not have a header manual get one from your Dealer and read it thoroughly Never attempt to start the engine or operate the machine except from the operator s seat Check the operation of all co...

Page 100: ...let engine idle for 3 minutes and then operate at moderate speed until oil has warmed up Watch coolant gauge in cab for temperature rising beyond normal operating range Check that coolant level at reserve tank mounted next to radiator stays between HOT and COLD marks on tank Refer to Engine Cooling System page 245 If over heating problems occur check for coolant leaks 4 3 3 Preseason Checks Annual...

Page 101: ...ating and A C control C to OFF 2 Start engine and operate at low idle until engine is warm 3 Click A C switch B from OFF to ON for one second then back to OFF for 5 to 10 seconds Repeat this step ten times Figure 4 6 Climate Control A Temperature Control B Blower Switch C Air Conditioning Switch 4 3 4 Daily Check 1 Check the machine for leaks or any parts that are missing broken or not working cor...

Page 102: ... engaged and move if normal starting circuitry is bypassed Start engine only from operator s seat with controls in NEUTRAL NEVER start engine while standing on ground Never try to start engine with someone under or 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 WA...

Page 103: ... about machine operation and condition Familiarize yourself with the gauges and monitor them carefully during start up operation Refer to 3 15 Engine Controls and Gauges page 54 CAUTION Check to be sure all bystanders have cleared the area 2 Sound horn C three times 3 Turn ignition key B to RUN position Single loud tone sounds engine warning lights illuminate as a self test and cab display module ...

Page 104: ...2 Cold Start page 90 Figure 4 10 Operator Controls A Throttle B Ignition Key C Horn D Grid Heater Light IMPORTANT Do NOT operate starter for longer than 15 seconds at a time If engine does not start wait at least two minutes before trying again After the third 15 second crank attempt allow solenoid to cool for 10 minutes before further cranking attempts If engine still does not start refer to 6 1 ...

Page 105: ...ducing engine wear With the ISC activated the engine speed automatically reverts to 2300 rpm when the header is engaged Programming instructions are provided in 3 18 5 Cab Display Module CDM Programming page 70 Shutting Down the Engine CAUTION Park on a flat level surface header on the ground and the ground speed lever in N DETENT position and steering wheel locked IMPORTANT Before stopping engine...

Page 106: ...y Running out of fuel can cause air locks and or contamination of the fuel system Refer to System Priming page 244 1 Stop windrower and remove key 2 Stand on platform to access the fuel tank filler pipe 3 Clean the area around filler cap A 4 Turn cap handle B counterclockwise until loose and then remove cap 5 Fill tank with approved fuel Refer to Lubricants Fluids and System Capacities page 199 IM...

Page 107: ...sage If the STOP ENGINE light illuminates stop the engine IMMEDIATELY and investigate If the yellow CAUTION light illuminates stopping immediately is optional You may continue operations and investigate later but you are STRONGLY advised to monitor the situation carefully Electrical The electrical system voltage is displayed on the cab display module CDM when selected with the SELECT button on the...

Page 108: ... loosely or with slack in the belt system Never wear the belt in a twisted condition or pinched between the seat structural members WARNING Avoid driving the machine with header removed Removing header decreases the weight on drive wheels reducing steering control If necessary to drive machine with header removed use transmission field speed range do NOT exceed 1500 rpm engine speed and avoid loos...

Page 109: ... until you are sure all bystanders have cleared the area Make sure area is clear before making turns as the ends of a header travel in a large arc Check the operation of all controls in a safe clear area before starting work Do know the capacity and operating characteristics of your machine Do NOT allow riders in or on the machine Do NOT operate unless seated in the operator s position Do NOT atte...

Page 110: ...ine and remove key from ignition A child or even a pet could engage an idling machine Turn off wipers Turn off lights unless required for inspection purposes Release seat belt Raise armrest and steering wheel for easier exit and re entry Lock the cab door when leaving the windrower unattended When the door is locked it can still be opened from inside the cab A swing away platform and steps A are p...

Page 111: ... switch B to either of the following 2 for road speed 0 16 mph 25 7 km h 1 for field speed 0 11 mph 17 7 km h 5 The cab display module CDM will display an engine status at C 6 Slowly push throttle D to full forward operating speed The CDM should display 2270 2330 rpm at E Figure 4 18 Operator Console A Ground Speed Lever B Ground Speed Range Switch C Engine Status Display D Throttle E RPM Display ...

Page 112: ...speed is recommended since steering will be less sensitive than at higher speed settings CAUTION Check again to be sure all bystanders have cleared the area 3 Move the ground speed lever GSL rearward to desired speed Figure 4 19 Operator s Console 4 Steer as shown Figure 4 20 Reverse Steering Spin Turning Hydrostatic steering provides significantly more manoeuvrability than mechanical steering CAU...

Page 113: ...t belt when operating windrower To stop the windrower 1 SLOWLY return the ground speed lever GSL A to NEUTRAL and into N DETENT 2 Turn steering wheel until it locks 3 Move throttle lever B to low idle position NOTE Avoid unnecessary idling Stop engine if it will be idling for longer than 5 minutes 4 Brakes are automatically engaged when steering wheel is locked in NEUTRAL position CAUTION Park on ...

Page 114: ... Park on a flat level surface header on the ground and the ground speed lever in N DETENT position and steering wheel locked Adjust the caster tread width as follows 1 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 at B NOTE Lifting device should have a lifting capacity of at least 5000 lb 2270 kg 2 Remove six bol...

Page 115: ... to ground IMPORTANT Torque bolts after first 5 and 10 hours of operation Figure 4 26 Caster Wheel Extensions 4 3 8 Transporting the Windrower Driving on the Road WARNING Collision between windrower and other vehicles may result in injury or death WARNING When driving windrower on public roadways Obey all highway traffic regulations in your area Use pilot vehicles in front and rear of windrower if...

Page 116: ... before transporting on roads Before driving windrower on a roadway 1 Ensure HEADER DRIVE switch A is pushed to OFF position down 2 Clean flashing amber lamps red tail lamp and head lamps and check that they work properly 3 Clean all reflective surfaces and slow moving vehicle emblems 4 Adjust interior rear view mirror and clean windows Figure 4 27 Header Drive Switch 5 Push LIGHT switch A to ROAD...

Page 117: ...le 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 Move ground speed lever GSL closer to NEUTRAL to reduce speed Lower header Set GROUND SPEED RANGE switch to 1 field speed With header ...

Page 118: ...he appropriate equipment to comply with all local regulations Before each towing trip a pre trip inspection must all be conducted to verify that all signal lighting and safety equipment is installed and functioning properly Do NOT connect any towed implement except for header transport trailers for 20 25 foot D Series headers or 30 35 foot D Series headers that are equipped with the slow speed tra...

Page 119: ...al cable into the storage position Refer to header operator s manual b Right Side Release the multi link and place into storage on windrower Refer to header operator s manual 3 Retrieve temporary lift pin from storage location on weight box and install into rear hole A at the top of the lift arms This provides additional lift height for transport wheel deployment CAUTION Check to be sure all bysta...

Page 120: ... to windrower linkage 9 Release the safety props on the header lift cylinders Refer to 4 4 1 Header Safety Props page 117 10 Start engine and lower header down onto the transport wheels Figure 4 36 Lift Arms 11 Use the HEADER TILT switches to release load on the cylinder if necessary 12 Shut down engine and remove key from ignition Figure 4 37 Ground Speed Lever GSL A Header Tilt Down B Header Til...

Page 121: ...connect the center link as follows a Loosen nut A and rotate barrel B to relieve load on link b Remove cotter pin D on pin C and remove pin to disconnect from windrower Reinstall pin in header Figure 4 39 Mechanical Link 15 Back windrower away from header 16 Remove tow bar sections from storage locations on header assemble and attach to header Refer to header operator s manual Attach optional weig...

Page 122: ...cure with hairpin NOTE Pins A were previously removed from the header lift linkage lower end Figure 4 41 Lift Arms At rear of windrower lower the drawbar bracket as follows 21 Hold drawbar support A and remove the two pins B at the forward end 22 Lower support to position shown and reinstall the two pins B in uppermost pair of holes in support 23 Alternative drawbar C can be removed if desired Fig...

Page 123: ...ts A Tow Bar B Drawbar Hole C Tow Bar Clevis Pin D Within 6 inches 150 mm 26 If the tow bar A is TOO FAR from the drawbar B a Remove pin C lift the drawbar support D until the tow bar clevis aligns and then install the drawbar pin E b Start engine and gently reverse the windrower until the drawbar support pivots down to transport position c Stop engine and remove key d Reinstall pin C to secure dr...

Page 124: ... and gently drive the windrower forward until the drawbar support pivots up to transport position c Stop engine and remove key d Reinstall pin B Figure 4 45 Towing Components 28 Connect safety chain A through the slot in the drawbar support B and securely attach the hook C to the chain Leave enough slack to allow the hitch to pivot Figure 4 46 Towing Components 169890 110 Revision A ...

Page 125: ...nal lights on header function properly 32 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 equipment is installed and fully functional Converting from Transport Mode to Field Operation DANGER Stop engine and remove key from ignition before leaving operator s seat for any reason A child or even a ...

Page 126: ...arness A on weight box Figure 4 49 Electrical Harness 3 Disconnect electrical harness A from windrower and store harness on tow bar Figure 4 50 Electrical Connector 4 Undo lock A remove safety chain B from drawbar and remove clevis pin C Figure 4 51 Drawbar Hitch 169890 112 Revision A ...

Page 127: ...Do NOT use alternative drawbar for any other purpose 8 Disassemble tow bar and store on header Refer to header operator s manual Figure 4 52 Drawbar Hitch 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 B and NOT installed at hole location A Figur...

Page 128: ...fety equipment is installed and fully functional 16 Proceed to operate the header Figure 4 55 Lift Arms Towing the Windrower Emergency In emergency situations for example towing out of a field or into a shop windrower may be towed without a trailer providing the following precautions are followed WARNING A proper towing apparatus is critical to safe towing Use the following guidelines Do NOT attac...

Page 129: ...ng speeds of more than 16 mph 26 km h will cause final drive gears to run at excessive speeds possibly severely damaging or causing the unit to fail Final Drives Disengage and engage final drives as follows 1 Remove the two bolts A at the center of drive wheel 2 Remove cap B and flip over so that dished side faces in The cap depresses a pin that disengages the gearbox 3 After towing reverse cover ...

Page 130: ...e pressure by 25 for storage Adjust to recommended operating pressure before next use 8 Repaint all worn or chipped painted surfaces to prevent rust 9 Lubricate the windrower thoroughly leaving excess grease on fittings to keep moisture out of bearings Apply grease to exposed threads and sliding surfaces of components 10 Check for worn components and repair Tighten loose hardware and replace any m...

Page 131: ...n the windrower DANGER To avoid bodily injury from fall of raised header always engage safety props when working on or around raised header and before going under header for any reason Engage safety props as follows 1 Start engine and press HEADER UP A switch to raise header to maximum height 2 Rephase cylinders if one end of the header does not raise fully If rephasing is needed proceed as follow...

Page 132: ...e 4 60 Safety Prop 4 To disengage safety props and for storage turn lever A away from header to raise safety prop until lever locks into vertical position Repeat for opposite cylinder Figure 4 61 Safety Prop 5 Start engine choose a level area and lower header to the ground Stop engine and remove key 169890 118 Revision A ...

Page 133: ... float the header Refer to your header operator s manual for float setting and adjustment guidelines Float Operating Guidelines When working with the cutterbar on the ground 1 Set center link to mid range position 05 0 on cab display module CDM Refer to 4 4 5 Adjusting Header Angle page 124 2 In rocky fields adjust skid shoes down to raise guards when operating at flattest header angle to minimize...

Page 134: ...draulic center link is installed use HEADER TILT switches B C to set center link to mid range position 5 0 on CDM A 3 Using HEADER DOWN switch E lower header fully with lift cylinders fully retracted 4 Shut down the engine and remove the key 5 Grasp the divider rod at the end of the header and lift The force to lift should be as noted in the following table and should be approximately the same at ...

Page 135: ...ve key Figure 4 63 GSL 3 Turn drawbolt A clockwise to increase float makes header lighter or counterclockwise to decrease float makes header heavier 4 Recheck the header float as described in Checking Float page 120 Figure 4 64 Header Float Adjustment 4 4 3 Levelling the Header The windrower linkages are factory set to provide the proper level for the header and should not normally require adjustm...

Page 136: ...Check drive wheel tire pressures Check and set float adjustment Refer to Checking Float page 120 To level the header follow these steps 1 Place float pins in locked out location A Figure 4 65 Float Pins 2 Park windrower on level ground 3 Set header approximately 6 in 150 mm off ground and check that member A is against link B Note the high and low end of header 4 Place wooden blocks under header c...

Page 137: ...TION Check to be sure all bystanders have cleared the area 9 Start engine and raise header slightly Check level of header 10 If additional levelling is required install the removed shim on the opposite linkage NOTE If required additional shims are available from your Dealer Figure 4 68 Lift Linkage 11 Once header is level return float pins to their engaged position A NOTE Float does NOT require ad...

Page 138: ...ngage Header a Move throttle A to adjust engine speed to idle b Push down on the yellow knob in the center of the HEADER DRIVE switch B and pull up on the black ring at the base of the switch A slight delay between switch ON and operating speed is normal 2 To Disengage Header a Push HEADER DRIVE switch B down to disengage header drive Figure 4 70 Operator Console 4 4 5 Adjusting Header Angle Heade...

Page 139: ...ver GSL handle so that cylinder retracts The CDM display will show a reading on the lower line of decreasing value between 00 0 and 10 0 To increase steepen header angle operate HEADER TILT DOWN switch D on GSL handle so the cylinder extends The CDM display will show a reading on the lower line of increasing value between 00 0 and 10 0 The HEADER TILT switch can be deactivated to prevent inadverte...

Page 140: ...r by pulling up on handle A to release the locking device and then lifting the hook off the header pin Figure 4 72 Center Link 2 Lower the handle A into the LOCK position 3 Push up on lock pin B only Handle should catch on casting and pin should NOT lift Figure 4 73 Center Link Hook A Handle B Lock Pin C Actuator Rod 4 Push up on actuator rod C and lock pin should lift with the handle Figure 4 74 ...

Page 141: ...utting height with the RETURN TO CUT feature This feature can be turned OFF or ON with a switch on the cab display module CDM The return to cut RTC feature provides preset cutting height and tilt angle settings for the header NOTE To enable the RTC header tilt feature the optional hydraulic center link and expansion module must be installed Refer to 7 1 12 Hydraulic Center Link page 339 and 7 1 10...

Page 142: ... header 2 Set RETURN TO CUT switch A to OFF indicator light is OFF 3 Adjust the header to the desired cutting height with the HEADER UP B or HEADER DOWN C switches on the ground speed lever GSL The cab display module CDM displays between 00 0 and 10 0 at D 4 Adjust the header angle with the HEADER TILT UP E or HEADER TILT DOWN F switches on the GSL The CDM displays between 00 0 and 10 0 This step ...

Page 143: ...e header will return to preset height 2 If the header is below the preset height press and hold the HEADER UP B switch to raise the header Release switch to stop header Alarm will sound when header rises past the preset height 3 If the header angle changes for machines equipped with optional hydraulic center link and expansion module double click two clicks within 0 5 seconds the HEADER TILT UP E ...

Page 144: ...RATION 4 4 7 Swath Roller Operation Refer to the operating instructions that are provided with an optional Swath Roller kit Refer to 7 1 15 Swath Roller page 339 for more information 169890 130 Revision A ...

Page 145: ...nkage If that is not the case refer to 4 6 2 Attaching Header Boots page 168 To attach a D Series header to a windrower equipped with a hydraulic center link follow these steps 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 1 Remove the hairpin A from pin B and remove the pins from both header legs ...

Page 146: ...s A enter the header legs B Continue to drive slowly forward until lift linkages contact the support plates in the header legs and the header nudges forward 5 Ensure that lift linkages are properly engaged in header legs contacting the support plates Figure 4 81 Header Leg and Boot 6 Activate HEADER TILT cylinder switches on ground speed lever GSL to extend or retract center link cylinder so that ...

Page 147: ...eader by pulling upward on rod end B of cylinder Figure 4 83 Hydraulic Center Link CAUTION Check to be sure all bystanders have cleared the area 10 Start engine and press the HEADER UP switch A to raise header to maximum height NOTE If one end of the header does NOT raise fully rephase the cylinders as follows a Press and hold the HEADER UP switch until both cylinders stop moving b Continue to hol...

Page 148: ...der stop B onto cylinder c Repeat for the opposite lift cylinder Figure 4 85 Cylinder Stop 12 Install the pin B through header leg engaging U bracket in lift linkage on both sides and secure with hairpin A 13 Raise header stand D to storage position by pulling spring pin C and lifting stand into uppermost position Release spring pin C Figure 4 86 Header Leg 169890 134 Revision A ...

Page 149: ... safety prop by turning lever A downward to release and lower stop until lever locks into vertical position 16 Repeat for opposite safety prop Figure 4 88 Cylinder Stop CAUTION Check to be sure all bystanders have cleared the area 17 Start engine and activate HEADER DOWN switch A on GSL to lower header fully 18 Stop engine and remove key Figure 4 89 GSL 169890 135 Revision A ...

Page 150: ...s Attaching a D Series Header Mechanical Center Link NOTE This topic assumes that draper header boots have already been attached to the windrower lift linkage If that is not the case refer to 4 6 2 Attaching Header Boots page 168 To attach a D Series header to a windrower equipped with a mechanical center link follow these steps DANGER Stop engine and remove key from ignition before leaving operat...

Page 151: ...ter link is too low it may contact the header as the windrower approaches the header for hookup Figure 4 93 GSL 3 Slowly drive the windrower forward so the boots A enter the header legs B Continue to drive slowly forward until lift linkages contact the support plates in the header legs and the header nudges forward 4 Ensure that lift linkages are properly engaged in header legs contacting the supp...

Page 152: ... A slight tap with a hammer is sufficient Figure 4 95 Mechanical Center Link CAUTION Check to be sure all bystanders have cleared the area 9 Press the HEADER UP switch A to raise header to maximum height NOTE If one end of the header does NOT raise fully rephase the cylinders as follows a Press and hold the HEADER UP switch until both cylinders stop moving b Continue to hold the switch for 3 4 sec...

Page 153: ...ety prop B onto cylinder c Repeat for the opposite lift cylinder Figure 4 97 Cylinder Stop 11 Install pin B through header leg engaging U bracket in lift linkage on both sides and secure with a hairpin A 12 Raise header stand D to storage position by pulling spring pin C and lifting stand into uppermost position Release spring pin C Figure 4 98 Header Leg 169890 139 Revision A ...

Page 154: ...safety prop by turning lever A downward to release and lower stop until lever locks into vertical position 15 Repeat for opposite safety prop Figure 4 100 Cylinder Stop CAUTION Check to be sure all bystanders have cleared the area 16 Start engine and activate HEADER DOWN switch on GSL A to lower header fully 17 Stop engine and remove key Figure 4 101 GSL 169890 140 Revision A ...

Page 155: ...hydraulics A at right hand side of windrower Refer to the draper header operator s manual Figure 4 103 Reel Hydraulics 4 5 2 Detaching a D Series Header Refer to the procedure that is appropriate for the center link installed on the windrower Detaching a D Series Header Hydraulic Center Link page 142 Detaching a D Series Header Mechanical Center Link page 145 169890 141 Revision A ...

Page 156: ...Start engine and press HEADER UP A switch to raise header to maximum height 2 Rephase cylinders if one end of the header does not raise fully If rephasing is needed proceed as follows a Press and hold the HEADER UP A switch until both cylinders stop moving b Continue to hold the switch for 3 4 seconds Cylinders are phased 3 Stop engine and remove key Figure 4 104 GSL 4 Pull lever A and rotate towa...

Page 157: ... with lynch pin CAUTION 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 B and NOT installed at hole location A Figure 4 107 Header Lift Linkage 8 To disengage safety props and for storage turn lever A away from header to raise safety prop until lever locks ...

Page 158: ...isconnect reel hydraulics A from header and store on bracket at windrower left cab forward side Refer to the draper header operator s manual for further information Figure 4 110 Reel Hydraulics CAUTION Check to be sure all bystanders have cleared the area 11 Start engine and activate HEADER TILT cylinder switch on ground speed lever GSL to release load on center link cylinder Figure 4 111 GSL A He...

Page 159: ...eader Mechanical Center Link To detach a D Series header from an M Series windrower equipped with mechanical center link follow these steps 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 1 Start engine and press HEADER UP A switch to raise header to maximum height 2 If one end of the header does NOT...

Page 160: ...fety prop B onto cylinder Repeat for the opposite cylinder Figure 4 115 Safety Prop 5 Remove the clevis pin B by removing hairpin A from header leg on both sides 6 Lower header stand D by pulling spring loaded pin C Release pin to lock stand Figure 4 116 Header Stands 169890 146 Revision A ...

Page 161: ...on B and NOT installed at hole location A Figure 4 117 Header Lift Linkage 8 To disengage safety props and for storage turn lever A away from header to raise safety prop until lever locks into vertical position Repeat for opposite cylinder Figure 4 118 Safety Prop 9 Disconnect header drive hydraulics A and electrical harness B from header and store in support on windrower left cab forward side Ref...

Page 162: ... to disconnect from windrower Reinstall clevis pin C in header 13 Tighten nut A against barrel A slight tap with a hammer is sufficient Figure 4 121 Mechanical Center Link 14 Reinstall pin A into header leg and secure with a hairpin B Figure 4 122 Header Leg 4 5 3 Attaching an A Series Header Refer to the procedure that is appropriate for the center link installed on the windrower Attaching an A S...

Page 163: ... pin from left and right header boots C on header Figure 4 123 Header Boot CAUTION 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 B and NOT installed at hole location A Figure 4 124 Header Lift Linkage CAUTION Check to be sure all bystanders have cleared t...

Page 164: ...elf Alignment Kit 4 Slowly drive the windrower forward so the feet A on the windrower enter the boots B on the header Continue to drive slowly forward until the feet engage the boots and the header nudges forward Figure 4 127 Header Boot 5 Activate HEADER TILT cylinder switches on ground speed lever GSL to extend or retract center link cylinder so that the hook lines up with the header attachment ...

Page 165: ...on rod end B of cylinder Figure 4 129 Hydraulic Center Link CAUTION Check to be sure all bystanders have cleared the area 9 Start engine and press the HEADER UP switch A to raise header to maximum height NOTE If one end of the header does NOT raise fully the lift cylinders require rephasing If rephasing is needed proceed as follows a Press and hold the HEADER UP switch until both cylinders stop mo...

Page 166: ...to release and lower the safety prop B onto cylinder c Repeat for the opposite lift cylinder Figure 4 131 Cylinder Stop 11 Install clevis pin A through each boot and foot and secure with hairpin Do this to both sides IMPORTANT Ensure clevis pin A is fully inserted and hairpin is installed behind bracket Figure 4 132 Header Boot 169890 152 Revision A ...

Page 167: ... secure with lynch pin Figure 4 133 Header Stand 15 Remove clevis pin from storage position B in linkage and insert in hole A to engage float springs Secure with hairpin Figure 4 134 Header Lift Linkage 16 Disengage safety prop by turning lever A downward to release and lower safety prop until lever locks into vertical position 17 Repeat for opposite safety prop Figure 4 135 Safety Prop 169890 153...

Page 168: ...trical harness B to header Refer to the auger header operator s manual Figure 4 137 Header Drive Hoses and Harness Attaching an A Series Header Mechanical Center Link To attach an A Series header to a windrower equipped with a mechanical center link follow these steps 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...

Page 169: ...without a header or weight box attached to windrower ensure that float engagement pin is installed in storage location B and NOT installed at hole location A Figure 4 139 Header Lift Linkage CAUTION Check to be sure all bystanders have cleared the area 2 Start the engine and activate HEADER DOWN button A on the ground speed lever GSL to fully retract header lift cylinders Figure 4 140 GSL 169890 1...

Page 170: ...t link to required length for proper header angle by rotating barrel B Tighten nut A against barrel A slight tap with a hammer is sufficient Figure 4 142 Mechanical Center Link CAUTION Check to be sure all bystanders have cleared the area 8 Start engine and press the HEADER UP switch A to raise header to maximum height NOTE If one end of the header does NOT raise fully the lift cylinders require r...

Page 171: ...to release and lower the safety prop B onto cylinder c Repeat for the opposite lift cylinder Figure 4 144 Cylinder Stop 10 Install clevis pin A through each boot and foot and secure with hairpin Do this to both sides IMPORTANT Ensure clevis pin A is fully inserted and hairpin is installed behind bracket Figure 4 145 Header Boot 169890 157 Revision A ...

Page 172: ... secure with lynch pin Figure 4 146 Header Stand 14 Remove clevis pin from storage position B in linkage and insert in hole A to engage float springs Secure with hairpin Figure 4 147 Header Lift Linkage 15 Disengage safety prop by turning lever A downward to release and lower safety prop until lever locks into vertical position 16 Repeat for opposite safety prop Figure 4 148 Safety Prop 169890 158...

Page 173: ...ader drive hoses A and electrical harness B to header Refer to the auger header operator s manual Figure 4 150 Header Drive Hoses and Harness 4 5 4 Detaching an A Series Header Refer to the procedure that is appropriate for the center link installed on the windrower Detaching an A Series Header Hydraulic Center Link page 160 Detaching an A Series Header Mechanical Center Link page 163 169890 159 R...

Page 174: ... one end of the header does NOT raise fully rephase the cylinders as follows a Press and hold the HEADER UP A switch until both cylinders stop moving b Continue to hold the switch for 3 4 seconds Cylinders are phased 3 Stop engine and remove key Figure 4 151 GSL DANGER To avoid bodily injury from fall of raised header always engage safety props when working on or around raised header and before go...

Page 175: ...igure 4 154 Header Stand 7 Remove the clevis pin from linkage A to disengage float springs and insert in storage hole B Secure with lynch pin Repeat for opposite linkage CAUTION 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 B and NOT installed at hole loc...

Page 176: ... to the ground 10 Activate HEADER TILT cylinder switch on ground speed lever GSL to release load on center link cylinder Figure 4 157 GSL A Header Tilt Up B Header Tilt Down 11 Stop engine and remove key from ignition 12 Lift hook release C and lift hook B off header pin NOTE If optional center link self alignment kit is installed lift release C and then operate the link lift cylinder with REEL UP...

Page 177: ...eader Mechanical Center Link WARNING Stop engine and remove key before making adjustments to machine A child or even a pet could engage the drive 1 Start engine and press HEADER UP button A on ground speed lever GSL to raise header to maximum height 2 If one end of the header does NOT raise fully follow these steps to rephase the cylinders a Press and hold the HEADER UP A switch until both cylinde...

Page 178: ...header and before going under header for any reason 4 Pull lever A and rotate toward header to lower safety prop B onto cylinder Repeat for opposite cylinder Figure 4 162 Safety Prop 5 Remove hairpin from the clevis pin A and remove clevis pin from the left and right header boots B Figure 4 163 Header Boot 169890 164 Revision A ...

Page 179: ...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 B and NOT installed at hole location A Figure 4 165 Header Lift Linkage 8 To disengage safety props and for storage turn lever A away from header to raise safety prop until lever locks into vertical position Repeat for opposite cylinder...

Page 180: ...header Figure 4 167 Mechanical Center Link 14 Disconnect header drive hydraulics A and electrical harness B Refer to the auger header operator s manual 15 Slowly back windrower away from header Figure 4 168 Header Drive Hydraulics 16 Reinstall clevis pin B and secure with hairpin A in header boot C 17 Repeat for the opposite side Figure 4 169 Header Boot 169890 166 Revision A ...

Page 181: ...quipped with D Series hydraulics have four header drive hoses on the LH side Figure 4 170 Draper Header Drive Hydraulics There are also up to five reel drive hoses on the RH side If necessary obtain the following kit from your MacDon Dealer Base Kit MD B5577 Installation instruction MD 169537 is supplied with the kit Figure 4 171 Draper Header Reel Hydraulics 169890 167 Revision A ...

Page 182: ...at hole location A Figure 4 172 Header Lift If NOT installed attach draper header boots supplied with header to windrower lift linkage as follows 1 Remove pin B from boot A Figure 4 173 Header Boot 2 Position boot B on lift linkage A and reinstall pin C Pin may be installed from either side of boot 3 Secure pin C with hairpin D 4 Repeat for opposite side Figure 4 174 Header Boot 4 6 3 Header Posit...

Page 183: ...with switches on the Ground Speed Lever GSL in the cab On D Series draper headers it can be set relative to the ground speed of the windrower using the HEADER INDEX feature or can run independently Refer to the operator s manual for your specific header for windrowing guidelines and recommended speeds Reel to Ground Speed Setting the speed of the reel relative to ground speed using the HEADER INDE...

Page 184: ...RPM or MPH or KPH12 d Press FAST C or SLOW D until desired minimum reel speed is displayed NOTE The reel will continue operating at the Minimum Reel Speed setting when ground speed drops below this value DISPLAY A will flash MIN REEL RPM or MPH or KPH to prompt you to change the minimum set point or increase ground speed if Ground Speed Plus Index is LESS THAN the Minimum Reel Speed Set Point 2 Se...

Page 185: ...peed affects the orientation of stalks in the windrow Faster draper speeds tend to form herringbone or dovetail configurations Refer to your header operator s manual for guidelines on what speed to use The draper speed can be set with switches on the cab display module CDM relative to the ground speed of the windrower with the HEADER INDEX function or can run independently Draper to Ground Speed S...

Page 186: ...APER MINIMUM SPEED as follows 1 Engage header 2 Set HEADER INDEX B switch to ON 3 Press DISPLAY SELECTOR E for DRAPER MIN 4 On cab display module CDM press SLOW D until beep is heard 5 Display A shows DRAPER MIN13 13 DISPLAY will flash MIN CONV MPH or KPH to prompt you to change the minimum set point or increase ground speed if Ground Speed Plus Index is less than the Minimum Draper Speed Set Poin...

Page 187: ...ows IMPORTANT Windrower can be moving but must be GREATER THAN minimum reel speed 1 Engage header 2 Set HEADER INDEX switch B to ON 3 Press DISPLAY SELECTOR E so that DRAPER INDX is displayed at A 4 On cab display module CDM press DRAPER FAST C or SLOW D until desired index is displayed at A Display shows DRAP IND MPH or KPH 1 9 to 3 0 169890 173 Revision A ...

Page 188: ... setting Windrower 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 Setting Draper Speed Independent of Ground Speed Figure 4 180 Operator Console A Display B Header Index C Draper Fast D Draper Slow E Display Selector Set the speed of the draper independently of ground speed as ...

Page 189: ... is equipped with the appropriate sensor and optional module the cab display module CDM will notify you when the knife speed reaches an overload preset usually 75 of knife speed The preset can be changed on the CDM Refer to 3 18 5 Cab Display Module CDM Programming page 70 NOTE The knife speed should be set within the range specified for each header Table 4 1 D Series Knife Speed Header Descriptio...

Page 190: ... B4666 is installed 7 If knife speed is NOT displayed the optional expansion module is not installed proceed to Setting Knife Speed without Expansion Module MD B4666 page 177 8 Compare the reading to Table 4 1 D Series Knife Speed page 175 Figure 4 181 Operator Console 9 If required adjust knife speed as follows 10 Shut down engine and open engine hood 11 Locate the knife drive pump A and knife sp...

Page 191: ...has been made torque jam nut A 15 Close hood start engine and recheck knife speed Figure 4 183 Knife Speed Adjuster Screw Setting Knife Speed without Expansion Module MD B4666 1 Check header knife drive box pulley speed with a handheld tachometer 2 Multiply the rpm reading by 2 to obtain the knife speed in strokes per minute 3 Compare reading to Table 4 1 D Series Knife Speed page 175 4 If require...

Page 192: ...eck Shift CAUTION Check to be sure all bystanders have cleared the area Shift decks as follows 1 Engage header by pushing down on the yellow HEADER DRIVE button A and pulling up on the black ring at the base of the switch Figure 4 185 Header Drive Button 2 Push the rocker switch to desired delivery position Deck s will move and direction of drapers will change accordingly 3 Operate windrower Figur...

Page 193: ...be independently changed from the knife speed by changing the auger drive sprocket Refer to the A30 D and A40 D Pull Type Mower Conditioner and Self Propelled Auger Header Operator s Manual MD 169000 Figure 4 187 A Display B Header Index Switch C Auger Fast D Auger Slow E Display Selector D Auger Slow Display the auger speed as follows 1 Engage header 2 Set HEADER INDEX switch B to OFF 3 On ground...

Page 194: ...tch C Auger Fast D Auger Slow E Display Selector D Auger Slow CAUTION Check to be sure all bystanders have cleared the area Change auger speed as follows 1 Engage header 2 Set HEADER INDEX switch B to OFF 3 On ground speed lever GSL press DISPLAY SELECTOR switch E until AUGER SPEED is displayed Display A shows AUGER SPEED16 4 7 to 9 9 4 Press FAST C or SLOW D on CDM until desired auger speed is di...

Page 195: ...y module CDM and on the ground speed lever 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 Figure 4 189 Operator s Console A Display B Header Index C Auger Fast D Auger Slow E Reel Fast F Reel Slow G Display Selector 1 Engage header 2 Set HEADER INDEX switch B to OFF 3 On ground spee...

Page 196: ... CDM Refer to 3 18 5 Cab Display Module CDM Programming page 70 NOTE The knife speed should be set within the range specified for each header Table 4 2 A Series Knife Speed Header Description Knife Speed Minimum Maximum Type Size rpm17 spm18 rpm17 spm18 Auger A30 D 775 1550 925 1850 Auger A40 D All 700 1400 975 1950 Setting Knife Speed With Expansion Module MD 4666 Installed DANGER Stop engine and...

Page 197: ...nstalled proceed to 8 Compare reading to Table 4 2 A Series Knife Speed page 182 Figure 4 190 Operator Console 9 If required adjust knife speed as follows 10 Shut down engine and open engine hood 11 Locate the knife drive pump A and knife speed adjuster screw B under the right cab forward side of the windrower NOTE The knife speed adjuster screw may have a plastic cap B covering it Pull this cap o...

Page 198: ...een made torque jam nut A 15 Close hood start engine and recheck knife speed Figure 4 192 Knife Speed Adjuster Screw Setting Knife Speed Without Expansion Module MD B4666 1 Check header knife drive box pulley speed with a handheld tachometer 2 Multiply the rpm reading by 2 to obtain the knife speed in strokes per minute 3 Compare reading to Table 4 2 A Series Knife Speed page 182 4 If required adj...

Page 199: ...ce and parts information is available from your MacDon Dealer 5 1 Preparation For Servicing WARNING To avoid personal injury before servicing adapter header or opening drive covers Fully lower the header If necessary to service in the raised position always engage lift safety props Disengage drives Stop engine and remove key Wait for all moving parts to stop 169890 185 Revision A ...

Page 200: ...kings 5 2 1 SAE Bolt Torque Specifications Torque values shown in this table are valid for non greased or non oiled threads and heads Therefore do NOT grease or oil bolts or cap screws unless otherwise specified in this manual Table 5 1 SAE Grade 5 Bolt and Grade 5 Free Spinning Nut Torque ft lbf in lbf Torque N m Nominal Size A Min Max Min Max 1 4 20 106 117 11 9 13 2 5 16 18 218 241 24 6 27 1 3 ...

Page 201: ... 9 306 338 413 456 1 8 459 507 619 684 Figure 5 2 Bolt Grades A Nominal Size B SAE 8 C SAE 5 D SAE 2 Table 5 3 SAE Grade 8 Bolt and Grade 8 Distorted Thread Nut Torque ft lbf in lbf Torque N m Nominal Size A Min Max Min Max 1 4 20 150 165 16 8 18 6 5 16 18 18 19 24 26 3 8 16 31 34 42 46 7 16 14 50 55 67 74 1 2 13 76 84 102 113 9 16 12 109 121 148 163 5 8 11 151 167 204 225 3 4 10 268 296 362 400 7...

Page 202: ...5 1 8 863 954 1165 1288 Figure 5 4 Bolt Grades A Nominal Size B SAE 8 C SAE 5 D SAE 2 5 2 2 Metric Bolt Specifications Table 5 5 Metric Class 8 8 Bolts and Class 9 Free Spinning Nut Torque ft lbf in lbf Torque N m Nominal Size A Min Max Min Max 3 0 5 13 14 1 4 1 6 3 5 0 6 20 22 2 2 2 5 4 0 7 29 32 3 3 3 7 5 0 8 59 66 6 7 7 4 6 1 0 101 112 11 4 12 6 8 1 25 20 23 28 30 10 1 5 40 45 55 60 12 1 75 70 ...

Page 203: ...104 115 16 2 0 119 132 161 178 20 2 5 233 257 314 347 24 3 0 402 444 543 600 Figure 5 6 Bolt Grades Table 5 7 Metric Class 10 9 Bolts and Class 10 Free Spinning Nut Torque ft lbf in lbf Torque N m Nominal Size A Min Max Min Max 3 0 5 18 19 1 8 2 3 5 0 6 27 30 2 8 3 1 4 0 7 41 45 4 2 4 6 5 0 8 82 91 8 4 9 3 6 1 0 140 154 14 3 15 8 8 1 25 28 31 38 42 10 1 5 56 62 75 83 12 1 75 97 108 132 145 14 2 0 ...

Page 204: ...Nominal Size A Min Max Min Max 3 0 5 12 13 1 3 1 5 3 5 0 6 19 21 2 1 2 3 4 0 7 28 31 3 1 3 4 5 0 8 56 62 6 3 7 6 1 0 95 105 10 7 11 8 8 1 25 19 21 26 29 10 1 5 38 42 51 57 12 1 75 66 73 90 99 14 2 0 106 117 143 158 16 2 0 165 182 222 246 20 2 5 322 356 434 480 24 3 0 556 614 750 829 Figure 5 8 Bolt Grades 169890 190 Revision A ...

Page 205: ...and flare seat B for defects that might cause leakage 2 Align tube C with fitting D and thread nut E onto fitting without lubrication until contact has been made between the flared surfaces 3 Torque the fitting nut E to the specified number of flats from finger tight FFFT or to a given torque value shown in the following table 4 To prevent the fitting D from rotating use two wrenches Place one wre...

Page 206: ...t lbf N m Flats Turns 3 3 16 3 8 7 16 6 8 1 1 6 4 1 4 7 16 9 16 9 12 1 1 6 5 5 16 1 2 5 8 12 16 1 1 6 6 3 8 9 16 11 16 18 24 1 1 6 8 1 2 3 4 7 8 34 46 1 1 6 10 5 8 7 8 1 46 62 1 1 6 12 3 4 1 1 16 1 1 4 75 102 3 4 1 8 14 7 8 1 3 8 1 3 8 90 122 3 4 1 8 16 1 1 5 16 1 1 2 105 142 3 4 1 8 19 Torque values shown are based on lubricated connections as in reassembly 169890 192 Revision A ...

Page 207: ...ng B into port until back up washer D and O ring A contacts on part face E 6 Position angle fittings by unscrewing no more than one turn 7 Turn lock nut C down to washer D and tighten to torque shown Use two wrenches one on the fitting B and the other on the lock nut C 8 Check the final condition of the fitting Figure 5 12 Hydraulic Fitting Table 5 11 O Ring Boss ORB Hydraulic Fittings Adjustable ...

Page 208: ...hread Size in ft lbf in lbf N m 6 9 16 18 19 21 26 29 8 3 4 16 34 37 46 50 10 7 8 14 55 60 75 82 12 1 1 16 12 88 97 120 132 14 1 3 8 12 113 124 153 168 16 1 5 16 12 130 142 176 193 20 1 5 8 12 163 179 221 243 24 1 7 8 12 199 220 270 298 169890 194 Revision A ...

Page 209: ...tings Non Adjustable page 195 6 Check the final condition of the fitting Figure 5 13 Hydraulic Fitting Table 5 12 O Ring Boss ORB Hydraulic Fittings Non Adjustable Torque Value21 SAE Dash Size Thread Size in ft lbf in lbf N m 3 3 8 24 106 115 12 13 4 7 16 20 14 15 19 21 5 1 2 20 15 24 21 33 6 9 16 18 19 21 26 29 8 3 4 16 34 37 46 50 10 7 8 14 55 60 75 82 12 1 1 16 12 88 97 120 132 14 1 3 8 12 113 ...

Page 210: ...e assembly so that the flat face of the sleeve A or C comes in full contact with O ring B 4 Thread tube or hose nut D until hand tight The nut should turn freely until it is bottomed out 5 Torque fitting further to the torque value in the table shown in the opposite column NOTE If applicable hold the hex on the fitting body E to prevent rotation of fitting body and hose when tightening the fitting...

Page 211: ...6 11 16 16 29 32 40 44 8 13 16 16 41 45 55 61 10 1 14 59 65 80 88 12 1 3 16 12 85 94 115 127 14 Note23 16 1 7 16 12 111 122 150 165 20 1 11 16 12 151 167 205 226 24 2 12 232 256 315 347 32 2 1 2 12 376 414 510 561 22 Torque values and angles shown are based on lubricated connection as in reassembly 23 O ring face seal type end not defined for this tube size 169890 197 Revision A ...

Page 212: ...cation Fuel Specification Sulphur by weight Water and Sediment by volume Cetane no C Lubricity Grade No 2 ASTM D975 0 5 Maximum 0 05 Maximum 40 Minimum 520 Microns Grade No 1 and 2 mix24 n a 1 Maximum 0 5 Maximum Preferred 0 1 Maximum 45 55 Cold Weather High Altitude 460 Microns In extreme situations when available fuels are of poor quality or problems exist which are peculiar to certain operation...

Page 213: ...0 Compliant With SAE Specs For API Class SJ and CH 4 Engine Oil 12 6 US quarts 11 9 liters 28 Air conditioning refrigerant29 Air conditioning system R134A 5 lbs 2 27 kg Air conditioning refrigerant oil30 Air conditioning system total capacity PAG SP 15 8 1 fl oz 240 cc Receiver drier MD 183273 Air conditioning system PAG SP 15 2 fl oz 60 cc Condenser MD 138983 Air conditioning system PAG SP 15 1 f...

Page 214: ...ality is important to the performance of the cooling system Distilled deionized or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate IMPORTANT Do NOT use cooling system sealing additives or antifreeze that contains sealing additives Do NOT mix ethylene glycol and propylene glycol base coolants Do NOT use coolants that contain ni...

Page 215: ... megapascals MPa Pressure pounds per square inch psi 14 5038 bar non SI bar pound feet or foot pounds ft lbf x 1 3558 newton meters N m Torque pound inches or inch pounds in lbf x 0 1129 newton meters N m Temperature degrees fahrenheit F F 32 x 0 56 Celsius C 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 Velocity miles per hour mph x 1 ...

Page 216: ...Position 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 1 Stop the engine and remove the key 2 Locate latch A behind grill and lift to release hood 3 Raise hood until strap B which should be looped under hooks C and D stops it at approximately a 40 angle 4 Remove strap from hook C and allow hood to ...

Page 217: ...cleaners or the latch 2 Pull down on strap B grasp the hood when within reach and lower until hood engages latch A Figure 5 17 Accessing Engine Compartment 5 4 3 Opening Hood Highest Position 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 1 Stop the engine and remove the key 169890 203 Revision A ...

Page 218: ... and allow hood to raise fully to approximately 65 Figure 5 18 Accessing Engine Compartment 5 4 4 Closing Hood Highest Position 1 Pull down on strap B and loop under lower hook D 2 Grasp the strap and loop under upper hook C IMPORTANT Failure to hook strap may result in it becoming entangled with the screen cleaners or the latch 3 Pull down on strap grasp the hood when within reach and lower until...

Page 219: ...on Major Service Position 5 5 1 Opening Platform Standard Position CAUTION Do NOT stand on the platform in the unlocked position It is unstable and may result in a fall 1 Approach the platform stair unit A on the LH side of the windrower Figure 5 20 Platforms 2 Push latch A and pull platform B toward walking beam until it stops and latch engages in open position Figure 5 21 Platform Latch 169890 2...

Page 220: ...sition It is unstable and may result in a fall This procedure describes how to close the platform A Figure 5 22 Platforms 1 If platform is latched in the open position push latch A to unlock it 2 Grasp handle B on platform and push forward until it stops and latch A engages Figure 5 23 Platform Latch 169890 206 Revision A ...

Page 221: ...ition It is unstable and may result in a fall 1 Open the hood Refer to 5 4 1 Opening Hood Lower Position page 202 IMPORTANT Failure to open hood will result in damage to the hood when the platform is moved 2 Approach the platform stair unit A on the LH side of the windrower Figure 5 24 Platforms 3 Unlock latch A and move platform B toward open position Do NOT lock in full aft position Figure 5 25 ...

Page 222: ...Position CAUTION Do NOT stand on the platform in the unlocked position It is unstable and may result in a fall 1 Swing link A all the way forward 2 Push the front cab forward end of platform towards the frame while moving the platform forward cab forward 3 Position link A on bracket and install bolt and nut Tighten enough so that link can still swivel on bracket Figure 5 27 Platforms 4 Move platfo...

Page 223: ...val Decal 5 6 1 Lubricating the Windrower 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 1 To avoid injecting dirt and grit wipe grease fitting with a clean cloth before greasing 2 Inject grease through fitting with grease gun until grease overflows fitting except where noted Refer to Lubricants Flu...

Page 224: ...locations that require lubrication Figure 5 30 Lubrication Points A Forked Caster Wheel Bearing 2 Places Outer Both Wheels B Forked Formed Caster Wheel Bearing 2 Places C Top Link 2 Places Both Sides Inner Both Wheels 50 Hrs 250 Hrs D Lubrication Decal MD 183411 E Caster Pivot Both Sides 169890 210 Revision A ...

Page 225: ... turn the steering wheel until it locks 2 With everyone clear of the machine engage header drive switch a After header drives are running stand up out of the seat In approximately 5 seconds the header should shut off b If NOT the Operator Presence System requires adjustment See your MacDon Dealer NOTE To restart the header move the HEADER DRIVE switch to OFF position and back to the ON position ag...

Page 226: ...e your MacDon Dealer 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 DETENT The machine should NOT mo...

Page 227: ...Ground Speed Lever GSL Fore Aft Movement The GSL should remain as positioned by the Operator yet be movable without excessive force The spring C is set at the factory to 2 1 2 in 64 mm If necessary adjust as follows 1 Hold nut A from turning and loosen jam nut B 2 To increase the pivot resistance turn the nut A clockwise to compress the spring 3 To decrease the resistance turn the nut A counterclo...

Page 228: ...rt 5 7 4 Steering Adjustments Checking Steering Link Pivots The following checks should be performed annually 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 1 Place ground speed lever GSL A in N DETENT shut down engine and remove key Figure 5 36 Operator Console 169890 214 Revision A ...

Page 229: ... evidence of interference of moving parts with hoses tubes and other linkages Figure 5 37 Windrower Underside 3 Check steering rod bolts A for looseness and ball joints B for any perceptible play or movement Figure 5 38 Steering Rods 169890 215 Revision A ...

Page 230: ...and tighten jam nut A to 60 70 ft lbf 81 95 N m Figure 5 39 Steering Rod Bolts 5 If steering steering rod ball joints A are loose they should be replaced See your MacDon Dealer Figure 5 40 Steering Rod Ball Joints 6 Check steering link bolts A for looseness and ball joint B for any perceptible play or movement Figure 5 41 Steering Link 169890 216 Revision A ...

Page 231: ...e closed before the engine can be started The switch is closed when the Neutral Interlock on the pump is activated by positioning the Ground Speed Lever 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 is energized preventing brake release 1 Check t...

Page 232: ...window and should be serviced daily Figure 5 44 Fresh Air Filter Servicing Fresh Air Intake Filter 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 1 Loosen knob B and slide retainer out to release filter A from rear of cab roof Figure 5 45 Fresh Air filter 169890 218 Revision A ...

Page 233: ...gure 5 46 Cleaning the Fresh Air Filter 5 Inspect filter before installing as follows a Hold a bright light on one side element and check carefully for holes Discard any element which shows the slightest hole b Be sure outer screen is not dented Vibration would quickly wear a hole in the filter c Be sure filter gasket is in good condition If gasket is damaged or missing replace element 6 Reinstall...

Page 234: ...B from the cover A 3 Clean or replace filter If cleaning filter refer to Cleaning Return Air Cleaner page 220 4 Assemble the cleaner B and cover A and position on cab wall over opening Figure 5 48 Return Air Filter 5 Secure filter assembly B to cab wall with knobs A Figure 5 49 Return Air Filter Cleaning Return Air Cleaner Clean the electrostatic filter as follows 169890 220 Revision A ...

Page 235: ... 4 Inspect filter for damage separation and holes Replace if damaged Figure 5 50 Return Air Filter Air Conditioning Condenser The air conditioning condenser should be cleaned daily with compressed air 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 Maintaining Engine Cooling B...

Page 236: ...eating air conditioning unit under the cab It is accessed by removing the cover from the unit Removing Air Conditioning Cover 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 1 Loosen the clamps A on the two drain hoses and pull the hoses off the air conditioning drain tubes Figure 5 51 HVAC System 2 ...

Page 237: ... side A first as shown Direct the air straight into the evaporator to prevent fin damage A nozzle extension would make this procedure easier 3 Repeat the previous step from the side opposite the blowers B 4 If dirt is still present soak evaporator in water to loosen dirt and then blow out with compressed air Figure 5 53 HVAC System Installing Air Conditioning Cover 1 Straighten any bent fins 2 Pos...

Page 238: ...ith an A C charge in the system It is located at the outlet of the evaporator under cab in A C box It will open when the pressure falls to 2 8 psi 14 55 kPa and close when pressure rises above 15 25 psi 103 172 kPa The high pressure switch is normally closed with an A C charge in the system and is located on the receiver drier right hand frame rail behind back of fuse panel It opens if pressure ex...

Page 239: ...MacDon Dealer for all other servicing procedures 5 7 7 Engine CAUTION NEVER operate engine in a closed building Proper ventilation is required to avoid exhaust gas hazards Keep the engine clean Straw and chaff on a hot engine are a fire hazard NEVER use gasoline naphtha or any other volatile material for cleaning purposes These materials are toxic and or flammable General Engine Inspection Engine ...

Page 240: ...he hood to the lowest position refer to 5 4 1 Opening Hood Lower Position page 202 3 Remove positive red cables A C from battery posts first then remove negative black cables B D from both battery posts Figure 5 57 Electrical System 4 Clean area around the plastic cap on access hole A Remove the cap 5 Insert the barring tool B into the flywheel housing until it engages the ring gear 6 Attach a 1 2...

Page 241: ... 4 2 Closing Hood Lower Position page 203 Figure 5 59 Battery Terminal Location Engine Oil Checking Engine Oil Level Check engine oil level frequently and watch for any signs of leakage To check the engine oil level follow these steps NOTE During the break in period a higher than usual oil consumption should be considered normal 1 Open the hood to the lowest position Refer to 5 4 1 Opening Hood Lo...

Page 242: ...Level Changing Engine Oil Refer to the following procedures Checking Engine Oil Level page 227 Draining Engine Oil page 228 Replacing Engine Oil Filter page 229 Adding Engine Oil page 229 Draining Engine Oil 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 NOTE The engine should be warm prior to chang...

Page 243: ...ng Hood Lower Position page 202 2 Clean around the filter head A 3 Remove filter 4 Clean gasket mating surface 5 Apply a thin film of clean oil to the gasket on the new filter Refer to Filter Part Numbers page 200 for recommended oil filter to use 6 Screw the new filter onto the filter mount until the gasket contacts the filter head 7 Tighten the filter an additional 1 2 to 3 4 turn by hand IMPORT...

Page 244: ...awn through a duct A from the cooling box that precleans the air and then through a dual element filter B The air cleaner canister is equipped with an aspirator C that removes dust continuously from the air cleaner housing The air cleaner is also equipped with an air filter restriction switch D that indicates when the primary filter element requires cleaning Refer to Filter Part Numbers page 200 F...

Page 245: ...rely damaging the engine Service air filter ONLY IF indicator A reads 25 inches H2O 6 20 kPa and or indicator B shows red IMPORTANT After servicing filters press button C to reset the gauge and clear the red indicator from window B Figure 5 66 Air Filter Restriction Indicator Removing Primary Air Filter 1 Open the hood refer to 5 4 1 Opening Hood Lower Position page 202 2 Slightly lift catch A at ...

Page 246: ...lace the secondary air filter A every year or after every third primary filter change even if it appears clean If you re changing the secondary air filter because it is dirty inspect the primary filter and the filter canister to determine the reason for contamination Examine the filter canister for cracks and replace if necessary Ensure filter sealing surfaces are soft flexible and sealing properl...

Page 247: ...pattern on the element clean side is a sign that the old element was NOT firmly sealed or that a dust leak exists Press on the fresh gasket to see if it springs back Check the gasket for correct sizing On a radial seal element the gasket surface is the inside diameter of the open end cap Make sure the gasket is seating evenly If the gasket is not forming a perfect seal you will NOT have protection...

Page 248: ...aner 2 Align arrow A to UNLOCK position on end cap and push end cap fully onto housing 3 Rotate end cap clockwise until catch A engages housing to prevent end cap from turning Figure 5 73 Engine Air Cleaner 4 Position end cap B onto filter housing with aspirator pointing approximately down 5 Secure end cap onto filter housing by closing latch A Figure 5 74 Engine Air Cleaner 169890 234 Revision A ...

Page 249: ...tion would quickly wear a hole in the filter 3 Check filter gasket for cracks tears or other signs of damage 4 Check element for oil or soot contamination 5 Check the secondary element for cleanliness If there is visible dirt on the secondary element replace both primary and secondary elements Do NOT clean IMPORTANT The air cleaner s primary outer filter element should be replaced after three clea...

Page 250: ...ing latches are secure NOTE Do NOT remove the secondary filter element unless it needs replacing Do NOT attempt to clean the secondary element A Replace only Figure 5 76 Engine Air Cleaner 1 Remove the primary filter refer to Removing Primary Air Filter page 231 IMPORTANT When replacing secondary filter reinsert new filter as soon as possible to prevent dirt from entering engine intake 2 Remove th...

Page 251: ... 1 Stop the engine and remove the key 2 Open the hood Refer to 5 4 3 Opening Hood Highest Position page 203 3 Open the left cab forward side maintenance platform Refer to 5 5 1 Opening Platform Standard Position page 205 4 Locate filter A on vent line against hydraulic oil reservoir 5 Release hose tension clamps B and slide away from filter Pull hoses off filter 6 Position new filter through hole ...

Page 252: ...l System Filters Refer to the following procedures Removing Primary Fuel Filter page 238 Installing Primary Fuel Filter page 239 Removing Secondary Fuel Filter page 240 Installing Secondary Fuel Filter page 240 Removing Primary Fuel Filter 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 1 Stop the en...

Page 253: ... of the primary filter Figure 5 81 Fuel Filter Locations 5 Clean around the primary filter A head 6 Disconnect the water in fuel WIF sensor B from bottom of filter 7 Turn drain valve C by hand counterclockwise until draining occurs and drain filter into a container 8 Remove filter A with a filter wrench 9 Clean gasket mating surface Figure 5 82 Fuel System Installing Primary Fuel Filter IMPORTANT ...

Page 254: ... and filter Figure 5 83 Fuel System Removing Secondary Fuel Filter 1 Stop the engine and remove the key 2 Open the hood refer to 5 4 3 Opening Hood Highest Position page 203 3 Clean around the secondary filter head A 4 Place a container under the filter to catch spilled fluid 5 Remove filter B with a filter wrench 6 Clean gasket mating surface Figure 5 84 Fuel System Installing Secondary Fuel Filt...

Page 255: ...tem page 244 Figure 5 86 Bottom of Fuel Tank Draining Fuel Tank Draining the fuel tank is necessary to remove old or contaminated fuel 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 DANGER Stop engine and remove key from ignition before leaving operator...

Page 256: ...e 5 87 Bottom of Fuel Tank 4 Place a 5 U S gallon 20 liter drain pan under the fuel supply hose A at primary filter 5 Loosen clamp B and pull fuel supply hose A off fitting Figure 5 88 Fuel System 6 Route hose to drain pan and open valve A to drain tank Figure 5 89 Fuel System 169890 242 Revision A ...

Page 257: ...g procedure to remove water from the fuel system Removing Water from Fuel System page 243 Removing Water from Fuel System Drain the water and sediment as follows from the separator daily or at any time the cab display module CDM water in fuel WIF light illuminates 1 Stop the engine and remove the key 2 Open the hood refer to 5 4 1 Opening Hood Lower Position page 202 3 Place a container under the ...

Page 258: ... 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 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 1 Stop the engine and remove the key 2 Open the hood to lowest position Refer to 5 4 1 Openin...

Page 259: ... kPa pressure in the cooling system CAUTION To avoid personal injury from hot coolant do NOT turn radiator cap until engine cools 1 Open the hood Refer to 5 4 3 Opening Hood Highest Position page 203 2 Open the platform Refer to 5 5 1 Opening Platform Standard Position page 205 3 Turn the cap A counterclockwise to the first notch to relieve pressure before removing cap completely 4 Turn the cap A ...

Page 260: ...on page 206 8 Close the hood Refer to 5 4 4 Closing Hood Highest Position page 204 Figure 5 94 Engine Cooling System Checking Coolant Level 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 Check coolant level in the coolant recovery tank daily 1 Stop the engine and remove the key 2 Open the hood Refer...

Page 261: ...s seat for any reason A child or even a pet could engage an idling machine CAUTION To avoid personal injury from hot coolant do NOT turn radiator cap until engine cools 1 Stop the engine remove the key Let the engine cool 2 Open the hood Refer to 5 4 3 Opening Hood Highest Position page 203 3 Open the platform Refer to 5 5 1 Opening Platform Standard Position page 205 4 Turn the radiator cap A to ...

Page 262: ...olant running onto frame Figure 5 97 Engine Cooling System 6 Close the heater shut off valve and disconnect hose on heater side of valve 7 Open valve to drain the block 8 When system is drained reattach hose on valve Figure 5 98 Engine Cooling System 9 Close radiator drain valve A at the bottom of the engine side of the radiator lower tank 10 Fill system with clean water through the radiator and r...

Page 263: ...ill system Refer to Adding Coolant page 249 17 Close the platform Refer to 5 5 2 Closing Platform Standard Position page 206 18 Close the hood Refer to 5 4 4 Closing Hood Highest Position page 204 Figure 5 100 Engine Cooling System Adding Coolant Check the coolant level in the coolant recovery tank A daily the tank should be at least one half full If less add coolant CAUTION To avoid personal inju...

Page 264: ...01 Engine Cooling System Maintaining Engine Cooling Box Refer to the following procedures Opening Cooler Box Screen page 250 Cleaning Screens and Coolers page 251 Cleaning Cooler Box Components page 252 Adjusting Screen Cleaner Duct to Screen Clearance page 254 Closing Cooler Box Screen page 255 Opening Cooler Box Screen 1 Open the hood Refer to 5 4 3 Opening Hood Highest Position page 203 2 Push ...

Page 265: ...eaned by the rotors they may be plugged If rotors are plugged clean as follows 1 Open the hood Refer to 5 4 3 Opening Hood Highest Position page 203 2 Remove nuts B 3 Pivot screen cleaner assembly C away from screen 4 Blow out debris from ducts A with compressed air 5 If ducts are plugged open the cooler box screen Refer to Opening Cooler Box Screen page 250 Figure 5 103 Engine Cooling System 6 Bl...

Page 266: ...leaning Cooler Box Components The radiator and oil cooler should be cleaned daily with compressed air More frequent cleaning may be necessary in severe conditions The charge air cooler and air conditioning condenser may also be cleaned at the same time To clean these components proceed as follows 1 Open cooler box screen Refer to Opening Cooler Box Screen page 250 2 Lift latch A and open the right...

Page 267: ...em 4 Lift latch A and open the left hand access door B Figure 5 108 Engine Cooling System 5 Loosen wing nut A and open access door B at top of cooling box NOTE Fins on coolers can be very easily bent which may interfere with its function Exercise caution when cleaning Figure 5 109 Engine Cooling System 169890 253 Revision A ...

Page 268: ...ct to Screen Clearance Check clearance between trailing edge of screen cleaner duct A and screen It should be 3 64 5 16 in 1 8 mm at all locations when rotating NOTE Screen cleaner ducts rotate counterclockwise and may touch screen as long as it continues to rotate If necessary adjust clearance as follows 1 Open the hood Refer to 5 4 1 Opening Hood Lower Position page 202 2 Loosen nut B on motor s...

Page 269: ...203 2 Inspect the area around clamps A for breakage cracks and rust through In addition to excess noise a leaky exhaust system may allow exhaust gases to escape to the cab 3 Check tubing for dents or crushed areas 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 increas...

Page 270: ...ngine to release tension 5 Remove belt A from compressor Figure 5 114 A C Compressor 6 Insert the drive end of a 1 2 in drive ratchet wrench into the belt tensioner B 7 Rotate tensioner counterclockwise until fan belt C can be slipped off pulley D Release tensioner and remove wrench 8 Remove belt in order 1 2 3 as shown Route fan belt around fan and remove belt 9 Install new belt C around fan and ...

Page 271: ...t could engage an idling machine 1 Shut down the engine and remove the key 2 Open the hood Refer to 5 4 1 Opening Hood Lower Position page 202 3 Loosen compressor mounting hardware B 4 Pry compressor away from engine so that a force of 8 12 ft lbf 35 55 N m deflects the belt A 3 16 in 5 mm at mid span 5 Tighten compressor mounting hardware B 6 Recheck tension and readjust as required 7 Close the h...

Page 272: ...ine speeds are factory set Refer to 2 2 Specifications page 29 for detailed information If specified speeds cannot be maintained see your MacDon Dealer Refer to Engine Intermediate Speed Control ISC page 91 for information about engine speed Throttle Adjustment The engine speed is controlled with the throttle lever that is connected to an electronic sensor inside the console The throttle lever in ...

Page 273: ...RVICING 5 7 8 Electrical System Batteries The M105 is equipped with two batteries that are located under the engine compartment hood at the left side of the engine compartment Figure 5 119 Batteries 169890 259 Revision A ...

Page 274: ...g a charger to charge battery in windrower Ensure all cables are securely connected before operating engine Figure 5 120 Alternator A Negative Terminal B Positive Terminal Maintaining Batteries CAUTION Do NOT attempt to service battery unless you have the proper equipment and experience to perform the job Have it done by a qualified Dealer Check battery charge once a year and more often if operati...

Page 275: ...sconnect switch is located on the battery tray Ensure switch is switched to POWER OFF position when performing major servicing to electrical components or for periods of non use to prevent inadvertent loss of battery charge Figure 5 121 Electrical System 169890 261 Revision A ...

Page 276: ...a two hour period results in no increase in voltage or decrease in current Figure 5 122 Charging Battery WARNING Gel and AGM Absorbed Glass Mat batteries require a voltage limited charger Charging a Gel or AGM battery on a typical shop charger even one time may greatly shorten its life If the electrolyte is accessible verify that plates are covered before beginning to charge At the end of charge a...

Page 277: ...ER 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 1 Stop the engine and remove the key 2 Move platform on left cab forward side of machine to open position Refer to 5 5 1 Opening Platform Standard Position page 205 3 Open hood to highest position to allow access to the batteries Refer to 5 4 3 Opening Hood...

Page 278: ...o the lowest position Refer to 5 4 1 Opening Hood Lower Position page 202 2 Remove red rubber cover A from windrower battery positive terminal Figure 5 124 Battery Boost Terminal 3 Attach one end of battery cable to positive terminal A of booster battery and other end to positive terminal B of windrower batteries 4 Attach second cable to negative terminal C of booster battery and then to a good gr...

Page 279: ...d this occur force the eye open and flood with cool clean water for five minutes Call a Doctor immediately Figure 5 127 Battery Safety 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 1 If battery is installed in windrower stop the engine and remove the key 2 Open the platform Refer to 5 5 1 Opening P...

Page 280: ...g machine 1 Open the hood refer to 5 4 3 Opening Hood Highest Position page 203 2 Open the platform refer to 5 5 1 Opening Platform Standard Position page 205 3 Remove the red plastic cover from positive cable clamps A C Loosen the clamps and remove cable from batteries 4 Loosen clamps B D on negative terminals and remove cable from batteries Figure 5 129 Electrical System 5 Remove the bolt A that...

Page 281: ...ation Rating Group CCA Volt Qty Maximum Dimension Heavy duty off road vibration resistant BCI 29H or 31A 650 12 2 13 in x 7 4 in x 9 13 in 334 x 188 x 232 mm 1 Position new batteries A on battery support Figure 5 132 Electrical System 2 Install battery angle B and secure it with bolt A Figure 5 133 Electrical System 169890 267 Revision A ...

Page 282: ... 4 4 Closing Hood Highest Position page 204 Figure 5 134 Electrical System Connecting Batteries 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 1 Stop the engine and remove the key 2 The battery main disconnect switch A is located on the right hand frame rail beside the batteries Ensure battery switc...

Page 283: ... position Figure 5 136 Batteries Field Lights Adjusting Field Lights The field lights are best adjusted with the machine in the field or equivalent to suit Operator preference 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 1 Hold onto handholds A on the cab front corners and stand on header anti sli...

Page 284: ...Lights Flood Lights Forward Adjusting Forward Flood Lights The forward flood lights are NOT adjustable Replacing Bulb in Cab Forward Flood Light 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 Replace bulbs as follows 1 Shut down engine and remove key Turn lights OFF 169890 270 Revision A ...

Page 285: ...move light bezel C 4 Remove light from receptacle Figure 5 140 Forward Flood Lights 5 Pinch the wire retainer A and lift away from hooks 6 Remove bulb B from body and pull wire from connector C 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 Figure 5 141 Flood Light Assembly 169890 271 Revision A ...

Page 286: ...ure 5 143 Forward Flood Light HID Auxiliary Lighting Optional MD B5596 Two optional High Intensity Discharge HID lights provide additional lighting during field operation Adjusting HID Auxiliary Lights if Installed If installed HID auxiliary lights are best adjusted with the machine in the field or equivalent to suit Operator preference DANGER Stop engine and remove key from ignition before leavin...

Page 287: ...op 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 1 Shut down engine and remove key Turn lights OFF NOTE Hold onto the handholds on the cab front corners and stand on the header anti slip strips or stand on the maintenance platform when accessing the HID auxiliary lights 2 Disconnect lamp connector A from elect...

Page 288: ...nstalling lamp only position new lamp B in lamp bracket C and secure with bolt A spring washer and nut Adjust lamp B to desired position and tighten bolt A Figure 5 147 HID Auxiliary Lights 7 If installing light bracket assembly locate light in center hole in light support B and secure with hardware C provided with light assembly Adjust light assembly to desired position and tighten nut C 8 Route ...

Page 289: ...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 adjustable Replace bulbs as follows 1 Shutdown the engine and remove the key 2 Remove the two screws A and remove light bezel B 3 Remove light from receptacle Figure 5 150 Swath Lights 169890 275 Revision A ...

Page 290: ...in optical unit and insert bulb into unit 7 Secure bulb with wire retainer A 8 Push wire into connector C IMPORTANT For proper lighting pattern be sure lights are installed right side up Figure 5 151 Lamp Assembly 9 Position light into light receptacle ensuring top is up and secure with bezel B and screws A Figure 5 152 Swath Lights Amber Lights DANGER Stop engine and remove key from ignition befo...

Page 291: ...il 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 1 Shut down engine and remove key Turn lights OFF 2 In the grill of the hood remove two screws A from light B and remove light 3 Remove connector from light 4 Connect wiring harness to new light B and install light with screws A Figure 5 154 R...

Page 292: ...header anti slip strips or stand on the maintenance platform when accessing the beacons A Figure 5 155 Warning Beacons 2 Turn lens A counterclockwise to unlock lens from base and remove lens Figure 5 156 Warning Beacons 3 Pinch retainer A and remove it from lamp socket 4 Pull lamp out of socket Figure 5 157 Beacon Lamp Assembly 169890 278 Revision A ...

Page 293: ...e halogen bulb as the oils or other chemicals from your skin will cause the bulb to fail prematurely Figure 5 158 Beacon Lamp Assembly 6 Connect harness to new lamp place lamp in socket and line up the flat side on lamp with recess in socket Figure 5 159 Beacon Lamp Assembly 169890 279 Revision A ...

Page 294: ... lamp and pinch tabs to secure retainer to socket Figure 5 160 Beacon Lamp Assembly 8 Line up the three lugs one is longer in the base with slots in lens and seat the lens against the rubber seal Figure 5 161 Beacon Lamp Assembly 169890 280 Revision A ...

Page 295: ...ht follow these steps 1 Shut down engine 2 Remove two screws A from the dome light assembly and remove the assembly 3 Disconnect the old dome light assembly from the wiring harness 4 Connect the new dome light MD 183413 to the wiring harness 5 Install the new dome light with two screws A Figure 5 163 Cabin Dome Light 169890 281 Revision A ...

Page 296: ...n place Figure 5 165 Ambient Light Fixture Turn Signal Indicators If the turn signal indicators on the cab display module CDM do NOT function contact your MacDon Dealer Circuit Breakers and Fuses The circuit breakers and fuses are located inside a fuse box mounted on the right cab forward side of the frame The circuit breakers automatically reset Fuses are the plastic blade type DANGER Stop engine...

Page 297: ...ses 1 To check fuse pull fuse A out of receptacle and visually examine 2 To replace fuse insert new fuse into receptacle IMPORTANT Replacement fuses should match rating on decal shown on following page Figure 5 167 Fuses Replacing Circuit Breakers and Relays 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 298: ...it breaker A pull breaker out of receptacle and install new circuit breaker 3 To replace relay B pull relay out of receptacle and install new relay 4 Reinstall cover and secure with wing nut Figure 5 168 Breakers and Relays 169890 284 Revision A ...

Page 299: ...MAINTENANCE AND SERVICING Fuse Box Decal Figure 5 169 Fuse Decal 169890 285 Revision A ...

Page 300: ...for any reason A child or even a pet could engage an idling machine 1 Stop engine and remove key 2 To check condition of fuse A pull tab A and open cover B Figure 5 170 125A Main Fuses 3 Visually examine fuse B for indications of melting 4 Remove fuse B remove two nuts C and pull fuse free from holder existing wiring may need to be pulled off the stud first 5 Install new fuse on studs and any exis...

Page 301: ...ive system the header lift and drive systems 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 eject fluids under high pressure Figure 5 173 Hydraulic Pressure Hazard 169890 287 Revision A ...

Page 302: ...air The hydraulic system components 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 filters and to adjust relief pressures as described in this manual See your MacDon Dealer for all other service Checking and Filling Hydraulic Oil Follow these steps to check and fill the hydraulic...

Page 303: ...o reach the FULL mark IMPORTANT Use good quality prefiltered oil Exercise care to prevent debris from falling into tank 5 Reinstall dipstick and filler cap and turn clockwise to tighten lock 6 Close the hood Refer to 5 4 2 Closing Hood Lower Position page 203 Figure 5 176 Checking Hydraulic Oil Hydraulic Oil Cooler The hydraulic oil cooler is located inside the cooling box behind the radiator It s...

Page 304: ... plug A and allow oil to drain 6 Clean off any metal debris that may have accumulated on magnetic plug Wipe plug with a clean cloth Check O ring condition Look for cracking breakage or deformation that may impede sealing ability and replace as required 7 Install drain plug A 8 Fill hydraulic oil reservoir Refer to Checking and Filling Hydraulic Oil page 288 Figure 5 177 Hydraulic Oil Drain Plug Ch...

Page 305: ...any oil that may leak out 4 Unscrew filter A with a filter wrench 5 Dispose of used oil and filter in accordance with local environmental legislation Figure 5 179 Hydraulic System Installing Charge Filter NOTE For charge filter replacement part number refer to Filter Part Numbers page 200 1 Clean the gasket surface of the filter head 2 Apply a thin film of clean oil to the filter gasket 3 Screw th...

Page 306: ...e and remove key from ignition before leaving operator s seat for any reason A child or even a pet could engage an idling machine 1 Stop the engine and remove the key 2 Locate the return filter A inside the left frame It is accessible from under the windrower 3 Clean around head of the filter A 4 Place a container beneath the filter A to collect any oil that may leak out 5 Unscrew filter A with a ...

Page 307: ...y a thin film of clean oil to the filter gasket C 3 Install new gasket into the groove B in the filter head A 4 Screw the new filter D onto the filter head until the gasket contacts the filter Figure 5 183 Hydraulic System 5 Tighten filter an additional 3 4 turn by hand IMPORTANT Do NOT use a filter wrench to install oil filter Overtightening can damage gasket and filter 6 Check hydraulic fluid le...

Page 308: ...e flow to the knife drive is mechanically set on the pump itself Adjusting oil flow changes knife speed To set the knife speed refer to the knife speed section for your header type D Series header 4 6 8 Knife Speed page 175 A Series header 4 7 3 Knife Speed page 182 Knife speed varies depending on the header size header type and whether the header has a single knife or double knife Knife speed is ...

Page 309: ...drop rate and readjust as required 6 Tighten setscrew B NOTE To reset to factory specifications fully close the needle valve and open it four turns counterclockwise 7 Close the platform Refer to 5 5 2 Closing Platform Standard Position page 206 Figure 5 187 Hydraulic Valve Block Adjusting Reel Drop Rate The reel should lower gradually when the lower reel switch is pressed From fully raised to full...

Page 310: ...ps are driven through a gearbox from the engine Each pump requires charge flow in order to Make up for internal leakage Maintain positive pressure in the main circuit Provide flow for cooling Replace any leakage losses from external valving or auxiliary systems The charge pressure is monitored The cab display module CDM sounds a tone and displays a flashing warning if charge pressure drops below 2...

Page 311: ...d fully Refer to 5 4 3 Opening Hood Highest Position page 203 2 Attach a 0 600 psi 4000 kPa pressure gauge to a hose that is long enough to allow pressure gauge to be read from the operator s seat 3 Locate the test port A which is located on the charge filter head Clean test port fitting and attach hose to the fitting 4 Start engine and leave at idle Pressure should be 200 to 250 psi 1379 to 1724 ...

Page 312: ...cardboard or paper to search for leaks Figure 5 190 Hydraulic Pressure Hazard IMPORTANT Keep hydraulic coupler tips and connectors clean Dust dirt water and foreign material are the major causes of hydraulic system damage DO NOT attempt to service hydraulic system in the field Precision fits require WHITE ROOM CARE during overhaul 5 7 10 Wheels and Tires Drive Wheel Inflating Drive Wheel Tire DANG...

Page 313: ...ired Under inflation of drive tires can cause side wall cracks Measure tire pressure annually with a gauge Maintain tire pressure as follows 1 Shut down the engine and remove key 2 Determine the type and size of tire that is installed on your machine 3 Refer to the following table to determine the appropriate tire pressure Table 5 19 Drive Wheel Tire Options Drive Wheel Tire Options 18 4 26 Bar 60...

Page 314: ...Lubricant page 302 Checking Wheel Drive Lubricant Level Check the wheel drive lubricant level every 200 hours or annually 1 Park the windrower on level ground 2 Position windrower so that plugs A and B are horizontally aligned with the center C of the hub 3 Remove plug A or B The lubricant should be visible through the port or running out slightly If lubricant needs to be added Refer to Adding Whe...

Page 315: ...ould be visible through the hole or slightly running out 4 If lubricant needs to be added remove the second plug B and add lubricant until lubricant runs out at A NOTE PRIOR TO FIRST CHANGE use SAE 85W140 API Service Class GL 5 Extreme Pressure Gear Lubricant NOTE AFTER FIRST CHANGE use SAE 75W90 API Service Class GL 5 Fully Synthetic Transmission Lubricant SAE J2360 preferred 5 Reinstall and tigh...

Page 316: ... point 2 Shut down the windrower and remove key from ignition 3 Place a large enough container about 2 quarts 2 liters under the lower drain plug B 4 Remove top plug A and drain lubricant Ideally the lubricant should be at operating temperature for good draining CAUTION Dispose oil in a manner that is in compliance with the local rules and regulations Figure 5 195 Wheel Drive 5 When lubricant has ...

Page 317: ...l ground and block all wheels 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 3 Place ground speed lever GSL A in N DETENT B shut down engine and remove key Figure 5 197 Ground Speed Lever CAUTION Jack stand must be capable of supporting a minimum of 5000 lb 2268 kg 4 Place a jack under the leg jack ...

Page 318: ...oints forward For Turf tires diamond tread be sure arrow on sidewall points in forward rotation 2 Lift wheel on hub with lifting device 3 Lower lifting device Figure 5 200 Drive Wheel Assembly 4 Line up the holes in the rim with the studs on the wheel drive hub and install wheel nuts A NOTE To avoid damage to wheel rims and studs tighten nuts by hand do NOT use an impact gun do NOT use lubricant o...

Page 319: ... Make sure all the air is removed from a tire before removing the tire from the rim Figure 5 203 Safely Filling a Tire with Air DANGER 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 T...

Page 320: ...mmy dampener kit is available for rear caster wheels Refer to 7 1 2 Anti Shimmy Shocks for Casters page 337 for information Table 5 20 Caster Tire Options Formed Caster Forked Caster 7 5 16SL Single Rib 10 16 Front Steer Tire 16 5L 16 1 Rib Implement Flotation 10 16 Front Steer Tire 10 psi 69 kPa 10 psi 69 kPa Tightening Caster Wheel Nuts At first use or when a wheel is removed check caster wheel ...

Page 321: ...own at right Repeat the tightening sequence three times Figure 5 204 Forked Caster Wheel Tightening Sequence Figure 5 205 Formed Caster Wheel Tightening Sequence Servicing Caster Wheels Refer to the following procedures Raising Caster Wheel Formed and Forked page 308 Lowering Caster Wheel Formed and Forked page 309 Removing Forked Caster Wheel page 309 Installing Forked Caster Wheel page 310 Remov...

Page 322: ...k windrower on level ground and block the drive wheels 2 Place the ground speed lever GSL A in N DETENT B stop the engine and remove the key Figure 5 206 GSL Position 3 Raise end of walking beam A using a suitable lifting device capable of lifting 5000 lb 2268 kg minimum until the caster wheel assembly B is slightly off the ground 4 Place a jack stand beneath the walking beam and lower the beam un...

Page 323: ...m the drive tires Figure 5 208 Caster Wheel Assembly Removing Forked Caster Wheel CAUTION Wheel assemblies are heavy Support wheel assembly before removing axle bolts 1 Raise caster wheel Refer to Raising Caster Wheel Formed and Forked page 308 2 Remove the eight bolts A four on each side of caster attaching axle B and cover C to forked caster E and remove wheel assembly D from caster E Figure 5 2...

Page 324: ...cover plates C and install eight bolts A four on each side of caster to secure axle B to caster E Torque bolts to 75 79 ft lbf 97 107 N m 5 Lower caster wheel Refer to Lowering Caster Wheel Formed and Forked page 309 Figure 5 212 Caster Wheel Assembly Removing Formed Caster Wheel 1 Raise caster wheel Refer to Raising Caster Wheel Formed and Forked page 308 2 Remove the six bolts A that secure the ...

Page 325: ... page 309 Figure 5 214 Caster Wheel Assembly Caster Wheels Anti Shimmy Shocks MD B5346 if installed Each caster can be equipped with a fluid filled anti shimmy dampener A If installed the mounting bolts B need to be checked periodically for security Refer to 5 7 11 Maintenance Schedule page 313 Inboard bolt should be tightened to 100 ft lbf 135 N m Outboard bolt should be tightened to 85 ft lbf 11...

Page 326: ...0 X 16 18 69 380 170 16 5 X 16 1 41 158 830 377 Table 5 22 Recommended Ballast Weight Recommended Ballast Header Description Level Ground Hills Per Tire Both Tires Per Tire Both Tires Type Size US Gallons Liters lb kg 35 US Gallons Liters lb kg 35 Recommended Tire Size A and D Series All Options 25 ft and Down 0 0 0 0 30 ft Single or Double Reel without Conditioner 35 ft Single Reel 0 0 10 38 200 ...

Page 327: ...ds etc CAUTION Carefully follow safety messages given in 1 Safety page 1 Break In Inspections Break In Inspections Hours Item Check 1 Hour Drive wheel nuts Torque 375 lbf ft 510 N m dry Repeat checks at one hour intervals until torque stabilizes at two consecutive checks A C compressor belt Tension Caster wheel nuts Torque 120 ft lbf 163 N m Caster wheel anti shimmy dampener bolts Inboard bolt tor...

Page 328: ...he header 5 Repaint all worn or chipped painted surfaces to prevent rust 6 Loosen drive belts 7 Lubricate the header thoroughly leaving excess grease on fittings to keep moisture out of bearings Apply grease to exposed threads cylinder rods and sliding surfaces of components Oil cutterbar components to prevent rust 8 Check for worn components and repair as necessary 9 Check for broken components a...

Page 329: ...r37 Charge Air Cooler37 Engine Oil Level37 Engine Coolant Level37 Fuel Tank37 Fuel Filter Water Trap37 Hydraulic Hoses and Lines37 Hydraulic Oil Cooler37 Hydraulic Oil Level37 Radiator37 Tire Inflation37 ANNUALLY38 A C Blower Antifreeze Concentration Battery Charge Battery Fluid Level Fuel Tank Vent Line Filter Steering Linkages END OF SEASON SERVICE Refer to End of Season Service page 314 50 HOUR...

Page 330: ... and Filter Engine Air Cleaner Primary Filter Element Formed Caster Wheel Hub Bearings Drive Wheel Lubricant 500 HOURS OR ONCE A YEAR36 38 Engine Oil and Filter Hydraulic Oil Filters Fuel Filters Safety Systems 1000 HOURS Drive Wheel Lubricant 1500 HOURS OR EVERY TWO YEARS36 Hydraulic Oil 2000 HOURS OR EVERY TWO YEARS36 Engine Coolant General Inspection 5000 HOURS OR EVERY TWO YEARS36 Engine Valve...

Page 331: ...pe of fuel Use proper fuel for operating conditions Fuel Specifications page 198 Crankcase oil too heavy Use recommended oil Lubricants Fluids and System Capacities page 199 Low battery output Have battery tested Check battery electrolyte level Poor battery connection Clean and tighten loose connections Batteries page 259 Faulty starter Contact Dealer Contact Dealer Loose electrical connection at ...

Page 332: ...t Dealer Contact Dealer Crankcase oil too light Use recommended oil Lubricants Fluids and System Capacities page 199 High oil consumption Oil leaks Check for leaks around gaskets seals and drain plugs Checking Engine Oil Level page 227 Unsteady fuel supply Change filter on fuel tank vent line Replace clogged fuel filter Removing and Installing Fuel Tank Vent Filter page 237 and Fuel System page 23...

Page 333: ... replace muffler Exhaust System page 255 Improper type of fuel Use proper fuel Fuel Specifications page 198 High or low engine temperature Remove and check thermostat Improper valve clearance Lack of power Faulty injectors Contact Dealer Engine temperature below normal Defective thermostat Remove and check thermostat Contact Dealer Check coolant level Checking Coolant Level page 246 Engine overhea...

Page 334: ...c motor Maintaining Engine Cooling Box page 250 Dirty radiator core Clean radiator Cooling system dirty Flush cooling system Engine Cooling System page 245 Defective thermostat Remove and check thermostat Defective temperature gauge or sender Check coolant temperature with thermometer Replace gauge if necessary Engine overheats Defective water pump Contact Dealer Contact Dealer Clogged or dirty ai...

Page 335: ...ble damage that might create back pressure Exhaust System page 255 Dirty or faulty injectors Engine out of time Engine emits black or grey exhaust Air in fuel system Contact Dealer Contact Dealer Engine out of time Contact Dealer Contact Dealer Improper type of fuel Consult your fuel supplier and use proper type fuel for conditions Fuel Specifications page 198 Cool engine Warm engine up to normal ...

Page 336: ...page 124 Relay not functioning Check relay and wire connections Main fuse defective blown Replace main fuse Key power fuse blown Replace 5 7 8 Electrical System page 259 Key switch worn or terminals loose Contact Dealer Switch at Interlock not closed or defective Adjust switch or replace Contact your Dealer Contact Dealer Starter cranks slowly or will not operate Crankcase oil too high viscosity U...

Page 337: ... Contact Dealer Lights dim High resistance in circuit or poor ground on lights Check the wiring circuit for a break in a wire or a poor ground Replacing Field Light Bulb page 270 Replacing Bulb in Cab Forward Flood Light page 270 Swath Lights page 275 Amber Lights page 276 Beacons if installed page 277 Burned out or defective light bulb Replace light bulb Replacing HID Lamp if Installed page 273 B...

Page 338: ...Reversed wires Contact Dealer Contact Dealer Broken or disconnected wire Contact Dealer Contact Dealer Circuit breaker tripped Breaker automatically resets No current to cab Battery disconnect switch is OFF Turn battery disconnect switch ON Battery Main Disconnect Switch page 261 169890 324 Revision A ...

Page 339: ...on CDM to increase flow D Series 4 6 7 Draper Speed page 171 and 4 6 6 Reel Speed page 169 A Series 4 7 1 Auger Speed page 179 Reel and or conveyor not turning Appropriate solenoid on flow control block not being energized Contact Dealer Reel and or conveyor turns but lacks power Relief pressure too low Check adjust clean relief valve Contact Dealer Hydraulic oil cooling system not working properl...

Page 340: ...ot closed or faulty Occupy operator s seat or replace switch Contact your Dealer Header drive not engaging Appropriate solenoid not being energized by activating switch Relief valve setting too low Contact Dealer Contact Dealer Header drive lacks power Header drive overload Reduce ground speed Driving Forward page 97 Warning alarm sounds Relief valve setting too low Contact Dealer Contact Dealer 1...

Page 341: ... page 97 Loose or worn controls Check controls 5 7 3 Ground Speed Lever GSL Adjustments page 212 Use proper oil Lubricants Fluids and System Capacities page 199 Check oil level and leaks Checking and Filling Hydraulic Oil page 288 Air in system Check hydraulic oil filters 5 7 9 Hydraulic System page 287 Brakes binding or not releasing fully Check pressure on brake release valve min 200 psi 1379 kP...

Page 342: ...ulic lines preventing proper oil flow Replace damaged lines Ground speed range control not working Contact Dealer Contact Dealer Steering controls worn or defective Check GSL and steering for loose worn or damaged ball joints and connecting rods 5 7 3 Ground Speed Lever GSL Adjustments page 212 and 5 7 4 Steering Adjustments page 214 Charge pressure relief valve misadjusted or damaged Check the va...

Page 343: ...venting proper oil flow Ground speed range control not working One wheel does not pull in forward or reverse Failed pump motor or power hub Contact Dealer Contact Dealer Mechanical interference in steering or ground speed linkage Adjust repair replace 5 7 3 Ground Speed Lever GSL Adjustments page 212 and 5 7 4 Steering Adjustments page 214 Brakes binding or not releasing fully Check pressure on br...

Page 344: ...ing brake not functioning Machine moves on flat ground with controls in NEUTRAL GSL cable misadjusted Steering wheel will not lock with GSL in N DETENT Transmission interlock misadjusted Steering wheel will not unlock Transmission interlock cylinder not working Contact Dealer Contact Dealer Insufficient road speed Ground speed range control in Mode 1 Field 0 11mph 17 7 km h Move ground speed range...

Page 345: ...Clean evaporator Cleaning Air Conditioning Evaporator Core page 223 Blower fan operating but no air coming into cab Air flow passage blocked Remove blockage Heater shut off valve at engine closed Open valve 3 10 1 Heater Shut Off page 47 Defective thermostat in engine water outlet manifold Replace thermostat Heater temperature control defective Replace control Heater not heating No thermostat in e...

Page 346: ...to specifications Tensioning Air Conditioner A C Compressor Belt page 257 and Replacing Air Conditioner A C Compressor Belt page 257 Dirty filters Plugged filters Clean fresh air and recirculation filters Cleaning Engine Air Filter Primary Element page 235 and Cleaning Return Air Cleaner page 220 Broken or disconnected electrical wire Check all terminals for loose connections check wiring for hidd...

Page 347: ...Refrigerant low Clogged expansion valve Clogged receiver drier Excessive moisture in system Air in system Air conditioning not producing sufficient cooling sufficient cooling defined as when air temperature in cab measured at louvered vent can be maintained at 25 f 14 c below ambient air temperature Blower motor sluggish in operation Contact Dealer Contact Dealer Windows fog up High humidity Run A...

Page 348: ...ir Conditioner A C Compressor Belt page 257 or Replacing Air Conditioner A C Compressor Belt page 257 Noisy clutch Remove clutch for service or replacement as required Noisy compressor Check mountings and repair Remove compressor for service or replacement Compressor oil level low Add SP 15 PAG refrigerant oil Air conditioning system too noisy Blower fan noisy due to excessive wear Remove blower m...

Page 349: ... Section Seat suspension not adjusted for operator s weight Adjust seat suspension 3 3 Operator s Seat Adjustments page 37 Rough ride High air pressure in tires Deflate to proper pressure Inflating Drive Wheel Tire page 298 and Inflating Caster Tire page 305 169890 335 Revision A ...

Page 350: ......

Page 351: ...eering system or the Trimble EZ Pilot wheel column based assisted steering system The windrower s ground speed lever GSL has an automated steering autosteer engage switch and the Trimble display mounting kit MD 183348 is supplied in the cab The Trimble AutoPilot system requires the MacDon automated steering hydraulic interface kit MD B5589 Installation instruction MD 169539 is included with the ki...

Page 352: ... Engine Distributor and provide your engine model and serial numbers to ensure the proper heater is supplied 7 1 9 Engine Fan Air Baffle Prevents the windrow from being disturbed by engine cooling fan air blast MD B5440 Instruction MD 169443 is included with the bundle 7 1 10 Expansion Module Allows electronic monitoring of header knife speed reel speed and header angle Also required for indexing ...

Page 353: ...link provides a manually adjustable connection between the windrower and the header mower conditioner MD B4665 7 1 15 Swath Roller An axle mounted swath roller increases the windrow s resistance to wind disturbance especially in canola or similar crops It can be fitted with a hydraulic lift with in cab controls Contact your MacDon Dealer for information 7 1 16 Towing Harness The towing harness is ...

Page 354: ...ve the windrower without an attached header attach the weight box to the header lift system The weight box allows transporting a header behind the windrower by providing additional weight on the drive wheels MD B5238 Weight box without harness40 MD B5240 Weight box without harness and concrete 40 Instruction MD 169280 is included with the bundle MD B5280 Wiring harness for weight box Includes hitc...

Page 355: ...ory CDM Error Message 3 Amber 719 Extended crankcase blow by pressure circuit Voltage above normal or shorted to high source 22 4 Amber 729 Crankcase Pressure Extended crankcase blow by pressure circuit Voltage below normal or shorted to low source Crankcase Pressure 32 3 Amber 2111 Coolant temperature 2 sensor circuit Voltage above normal or shorted to high source 0 Red 2114 Coolant temperature 2...

Page 356: ...r Pedal Position Accelerator pedal or lever position sensor circuit Voltage below normal or shorted to low source 8 154 154 Abnormal frequency pulse width or period 12 154 154 Throttle Position Sensor Bad device or component 91 19 Red 287 Accelerator Pedal Position SAE J1939 multiplexing accelerator pedal or lever sensor system error Received network data in error Accelerator Pedal Position 1 Ambe...

Page 357: ... Indicator 1 Red 415 157 Oil pressure low Data valid but below normal operational range Most severe level 2 Amber 435 Oil pressure sensor circuit Data erratic intermittent or incorrect 3 Amber 135 157 Oil pressure sensor circuit Voltage above normal or shorted to high source 4 Amber 141 157 Oil pressure sensor circuit Voltage below normal or shorted to low source 10 157 157 Engine oil pressure sen...

Page 358: ...ssure sensor circuit Voltage below normal or shorted to low source 102 10 Amber 197 Boost Pressure Intake manifold pressure sensor circuit Abnormal rate of change Boost Pressure 10 Amber 2345 Turbocharger speed invalid rate of change detected Abnormal rate of change 16 Amber 595 Turbocharger 1 speed high Data valid but above normal operational range Moderately severe level 103 18 Amber 687 Turboch...

Page 359: ... 133 Intake Manifold Intake manifold 1 temperature Data valid but above normal operational range Moderately severe level Intake Manifold 1 Temperature 3 135 1785 Voltage above normal or shorted high 4 135 1785 Voltage below normal or shorted low 106 10 135 1785 Inlet Manifold Pressure Sensor Inlet manifold pressure sensor 5v supply connection open circuit Inlet Manifold Pressure Sensor 107 15 Ambe...

Page 360: ...mperature low Data valid but above normal operational range Most severe level 2 Amber 334 Coolant temperature sensor circuit Data erratic intermittent or incorrect 3 Amber 144 168 Coolant temperature sensor circuit Voltage above normal or shorted to high source 4 Amber 145 168 Coolant temperature sensor circuit Voltage below normal or shorted to low source 15 None 2963 168 Engine coolant temperatu...

Page 361: ...e above normal or shorted to high source 4 Amber 452 159 Injector metering rail 1 pressure sensor circuit Voltage below normal or shorted to low source 16 Amber 553 Injector metering rail 1 pressure high Data valid but above normal operational range Moderately severe level 157 18 Amber 559 Injector Metering Rail 1 Pressure Injector metering rail 1 pressure low Data valid but below normal operation...

Page 362: ...oltage 0 422 422 Excessive battery power 1 Low battery power 2 ECM Battery Power Intermittent 16 Amber 442 Electrical Potential Voltage Battery 1 voltage high Data valid but above normal operational range Moderately severe level 168 18 Amber 441 Electrical Potential Voltage Battery 1 voltage low Data valid but below normal operational range Moderately severe level ECM Battery Power 3 Amber 249 Amb...

Page 363: ...ber 425 Engine oil temperature Data erratic intermittent or incorrect 3 Amber 212 Engine oil temperature sensor 1 circuit Voltage above normal or shorted to high source 175 4 Amber 213 Oil Temperature Engine oil temperature sensor 1 circuit Voltage below normal or shorted to low source Oil Temperature 0 Red 234 Engine speed high Data valid but above normal operational range Most severe level 2 Amb...

Page 364: ...high source 4 Amber 238 System Diagnostic Code 1 Sensor supply voltage 3 circuit Voltage below normal or shorted to low source 16 Amber 2292 Fuel Inlet Meter Device Fuel inlet meter device Data valid but above normal operational range Moderately severe level 18 Amber 2293 Fuel Inlet Meter Device Fuel inlet meter device flow demand lower than expected Data valid but below normal operational range M...

Page 365: ...actuator 1 circuit error Condition exists Fuel Control Valve 1 637 11 143 143 Primary To Secondary Speed Signal Calibration fault Primary to secondary speed signal 9 Amber 285 247 SAE J1939 multiplexing PGN timeout error Abnormal update rate 639 13 Amber 286 SAE J1939 Datalink SAE J1939 multiplexing configuration error Out of calibration SAE J1939 Datalink 1484 31 None 211 J1939 Error Additional a...

Page 366: ...t high 652 7 Amber 1141 2 Cylinder 2 Injector Injector cylinder 2 Mechanical system not responding properly or out of adjustment Injector Cylinder 02 2 113 Cylinder 3 injector erratic intermittent or incorrect 5 Amber 324 3 Injector solenoid cylinder 3 circuit Current below normal or open circuit 6 N A 3 Injector current high 653 7 Amber 1142 3 Cylinder 3 Injector Injector cylinder 3 Mechanical sy...

Page 367: ...circuit Current below normal or open circuit 6 N A 6 Injector current high 656 7 Amber 1145 6 Cylinder 6 Injector Injector cylinder 6 Mechanical system not responding properly or out of adjustment Injector Cylinder 06 5 199 199 Current low 676 6 199 Glow Plug Start Aid Relay Current high Glow Plug Start Aid relay 677 3 Amber 584 Starter Solenoid Lockout Relay Driver Circuit Starter relay circuit V...

Page 368: ... shorted to high source 729 4 2427 Inlet Air Heater Driver 1 Intake air heater 1 circuit Voltage above normal or shorted to high source Grid Heater 3 Amber 387 Accelerator pedal or lever position sensor supply voltage circuit Voltage above normal or shorted to high source 1043 4 Amber 284 Internal Sensor Voltage Supply Engine speed position sensor crankshaft supply voltage circuit Voltage below no...

Page 369: ...nsor Circuit Voltage ECM internal temperature sensor circuit Voltage above normal or shorted to high source 1136 4 Amber 698 ECM internal temperature sensor circuit Voltage below normal or shorted to low source Sensor Circuit Voltage 3 Amber 691 Turbocharger 1 compressor inlet temperature sensor circuit Voltage above normal or shorted to high source 1172 4 Amber 692 Turbocharger 1Compressor Inlet ...

Page 370: ...oil and filter Condition exists Engine Oil Change Interval 3 Amber 297 Auxiliary pressure sensor input 2 circuit Voltage above normal or shorted to high source 4 Amber 298 Auxiliary pressure sensor input 2 circuit Voltage below normal or shorted to low source 1388 14 Red 296 Auxiliary Pressure Auxiliary pressure sensor input 1 Special instructions Auxiliary Pressure 1563 2 Amber 1256 Control Modul...

Page 371: ...15 None 2346 System Diagnostic Code 1 Turbocharger turbine inlet temperature calculated Data valid but above normal operational range Least severe level System Diagnostic Code 1 3 Amber 2115 Coolant pressure 2 circuit Voltage above normal or shorted to high source 4 Amber 2116 Coolant pressure 2 circuit Voltage below normal or shorted to low source 2981 18 Amber 2117 Coolant Pressure Coolant press...

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Page 373: ... fault detected Error Codes E14 to E23 not allocated E24 E124 DECK SHFT RIGHT P95 Right Deck Shift solenoid P95 fault detected E25 E125 DECK SHFT LEFT P96 Left Deck Shift solenoid P96 fault detected E26 E27 E28 E128 TILT P2A Header Tilt solenoid P2A V2A fault detected E29 E129 TILT P4C Header Tilt solenoid P4C V4C fault detected E30 E130 4 WAY VALVE P5A 4 Way valve solenoid P5A V5A fault detected ...

Page 374: ...NIFE OVERLOAD Low knife speed detected less than programmed overload speed in CDM E66 LOW VOLTS Low system voltage 11 5 VDC E67 TRANS OIL PRESSURE Supercharge pressure low switch 208 on hydraulic schematic E68 TRANS Temp Oil Tank temp 221 F 105 C E69 E70 E71 LOW HYDRAULIC OIL Low hydraulic oil level sensor tripped switch 225 on hydraulic schematic E72 HIGH VOLTS System voltage above 15 5 VDC Error...

Page 375: ...onnect switch 261 maintaining 260 removing 266 safety 8 belt A C compressor belt replacing 257 tensioning 257 alternator fan belt replacing 256 tensioning 256 break in inspection 313 C cab display module CDM CDM WCM fault codes 79 engine and windrower functions 60 engine error codes 79 341 engine warning lights 67 header functions 61 operating screens 62 programming 70 warning alarms 67 cab temper...

Page 376: ...tery 260 checking and replacing fuses 283 fuse box decal 285 inspecting 125A main fuse 286 preventing damage to electrical system 260 replacing 125A main fuse 286 replacing circuit breaker relay 283 end of season service 314 engine 225 air intake system 230 belt 256 cleaning filter element 235 engine compartment hood 202 engine controls and gauges 54 engine cooling system 245 engine error codes on...

Page 377: ...g installing fuel tank vent filter 237 fuel fluids and lubricants 198 priming 244 fuse accessing 282 checking and replacing 283 inspecting and replacing 125A 286 fuse box decal 285 G glossary 27 gps automated steering systems 337 GSL See header controls H header definition 27 header angle 124 header controls 56 console header switches deck shift switch 56 display selector switch 58 ground speed le...

Page 378: ...sting 295 return filter 292 installing return filter 293 removing return filter 292 traction drive hydraulics 296 charge pump pressure 297 transmission oil pressure 296 warnings 287 hydraulics safety 6 traction drive hydraulics 296 K knife speed A Series header 182 setting with expansion module 182 setting without expansion module 184 D Series header 175 setting with expansion module 175 setting w...

Page 379: ... engine oil 228 checking level 227 draining 228 replacing engine oil filter 229 oil change See oil engine operation 85 See also engine operation See also header operation break in period 86 daily check 87 driving the windrower 94 operating with a header 117 A Series header 179 D Series header 167 preseason checks annual service 86 distributing A C compressor coolant 87 return to cut feature progra...

Page 380: ...specting radiator cap 245 radio 51 rear view mirror 46 reel height D Series header 169 reel index 169 reel minimum speed 169 reel speed A30 D header 181 A40 D header 181 D Series header 169 reel to ground speed 169 relay replacing 283 return to cut feature 127 programming return to cut 128 using return to cut 129 rpm definition 27 S SAE bolt torque 186 definition 27 safety alert symbols 1 battery ...

Page 381: ...ydraulics 325 operator s station 335 steering and ground speed control 330 traction drive 327 truck definition 27 V ventilating See HVAC system W wheel and tire 298 See also drive wheelinstalling adjusting caster tread width 100 caster wheel 100 305 anti shimmy dampener 311 ballast requirement 312 caster wheel nut torque 306 inflating caster tire 305 installing forked caster wheel 310 installing f...

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Page 384: ...3 t 204 885 5590 f 204 832 7749 MacDon Inc 10708 N Pomona Avenue Kansas City Missouri United States 64153 1924 t 816 891 7313 f 816 891 7323 MacDon Australia Pty Ltd A C N 079 393 721 P O Box 243 Suite 3 143 Main Street Greensborough Victoria Australia 3088 t 03 9432 9982 f 03 9432 9972 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Cent...

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