MacDon M150 Operator'S Manual Download Page 214

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TROUBLESHOOTING

* See your MacDon Dealer
** Refer to Windrower Technical Manual

Form 169017 / 169087 / 169095

212

Revision C

8 TROUBLESHOOTING

8.1 ENGINE

SYMPTOM PROBLEM

SOLUTION

SECTION

M150 M200

Engine Hard To

Start Or Will Not

Start.

Controls not in neutral.

Move GSL to neutral.

6.3.5.1

Move steering wheel to locked position.

Disengage header clutch.

5.17.1

Neutral interlock misadjusted.

Contact MacDon Dealer.

No fuel to engine.

Fill empty fuel tank, replace clogged filter.

6.3.5.5
7.8.6.2

6.3.5.5
7.9.6.2

Old fuel in tank.

Drain tank, refill with fresh fuel

7.9.6

Water, dirt or air in fuel system.

Drain, flush, fill and prime system.

Improper type of fuel.

Use proper fuel for operating conditions. 7.3.1.1

Crankcase oil too heavy.

Use recommended oil.

7.3.1.3

Low battery output.

Have battery tested. Check battery
electrolyte level.

7.11.1

Poor battery connection.

Clean and tighten loose connections.

Faulty starter.

Contact MacDon Dealer.

Wiring shorted, circuit breaker
open.

Check continuity of wiring and breaker
(manual reset).

7.11.13

Loose electrical connection at fuel
pump.

Ensure connector at pump is fully pushed in.

ECM fuse (1 of 2) blown.
ECM Ignition relay faulty.
Neutral Logic relay faulty.

Replace. 7.11.13

Faulty injectors

Contact MacDon Dealer.

Engine Knocks.

Insufficient oil.

Add oil.

7.8.3

7.9.2

Engine out of time.

Contact MacDon Dealer.

Low or high coolant temperature.

Remove and check thermostat. See "Engine
Overheats".

Improper fuel.

Use proper fuel.

7.3.1.1

Low Oil Pressure.

Low oil level.

Add oil.

7.8.3

7.9.2

Improper type of oil.

Drain, fill crankcase with proper oil.

7.8.4

7.9.3

Worn components.

Contact MacDon Dealer.

High Oil

Consumption.

Crankcase oil too light.

Use recommended oil.

7.3.1.3

Oil leaks.

Check for leaks around gaskets, seals, and
drain plugs.

7.8.4 7.9.3

Internal parts worn.

Contact MacDon Dealer.

Summary of Contents for M150

Page 1: ...M150 M200 Self Propelled Windrower OPERATOR S MANUAL Revision C Part 169017 25 ...

Page 2: ...M200 Self Propelled Windrower CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Battery posts terminals and related accessories contain lead and lead components Wash hands after handling ...

Page 3: ... Contents and the Index to guide you to specific areas Study the Table of Contents to familiarize yourself with how the material is organized Keep this manual handy for frequent reference and to pass on to new operators or owners Call your MacDon Dealer if you need assistance information or additional copies of this manual A manual storage case is provided in the cab NOTE The M150 and M200 Windrow...

Page 4: ...ional 22 5 7 5 Slow Moving Vehicle SMV Signs 22 5 8 WINDSHIELD WIPERS 23 5 9 REAR VIEW MIRRORS 23 5 10 CAB TEMPERATURE 23 5 10 1 Heater Shut Off Valve 23 5 10 2 Air Distribution 23 5 10 3 Controls 24 5 10 4 A C Compressor Protection 24 5 11 INTERIOR LIGHTS 24 5 12 OPERATOR AMENITIES 25 5 13 RADIOS 26 5 13 1 AM FM Radio 26 5 13 2 Antenna Mounting 26 5 14 HORN 26 5 15 ENGINE CONTROLS GAUGES 27 5 16 ...

Page 5: ...raper Speed 97 6 5 8 Knife Speed 99 6 5 9 Deck Shift Optional 100 6 6 A SERIES HEADER OPERATION 101 6 6 1 Header Attachment 101 6 6 2 Header Detachment 104 6 6 3 Auger Speed 106 6 6 4 Reel Speed 107 6 6 5 Knife Speed 108 6 7 R SERIES HEADER OPERATION 109 6 7 1 Header Attachment 109 6 7 2 Header Detachment 112 6 7 3 Disc Speed 114 6 7 4 Converging Drum Assemblies Grass Seed Header 115 7 MAINTENANCE...

Page 6: ...nce 177 7 11 ELECTRICAL SYSTEM 179 7 11 1 Battery 179 7 11 2 Headlights Engine Forward 184 7 11 3 Field lights Cab Forward 186 7 11 4 Flood Lights Forward 186 7 11 5 Flood Lights Rear 187 7 11 6 Red and Amber Lights 188 7 11 7 Red Tail Lights If Installed 189 7 11 8 Beacons If Installed 189 7 11 9 Gauge Light 191 7 11 10 Dome Light 191 7 11 11 Ambient Light 191 7 11 12 Turn Signal Indicators 191 7...

Page 7: ... KIT 221 9 6 INTERNAL BOOSTER SPRING KIT 221 9 7 LIGHT HEADER FLOTATION KIT 221 9 8 WINDSHIELD SHADES 221 9 9 DISC HEADER VALVE 221 9 10 AM FM RADIO 221 9 11 CENTER LINK SELF ALIGNMENT KIT 221 9 12 PRESSURE SENSOR KIT 221 9 13 HYDRAULIC CENTER LINK 221 9 14 WEIGHT BOX 221 9 15 TOWING HARNESS 221 9 16 SWATH ROLLER 221 9 17 WARNING BEACONS 222 9 18 AUTO STEER 222 9 19 LIGHTING AND MARKING KIT FOR CA...

Page 8: ...unsafe practices CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It is also used as a reminder of good safety practices 2 3 SAFETY SIGNS 2 3 1 SAFETY SIGN INSTALLATION Refer to the illustration on this and following pages and proceed as follows a Be sure the installation area is clean and dry b Decide on the exact location before you r...

Page 9: ...ign Locations continued LIFT LINKAGES 163561 FRONT OF PLATFORM 134070 HORIZONTAL FORMAT AND ON OIL RESERVOIR UNDER HOOD BOTH SIDES 44944 VERTICAL FORMAT BELOW DOOR HANDLE 32744 IN CAB 32744 BEHIND DOOR ON SILL LH SIDE ONLY 160396 BEHIND DOOR ON SILL 109843 ...

Page 10: ...SAFETY Form 169017 169087 169095 8 Revision C Safety Sign Locations continued IN CAB 109868 IN CAB 109844 BEHIND DOOR ON SILL 109843 FRONT OF PLATFORM 110989 IN CAB 160422 BEL0W DOOR HANDLE 32744 ...

Page 11: ...SAFETY Form 169017 169087 169095 9 Revision C Safety Sign Locations continued ON FRAME 42130 ON FAN SHROUD 134068 ON FRAME 110986 ...

Page 12: ...SAFETY Form 169017 169087 169095 10 Revision C Safety Sign Locations continued ON DRINK COOLER 160429 INSIDE FRAME 32743 ON FRAME 110986 ON LIFT LINKAGE 163562 ...

Page 13: ...ide a first aid kit for use in case of emergencies Keep a fire extinguisher on the machine Be sure the extinguisher is properly maintained and be familiar with its proper use Keep young children away from machinery at all times Be aware that accidents often happen when the operator is tired or in a hurry to get finished Take the time to consider the safest way Never ignore warning signs of fatigue...

Page 14: ...e slippery Wet spots can be dangerous when working with electrical equipment Be sure all electrical outlets and tools are properly grounded Use adequate light for the job at hand Keep machinery clean Straw and chaff on a hot engine are a fire hazard Do not allow oil or grease to accumulate on service platforms ladders or controls Clean machines before storage Never use gasoline naphtha or any vola...

Page 15: ...l CDM Cab Display Module DWA Double Windrow Attachment Engine Forward Windrower operation with the operator and engine facing in the direction of travel ISC Integrated Speed Control N DETENT The slot opposite the neutral position on operator s console rpm Revolutions per minute SAE Society Of Automotive Engineers WCM Windrower Control Module Windrower Windrower with header attached Windrower Tract...

Page 16: ...nch mm TIRES Inch mm SHIPPING Inch mm WHEEL BASE Inch mm CAB FWD ENG FWD DRIVE TIRE Inner Outer 138 7 3522 142 9 3630 158 3 4021 120 7 3066 Outer Outer 134 2 3410 146 1 3712 157 1 3990 Inner Inner 120 1 3050 131 6 3342 150 0 3810 CASTER TIRE Minimum 93 2 2367 115 4 2932 Maximum 135 8 3448 158 0 4013 ENGINE FORWARD TREAD CASTERS CAB FORWARD 45 7 in 1160 TREAD HUBS TIRES WHEEL BASE WHEEL BASE 133 in...

Page 17: ...rd Low Range 0 11 mph 17 7 km h Mid Range 0 16 mph 25 7 km h Reverse Cab Forward 6 mph 9 6 km h Transport Engine Forward High Range 0 23 mph 37 km h Transmission Type 2 Piston Pumps 1 per Drive Wheel Displacement 2 65 cu in 44 cc Flow 40 U S gpm 151 L min Final Drive Type Planetary Gearbox Ratio 30 06 1 Wheel Motor Displ Low Range 4 15 cu in 68 cc Mid Range 2 93 cu in 48 cc High Range 2 0 cu in 33...

Page 18: ...tside Field Radio Two Speakers and Antenna Factory Installed Radio Dealer Installed SYSTEM MONITORING Speeds Ground mph or km h Engine rpm Knife spm Disc rpm Reel rpm or mph km h Conveyor Ref No Header Height Angle Float Optional Knife or Reel Drive Pressure Height Angle Float Knife Drive and Reel Drive Pressures TIRE OPTIONS Size Drive 18 4 26 Bar 18 4 26 Turf 600 65 R28 Bar 23 1 26 Turf 580 70 R...

Page 19: ...NSOLE The console contains controls to operate the windrower as well as amenities for the operator The console position is adjustable to suit each particular operator The console is attached to the seat and does not require adjustment when repositioning the Operator s seat a Pull lever A and slide console fore or aft to desired position The height also increases slightly as the console is moved af...

Page 20: ...y will flash NOT IN NEUTRAL accompanied by an alarm When the seat is in between cab forward and engine forward positions the engine will shut off if the transmission is not locked in the neutral position The lower display will flash LOCK SEAT BASE until the seat base is locked into position 5 3 SEAT ADJUSTMENTS The Operator s seat has several adjustments Refer to the following illustration for the...

Page 21: ...securely fasten your seat belt and ensure trainer s seat belt is fastened if occupied The seat belt can help ensure your safety if it is used and maintained Never wear a seat belt loosely or with slack in the belt system Never wear the belt in a twisted condition or pinched between the seat structural members a To fasten seat belt pull belt completely across your body Push the metal eye into the b...

Page 22: ...ward mode The position of the Operator s station automatically determines the lighting IMPORTANT Red reflector tape is applied to aft locations to be visible in engine forward mode Only amber tape is allowed in cab forward mode 5 7 1 CAB FORWARD LIGHTING FIELD FRONT CAB FWD FIELD LIGHTS REAR CAB FWD FIELD LIGHTS SWATH LIGHTS HIGH LOW LIGHTS Controls High Low Beam For Road Lights High Low LIGHTS Co...

Page 23: ... is in the ROAD position The hazard lights must be activated with the switch on the CDM when driving on the road IMPORTANT Optional red tail lighting and marking kit must be installed so that road travel in the cab forward mode complies with road travel regulations See your MacDon Dealer REAR ENG FWD FRONT ENG FWD TAIL BRAKE LIGHTS RED TURN SIGNALS HAZARDS AMBER TURN SIGNALS HAZARDS AMBER HIGH LOW...

Page 24: ...ONAL The beacon lights are functional when the ignition and the beacon switches are on The beacons must be used when driving on the road 5 7 5 SLOW MOVING VEHICLE SMV SIGNS The Slow Moving Vehicle SMV signs must be visible when travelling on the road BEACON LIGHTS AMBER ENGINE FORWARD CAB FORWARD ...

Page 25: ... The heater evaporator blower assembly is located under the cab floorboard and is accessible from beneath the windrower 5 10 1 HEATER SHUT OFF VALVE A shut off valve 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 5 10 2 AIR DISTRIBUTION Cab air distribution is controlled th...

Page 26: ...to 220 280 psi 1517 1930 kPa the switch closes and allows the compressor to run If the air conditioning system is shutdown by either switch locate the source of the problem and correct it before operating the system The Windrower Control Module WCM monitors the compressor operation and when it senses rapid pressure changes that cause the compressor to rapidly engage and disengage a CHECK A C SYSTE...

Page 27: ...orm 169017 169087 169095 25 Revision C 5 12 OPERATOR AMENITIES MANUAL STORAGE CASE CIGARETTE LIGHTER UTILITY TRAY UNDER ARMREST UTILITY TRAY ASHTRAY CUPHOLDER AUXILIARY POWER AUXILIARY POWER GROUND SWITCHED BATTERY COOLER ...

Page 28: ... 5 13 2 ANTENNA MOUNTING A roof mounted antenna base for installing a magnetic antenna is available as an option from your MacDon Dealer Order part 160288 or see illustration for part dimensions for a homemade version It accommodates most CB 2 way radio and satellite radio antennas A knockout for the antenna lead is provided on the cab post IMPORTANT Antenna base can only be installed on the LH an...

Page 29: ...M FULL Push Lever Forward OPERATING See Section 6 3 6 CLOSED Pull Lever Back IGNITION SWITCH ACC Fully Counter Clockwise OFF All Electrical Systems Off RUN Clockwise START Fully Clockwise To Crank Engine Release and Switch Returns to RUN REMOVE KEY WHEN WINDROWER NOT IN USE KEY ALSO LOCKS DOORS FUEL Indicates Fuel Level In Tank E Empty F Full ENGINE TEMPERATURE Indicates Engine Coolant Temperature...

Page 30: ...tor and Header Momentary Switch On Monitor FAST SLOW GROUND SPEED LEVER GSL Controls Speed and Direction of Movement F Forward N Neutral N DETENT Engages Neutral Interlock and Applies Park Brake When Steering Locked In Center R Reverse GROUND SPEED RANGE SWITCH Shifts Transmission Speed Range H 0 23 mph 37 km h ENGINE FORWARD ONLY 0 16 mph 25 7 km h CAB FORWARD ONLY L 0 11 mph 17 7 km h N DETENT T...

Page 31: ...nal hydraulic reversing kit must be installed IMPORTANT To prevent improper operation and damage to the reel on D Series draper headers when the reverser kit is installed If switching between A40D auger header and D50 or D60 draper header the hose plumbing to the reverser valve must be changed to suit the header type Refer to Instruction Form 169213 that was supplied with the reversing kit Reverse...

Page 32: ...ch of the header controls Press switch to scroll through settings 5 17 3 2 Reel Position Switches The reel position switches perform the following functions depending on CDM programming and which header is attached Double Windrow Attachment DWA Position on Draper and Auger Headers See Section 6 4 7 Reel Fore Aft Position and Height on Draper Headers See Sections 6 5 4 and 6 5 5 Grass Seed Drum Pos...

Page 33: ...or disc speed Release switch at desired speed Auger Header A30 Not applicable A40 Auger speed is automatically maintained when reel speed is changed IMPORTANT Reel speed on auger header must not exceed 85 rpm IMPORTANT Auger speed must not exceed 320 rpm Draper Header Reel speed is limited in INDEX HEADER SPEED mode Rotary Header Conditioner speed automatically adjusts when disc speed is changed N...

Page 34: ... deck shifting for double windrowing options with a draper header Draper Header with Fixed Decks Auger Header Rotary Header Selects pre programmed header float settings Refer to Section 6 4 2 Header Flotation for instructions to preset the float NOTE Refer to the specific Header section in this instructional manual for detailed switch operating modes FLOAT PRESET 2 FLOAT PRESET 3 FLOAT PRESET 1 CE...

Page 35: ...yor Speed to Ground Speed Push On Push Off Illuminates In On Position SELECT SWITCH Allows Operator To Select Display Item Bottom Line Push To Select RETURN TO CUT HEIGHT SWITCH Allows Cutting Height Pre Set Push On Push Off Illuminates In On Position FLOAT SWITCH HEADER LEFT SIDE Same As Above NOTE HEADER MUST BE ENGAGED HAZARD WARNING LIGHTS SWITCH Activates Hazard Warning Lights Cancels Turn Si...

Page 36: ...roll Through Display with CDM Switch or GSL Switch DISPLAY DESCRIPTION ROAD GEAR Upper Line Ground Speed Range Switch In High Range ENGINE HRS Upper or Lower Line Total Engine Operating Time HEADER HRS Upper or Lower Line Total Header Operating Time TOTAL ACRES Upper or Lower Line TOTAL HECT if Metric Total Area Cut By Machine HEADER HEIGHT Upper or Lower Line Distance Setting 00 0 10 0 Between Cu...

Page 37: ...RES If Metric Area Cut Since Last Reset To Reset Display SUB ACRES On Lower Line And Hold Down Program Switch Until Display Resets 5 7 Seconds TOTAL ACRES TOTAL HECT If Metric Total Area Cut By Machine HEADER HEIGHT Distance Setting 00 0 10 0 Between Cutterbar and Ground HEADER ANGLE Angle Setting 00 0 10 0 Header Relative to Ground L FLOAT R Float Setting 0 0 10 0 VOLTS Engine Electrical System O...

Page 38: ...Minute HEADER HEIGHT HEIGHT SENSOR If Sensor Disabled Distance Setting 00 0 10 0 Between Cutterbar and Ground HEADER ANGLE TILT SENSOR If Sensor Disabled Angle Setting 00 0 10 0 Header Relative To Ground L FLOAT R FLOAT SENS DISABLED If Sensor Disabled Left And Right Float Setting 0 0 10 0 LOAD _____ If Metric Bar Graph Representing Hydraulic Operating Pressure Full Scale Is Pre Programmed Overloa...

Page 39: ...e Speed In Strokes Per Minute HEADER HEIGHT HEIGHT SENSOR Sensor Disabled Distance Setting 00 0 10 0 Between Cutterbar and Ground HEADER ANGLE TILT SENSOR Sensor Disabled Angle Setting 00 0 10 0 Header Relative To Ground L FLOAT R Left And Right Float Setting 0 0 10 0 LOAD _____ If Metric Bar Graph Representing Hydraulic Operating Pressure Full Scale Is Pre Programmed Overload Pressure M150 2500 4...

Page 40: ... HEIGHT HEIGHT SENSOR Sensor Disabled Distance Setting 00 0 10 0 Between Cutterbar and Ground HEADER ANGLE TILT SENSOR Sensor Disabled Angle Setting 00 0 10 0 Header Relative To Ground L FLOAT R Left And Right Float Setting 0 0 10 0 LOAD _____ If Metric Bar Graph Representing Hydraulic Operating Pressure Full Scale Is Pre Programmed Overload Pressure M150 2500 4000 PSI M200 2500 4800 PSI If Sensor...

Page 41: ...Metric Total Area Cut By Machine DISC RPM REEL SENSOR If Sensor Disabled Disc Rotational Speed HEADER HEIGHT HEIGHT SENSOR If Sensor Disabled Distance Setting 00 0 10 0 Between Cutterbar and Ground HEADER ANGLE TILT SENSOR If Sensor Disabled Angle Setting 00 0 10 0 Header Relative To Ground L FLOAT R Left And Right Float Setting 0 0 10 0 LOAD _____ If Metric Bar Graph Representing Hydraulic Operat...

Page 42: ...ressed On CDM See Note 2 HAZARD Indicates Hazard Warning Lights Are On When Is Pressed On CDM HEADER REVERSE Header Drive Running In Reverse HEADER ENGAGED Header Drive Engaged ROAD GEAR With Hi Range Selected On Console Switch Engine Forward Only See Note NOTE 1 If road light kit is not installed CDM will display LEFT STOP LAMP as a malfunction 2 If road light kit is not installed CDM will displa...

Page 43: ...hen the ignition is turned on and at engine operating speeds above 500 rpm 5 18 4 1 Engine Warning Lights WATER IN FUEL Illuminates Yellow Service Recommended CAUTION Illuminates Yellow Prompt Attention Is Required Refer to Display Code DISPLAY Displays Malfunction Code Refer to Pages 226 232 ENGINE PREHEAT Illuminates Yellow Wait To Start Engine STOP Illuminates Red Stop Engine Immediately Refer ...

Page 44: ...Repeats Every 30 Minutes Until Condition Is Corrected Engine Air Filter Requires Servicing ENGINE OIL PRESSURE 9 Continuous Loud Tone Until Oil Pressure Is Regained Low Engine Oil Pressure ENGINE TEMPERATURE 9 Ongoing Intermittent Moderate Tone Until Temperature Is Below 215 F 102 C Engine Temperature Over 230 F 110 C HEADER DISENGAGED None Normal DISENGAGE HEADER 9 None Header Switch Is In On Pos...

Page 45: ...perator Not Detected In Seat With Header Engaged or Out Of Neutral Detent Engine Shutdown After 5 Seconds NO OPERATOR ENGINE SHUTDOWN Continuous Tone Engine Shutdown When Operator Not Detected In Seat With Machine Moving Under 5 mph 8 km h NOT IN PARK 9 Short Beep With Each Flash GSL or Interlock Switches Not Closed With Key On Engine Off PLACE GSL INTO N Beeps At 2 Per Second Until Corrected GSL ...

Page 46: ...eader ID code is displayed c Press SELECT TRACTOR SETUP is displayed on upper line d Press SET KNIFE SPEED is displayed e Press or to change value on lower line f Press SELECT KNIFE OVERLOAD SPD is displayed g Press or to change value on lower line h Press SELECT KNIFE OVERLOAD SPD is displayed i Press or to change value on lower line j Press SELECT to advance to the next L1 item and press arrow k...

Page 47: ... R 2 8 L2 M x x x 5 8 0 7 0 R 2 6 T U R F L1 C x x x S E T E N G I N E I S C R P M L2 M x x x N O Y E S S E T C O N T R O L L O C K S L1 C x x x P R E S S H A Z A R D T O S E T L2 M x x x I S C R P M O F F L1 C x x x P R E S S H A Z A R D T O S E T L2 M x x x I S C R P M 2 0 0 0 L1 C x x x P R E S S H A Z A R D T O S E T L2 M x x x I S C R P M 1 9 0 0 L1 C x x x P R E S S H A Z A R D T O S E T L2 ...

Page 48: ...6 4 8 6 H R S L O C K E D L1 C x x x D R A P E R S P E E D L2 M x x x 5 7 5 1 H R S E N A B L E D L2 M x x x 6 4 8 6 H R S L O C K E D L1 C x x x A U G E R S P E E D L2 M x x x 5 7 5 1 H R S E N A B L E D L2 M x x x 6 4 8 6 H R S L O C K E D L1 C x x x K N I F E S P E E D L2 M x x x 5 7 5 1 H R S E N A B L E D L2 M x x x 6 4 8 6 H R S L O C K E D L1 C x x x D I S K S P E E D L2 M x x x 5 7 5 1 H R...

Page 49: ...librated The operator will be prompted to extend the header tilt and HOLD will flash until the system has completed reading in the signal with the header tilt fully extended HOLD will change to DONE with buzzer When the header tilt extend is done the CDM will prompt the user to press the header tilt retract COMPLETE with buzzer will flash on the screen for 2 seconds when the calibration is finishe...

Page 50: ... L E L1 C x x x H Y D O I L T E M P S E N S O R L2 M x x x E N A B L E D I S A B L E L1 C x x x E X I T S E N S O R S E T U P L2 M x x x N O Y E S K N I F E S P E E D S E N S O R L1 C x x x R E A D S E N S O R I N P U T S L2 M x x x N O Y E S A C T I V A T E F U N C T I O N S L1 C x x x S E N S O R I N P U T L2 M x x x H D R H E I G H T 3 5 9 V L1 C x x x S E N S O R I N P U T L2 M x x x H D R A N...

Page 51: ...L2 M x x x S K A U G E R L2 M x x x D K A U G E R L2 M x x x G R A S S S E E D L2 M x x x 2 0 F T S K D R A P E R L2 M x x x 2 5 F T S K D R A P E R L2 M x x x 3 0 F T S K D R A P E R W L2 M x x x 3 5 F T S K D R A P E R L2 M x x x 1 5 F T D K D R A P E R L2 M x x x 2 0 F T D K D R A P E R L2 M x x x 2 5 F T D K D R A P E R L2 M x x x 3 0 F T D K D R A P E R L2 M x x x 3 5 F T D K D R A P E R L2 M...

Page 52: ...Series Rotary Header Disc Speeds CROP CONDITION DISC RPM Alfalfa Heavy 2100 2300 Light 1800 2000 Sudan Sorghum Haygrazer Timothy Tall and Stemmy 2300 2500 Short Grass Dense 2500 Thin 2000 2200 Suggested Overload Setting 1300 rpm 5 18 6 3 Engine Error Codes The CDM displays Error Codes when there is a fault with one of the several sensors that monitor and control engine operation to assist the oper...

Page 53: ...ot modify the machine Unauthorized modifications may impair the function and or safety and affect machine life The safety information given in this manual does not replace safety codes insurance needs or laws governing your area Be sure your machine meets the standards set by these regulations 6 2 SYMBOL DEFINITIONS The following symbols are used to depict functions or reactions at the various ins...

Page 54: ...m Header Tilt Up Header Index Header Down Return To Cut Header Up Conveyor Auger Speed Header Tilt Down Float Left Increase Float Right Decrease Reel Speed Deck Shift Disc Speed Float Reel Down Header Engage Reel Forward Header Disengage Reel Up Push Down Header Disengage Reel Rearward Pull Up Header Engage Display Select Header Reverse DWA Down DWA Up DWA Draper Speed ...

Page 55: ...or good artificial light 6 3 2 BREAK IN PERIOD The Windrower is ready for normal operation However there are several items to check and watch out for during the first 150 hours In addition to the following perform the items specified in to Section 7 14 1 Break In Inspection Requirements DANGER Before investigating an unusual sound or attempting to correct a problem place GSL in N DETENT shut off e...

Page 56: ...move plastic bags and or tape from all sealed openings air cleaner intake exhaust pipe fuel tank 3 Charge battery and install Be sure terminals are clean and cables are connected securely 4 Adjust tension on A C compressor belt See Section 7 8 10 1 or 7 9 10 1 Tension 5 Cycle A C switch to distribute A C refrigerant oil c Perform annual maintenance See Section 7 14 MAINTENANCE SCHEDULE 6 3 4 DAILY...

Page 57: ... 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 WARNING Before starting engine securely fasten your seat belt and ensure trainer s seat belt is fastened if occupied The seat belt can help ensure your safety if it is used and main...

Page 58: ...ral or header clutch engaged DO NOT START ENGINE See your MacDon Dealer h Cold Start engine temperature below 40 F 5 C See specific engine for your windrower M200 CAT ENGINE 1 Set throttle D to start position E fully back low idle 2 Turn key to RUN 3 Glow plug light on CDM will cycle on off on after 2 seconds for a pre set length of time The operating period for the glow plug light will change dep...

Page 59: ...med engine speed is activated when the header is engaged 6 3 5 4 Shutdown CAUTION Be sure windrower is safely parked on a flat level surface header on the ground and the neutral lock brakes are engaged IMPORTANT Before stopping engine run at low idle for approximately five minutes to cool hot engine parts and allow turbocharger to slow down while engine oil pressure is available a Turn key counter...

Page 60: ...uous loud tone will sound and the CDM display will flash ENGINE OIL PRESS Shutdown the engine immediately if warning occurs while operating or if it continues for more than a few seconds after engine startup 6 3 5 8 Electrical IGNITION ENGINE READING INDICATED CONDITION On Running 13 8 15 0 Normal 16 0 See Note Regulator Out of Adjustment 12 5 See Note Alternator Not Working or Regulator Out of Ad...

Page 61: ...ically that is turning the steering wheel varies the hydraulic flow to one drive wheel relative to the other drive wheel The reaction of this type of steering is different than conventional steering mechanisms CAUTION With the engine running moving the ground speed lever out of N DETENT unlocks steering Any movement of steering wheel will then cause the machine to move even if the ground speed lev...

Page 62: ...and reel Disengage header drives Stop engine 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 ca...

Page 63: ...stened c Start engine if not running Refer to Section 6 3 5 1 Starting d There are two cab forward speed ranges Set ground speed range switch D to either H 0 16 mph 25 7 km h or L 0 11 mph 17 7 km h e Slowly push throttle F to full forward operating speed CDM should display 2270 2330 RPM at G CAUTION Check again to be sure all bystanders have cleared the area f Slowly move the GSL A forward to des...

Page 64: ...e cleared the area c Move the GSL A rearward to desired speed d Steer as shown below 6 3 6 3 Engine Forward Operation a Swivel Operator s station to engine forward position as follows 1 Place ground GSL A in N DETENT and lock steering wheel Engine can be running IMPORTANT If GSL is not in N DETENT damage to the GSL cable may result when swivelling Operator s station 2 Pull up on knob B and hold to...

Page 65: ... example driving up a ramp up a hill or up out of a ditch 1 Move the GSL A closer to neutral 2 Switch speed range control D to L low range g Once condition as per f no longer exists 1 Set GSL to not more than half maximum forward speed 2 Move speed range control D to H high range Steering is more sensitive in this speed range 6 3 6 3 1 Reverse In Engine Forward Mode WARNING Back up slowly Steering...

Page 66: ...will increase ground speed as well e To stop the turn return the steering wheel to center 6 3 6 5 Stopping WARNING Do not move ground speed lever rapidly back to neutral Operator may be thrown forward by sudden stop Always wear seat belt when operating windrower a SLOWLY return the GSL A to neutral and into N DETENT b Turn steering wheel until it locks c Move throttle lever F to low idle position ...

Page 67: ...s seat for any reason A child or even a pet could engage an idling machine a Raise rear of windrower slightly so that most of the weight is off the casters using a jack or other lifting device under the frame where shown NOTE Lifting device should have lifting capacity of at least 5000 lb 2270 kg b Remove bolts and washers A and B from left and right sides of the walking beam c Slide walking beam ...

Page 68: ...d weight box CAUTION Check local laws for width regulations and lighting and marking requirements before transporting on roads WARNING Do not drive windrower on the road in the cab forward mode unless the optional lighting marking kit is installed as lighting reflector visibility will not be compliant with road regulations WARNING Do not drive windrower on a road or highway at night or in conditio...

Page 69: ...g a header refer to Section 6 3 8 2 Towing Header with Windrower WARNING To avoid serious injury or death from loss of control Do not make abrupt changes in steering direction Anticipate turns and steep slopes by slowing down well in advance Do not rapidly accelerate or decelerate while turning When travelling on steep slopes i Move ground speed lever closer to neutral to reduce speed ii Lower hea...

Page 70: ...d remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine b Disconnect hydraulic and electrical connections 1 Left Side Store hydraulic hoses and electrical cable into the storage position See Header Operator s Manual 2 Right Side Release the multi link and place into storage on windrower See Header Operator s Manual c Retrieve te...

Page 71: ...cylinders 3 Lower header down onto the transport wheels 4 Disengage the top link from the header Use the header tilt switch to release load on the cylinder if necessary NOTE If optional self alignment kit is installed the top link can be raised or lowered using the Reel UP and DOWN buttons on the GSL MECHANICAL LINK M150 1 Loosen nut G and rotate barrel H to relieve load on link 2 Remove cotter pi...

Page 72: ...til latch C captures the end A 3 Secure latch C with clevis pin D 4 Remove the L pin from end E of aft section if installed 5 Position end F of the forward section into end E of the aft section 6 Lower forward section into aft section 7 Fully insert L pin G in upper hole and turn pin to lock it Secure with ring pin H continued next page G H E F E F A C D B AFT SECTION FORWARD SECTION A ...

Page 73: ...e location C and not installed at hole location B 1 Drive windrower so that windrower lift arms are positioned into the weight box pockets 2 Raise lift arms slightly and install locking pins D into pockets and through windrower header lift linkages Secure with hairpin NOTE Pins D were previously removed from the header lift linkage lower end 3 Route the weight box harness O to the electrical conne...

Page 74: ...away from the linkage at the rear of the lift arm o Attach slow speed transport hitch to the weight box tongue with drawbar pin secure using lynch pin Attach safety chain p Connect hitch harness to electrical socket at front of weight box q Remove the temporary lift pins A should be loose in lift arm and place into storage holes on weight box A ...

Page 75: ...t box c Disconnect wiring connector B at front wheel d Remove clevis pin C e Push latch D and lift tow bar E from hook Release latch and replace clevis pin f Unhook tow bar from weight box g Start engine and lower lift arms until rear of lift arms floats up and away from the lift arm mechanism h Stop engine and remove key from ignition i Remove temporary lift pins F from weight box and install pin...

Page 76: ...ttached to windrower ensure that float engagement pin is installed in storage location H and not installed at hole location G n Remove pins J securing lift linkages to weight box and retain pins for attaching header to windrower o Disengage lift cylinder locks p Lower weight box onto blocks and back away q Attach header to windrower Refer to Section 6 5 1 Header Attachment r Convert header into fi...

Page 77: ...d should attach to tow bar at same height as towing vehicle hitch Towing apparatus should be removed for field operation to avoid interference with windrow WARNING With final drives disengaged the windrower may roll on a sloped surface Before disengaging final drives attach windrower to towing vehicle After towing engage drives and ensure GSL is in N DETENT before detaching from towing vehicle IMP...

Page 78: ...ve material This will protect the switches instruments tires etc from inclement weather f If no cover is available seal air cleaner intake and exhaust pipe with plastic bags and or waterproof tape g If possible block up windrower to take weight off tires If it is not possible to block up the machine increase tire pressure by 25 for storage Adjust to recommended operating pressure before next use h...

Page 79: ...or death from fall of raised header always engage cylinder stops before going under header for any reason Engage cylinder stops as follows a Press HEADER UP switch to raise header to maximum height NOTE If one end of the header does not raise fully the lift cylinders require re phasing Proceed as follows 1 Press and hold the HEADER UP switch until both cylinders stop moving 2 Continue to hold the ...

Page 80: ... Header Angle In rocky fields adjust skid shoes down to raise guards when operating at flattest header angle to minimize scooping rocks Adjust header height or adjust header angle to minimize pushing soil 6 4 2 2 Float Adjustment The M Series windrowers are equipped with primary coarse and secondary fine adjustment systems The primary or coarse adjustment uses drawbolts to change the tension on th...

Page 81: ... CYL FULLY RETRACTED Auger 75 85 lbf 335 380 N Rotary 95 105 lbf 426 471 N Draper 75 85 lbf 335 380 N With Stabilizer Transport Wheels Raised if equipped b If necessary coarse adjust the float with the drawbolts as follows CAUTION Check to be sure all bystanders have cleared the area 1 Start engine 2 Using HEADER UP switch on GSL Raise the header fully shutdown the engine and remove the key 3 Turn...

Page 82: ...lift cylinders fully retracted e Using left float switch push to increase float or to decrease float on left side of header DISPLAY will indicate selected float for left side for example 8 0 L FLOAT R XX X f Repeat for right side float with right switch DISPLAY will indicate float for both sides for example 8 0 L FLOAT R 3 0 g Select a second preset with the float preset switch h Repeat steps e an...

Page 83: ...mber B is against link C Note high and low end of header 4 Place wooden blocks under header cutterbar and legs and lower header onto blocks so that members B lift off links C Stop engine DANGER Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine 5 On high side remove nut washer and bolt D that attaches shims E ...

Page 84: ...on as follows IMPORTANT To prevent improper operation and damage to the reel on D Series draper headers when the reverser kit is installed IMPORTANT If switching between A40D auger header and D50 or D60 draper header the hose plumbing to the reverser valve must be changed to suit the header type Refer to Instruction Form 169213 that was supplied with the reversing kit 1 Disengage header IMPORTANT ...

Page 85: ...ocky or wet do not use the tilt control on the go Instead use the header height switch 6 4 5 1 Hydraulic Center Link Change header angle as follows a To decrease flatten header angle operate HEADER TILT UP switch on GSL handle so that cylinder A retracts The CDM display will show a reading on the lower line of decreasing value between 00 0 and 10 0 b To increase steepen header angle operate HEADER...

Page 86: ...off the header pin 2 Lower the handle into the lock position 3 Push up on pin B only Handle should catch on casting and pin should not lift 4 Push up on actuator rod C and pin should lift with the handle 6 4 5 2 Mechanical Center Link a Loosen nut D and rotate barrel E to adjust length so that link lines up with header bracket b Install pin F and secure with cotter pin c Adjust link to required le...

Page 87: ...6 4 6 2 Auto Raise Height a Program the RETURN TO CUT feature as follows IMPORTANT The windrower must be running with the header engaged 1 RETURN TO CUT switch must be off indicator light is off 2 Adjust the header to the desired cutting height with the HEADER UP or HEADER DOWN switches on the GSL CDM displays between 00 0 and 10 0 3 Adjust the header angle with the HEADER TILT UP or HEADER TILT D...

Page 88: ...2 Press PROGRAM and SELECT on CDM to enter programming mode 3 Press SELECT TRACTOR SETUP is displayed on upper line 4 Press then SELECT SET KNIFE SPEED is displayed 5 Press SELECT until AUTO RAISE HEIGHT is displayed 6 Press or to change value on lower line Range is 0 0 to 10 0 where 10 0 is fully raised 7 Press PROGRAM to exit programming mode when finished entering desired values b Use the AUTO ...

Page 89: ...Raising the side delivery system shuts off the draper and allows the crop to be deposited between the windrower wheels as it would be without the side delivery system Refer to MacDon M Series Windrower Double Windrow Attachment Manual Form 169216 for complete operating and maintenance instructions The manual is shipped with the DWA Kit 6 4 7 1 Deck Position The deck is raised and lowered with the ...

Page 90: ...in storage location A and not installed at hole location B a If not installed attach draper header boots supplied with header to windrower lift linkage as follows 1 Remove pin C from boot D 2 Locate boot D on lift linkage E and reinstall pin C Pin may be installed from either side of boot 3 Secure pin C with hairpin 4 Repeat for opposite side b Remove hairpin on pins F and remove pins from header ...

Page 91: ...e barrel H to adjust length so that link lines up with header bracket 2 Install pin J and secure with cotter pin 3 Adjust link to required length for proper header angle by rotating barrel H Tighten nut G against barrel A slight tap with a hammer is sufficient 4 Proceed to step g HYDRAULIC LINK WITHOUT SELF ALIGNMENT KIT M200 STD M150 OPTION 1 Relocate the pin at the frame linkage as required to p...

Page 92: ... header with REEL DOWN switch until it locks into position handle is down g Raise the header fully with the HEADER UP switch on the GSL Stop engine and remove key DANGER To avoid bodily injury from fall of raised header always engage header lift cylinder stops when working on or around raised header h Engage lift cylinder stops on both lift cylinders Refer to Section 6 4 1 Header Lift Cylinder Sto...

Page 93: ...nect reel hydraulics R at RH side of windrower Refer to the Draper Header Operator s Manual 6 5 2 HEADER DETACHMENT a Raise the header fully with the header up switch on the GSL Stop engine and remove key DANGER To avoid bodily injury from fall of raised header always engage header lift cylinder stops when working on or around raised header b Engage lift cylinder stops on both lift cylinders Refer...

Page 94: ... windrower ensure that float engagement pin is installed in storage location E and not installed at hole location D f Disengage lift cylinder stops g Start engine choose a level area and lower header to the ground Stop engine and remove key h Disconnect header drive hydraulics F and electrical harness G from header Refer to the Draper Header Operator s Manual i Disconnect reel hydraulics H and sto...

Page 95: ...K M200 STD M150 OPTION 1 Start engine and activate header tilt cylinder switch on GSL to release load on center link cylinder 2 Disconnect center link by lifting release M and lift hook N off header NOTE If optional center link self alignment kit is installed lift release M and then operate the link lift cylinder with REEL UP switch on GSL to disengage the center link from the header k Slowly back...

Page 96: ...elative 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 6 5 6 1 Reel to Ground Speed Setting the speed of the reel relative to ground speed using the Header Index function allows the operator to run the engine at lower rpm while maintaining the desir...

Page 97: ... and set at 5 5 Display shows 13 5 5 5 REEL IND where 13 5 8 5 5 is the reel speed in mph and 5 5 is the header index setting Windrower speed drops to 7 5 mph at same Header Index setting Display shows 13 0 5 5 REEL IND where 13 0 7 5 5 5 is the reel speed in mph and 5 5 is the header index setting Windrower is operating at 8 mph with Header Index on and set at 1 0 Display shows 9 0 1 0 REEL IND w...

Page 98: ...CAUTION Check to be sure all bystanders have cleared the area NOTE This procedure can also be used to change the reel speed on the go These changes become the new set points MPH or KPH ENGAGE HEADER HEADER INDEX SWITCH OFF ON GSL PRESS REEL SPEED SWITCH FAST OR SLOW DISPLAY SHOWS REEL MPH DONE SPEED O K NO YES DISPLAY SELECTOR DISPLAY HEADER INDEX FAST SLOW ...

Page 99: ... the Draper Index NOTE Reducing engine speed saves fuel and reduces noise in the cab Ground cutting speed can be maintained using this feature a Set Draper Minimum Speed as follows IMPORTANT Windrower can be moving but must be less than minimum draper speed NOTE DISPLAY will flash MIN CONV MPH or KPH to prompt the operator to change the minimum set point or increase ground speed if Ground Speed Pl...

Page 100: ...r index 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 6 5 7 2 Draper Speed Independent of Ground Speed Set the speed of the draper independently of ground speed as follows NOTE This procedure can also be used to change the draper speed on the go CAUTION Check...

Page 101: ... NO HEADER and the knife speed reverts to a range from 0 1400 strokes per minute and the operator can then pre set the speed NOTE The knife speed cannot be programmed outside the range specified for each header HEADER DESCRIPTION KNIFE SPEED Strokes Per Minute SPM TYPE SIZE FT MINIMUM MAXIMUM Draper DK 15 1500 1900 Draper DK 20 and 25 1400 1700 Draper DK 30 1200 1600 Draper DK 35 1500 Draper DK 40...

Page 102: ... to be sure all bystanders have cleared the area a Engage header b Using HEADER TILT SWITCHES set center link to mid range position 05 0 on DISPLAY c Push deck shift switch to desired delivery position See opposite d Using HEADER DOWN switch lower header fully with lift cylinders fully retracted e Using left float switch push to increase float or to decrease float on left side of header DISPLAY wi...

Page 103: ...ndrower ensure that float engagement pin is installed in storage location C and not installed at hole location D CAUTION Check to be sure all bystanders have cleared the area b Start the engine and activate HEADER DOWN button on the GSL to fully retract header lift cylinders c Slowly drive windrower forward so that feet E on windrower enter boots B on the header Continue to drive slowly forward un...

Page 104: ... the hook over the header pin 2 Activate HEADER TILT cylinder switches on GSL to extend or retract center link cylinder so that the hook lines up with the header attachment pin 3 Push down on rod end of link cylinder until hook engages pin on header and is locked 4 Check that center link is locked onto header by pulling upward on rod end of cylinder HYDRAULIC LINK WITH OPTIONAL SELF ALIGNMENT KIT ...

Page 105: ...s fully inserted and hairpin is installed behind bracket h Remove lynch pin from pin J in stand K i Hold stand and remove pin J j Reposition stand to storage position by inverting stand and relocating on bracket as shown Reinsert pin J and secure with lynch pin k Remove pin L from storage position in linkage and insert in hole M to engage float springs Secure with lynch pin l Disengage lift cylind...

Page 106: ... boots B on header d Lower stand C by pulling pin D inverting stand and relocating on bracket Reinsert pin D and secure with hairpin e Remove pin from linkage E to disengage float springs and insert in storage hole F Secure with lynch pin Repeat for opposite linkage IMPORTANT To prevent damage to the lift system when lowering header lift linkages without a header or weight box attached to windrowe...

Page 107: ... Activate header tilt cylinder switches on GSL to release load on center link cylinder K 2 Lift hook release L and lift hook M off header pin NOTE If optional center link self alignment kit is installed lift release L and then operate the link lift cylinder with REEL UP switch on GSL to disengage the center link from the header i Disconnect header drive hydraulics N and electrical harness O Refer ...

Page 108: ...ed can be independently changed from the knife speed by changing the drive sprocket Refer to A30S A30D and A40D Self Propelled Windrower Headers Operator s Manual Display the auger speed as follows ENGAGE HEADER HEADER INDEX SWITCH OFF ON GSL PRESS SELECTOR BUTTON OR SELECT SWITCH ON CDM FOR AUGER SPEED 00 0 99 0 00 0 150 rpm 99 0 320 rpm Auger Speed Not To Exceed 320 rpm DISPLAY SELECTOR DISPLAY ...

Page 109: ...the reel speed can be changed by installing a different size auger drive sprocket or by varying the windrower engine rpm Display the reel speed as follows ENGAGE HEADER HEADER INDEX SWITCH OFF ON GSL PRESS SELECTOR BUTTON OR SELECT SWITCH ON CDM FOR REEL RPM 15 00 85 00 YES 15 00 85 00 ENGAGE HEADER HEADER INDEX SWITCH OFF ON GSL PRESS SLOW DISPLAY SHOWS REEL RPM DONE SPEED 15 00 NO YES ON CDM PRE...

Page 110: ...he CDM displays NO HEADER and the knife speed reverts to a range from 0 1400 strokes per minute and the operator can then pre set the speed HEADER DESCRIPTION KNIFE SPEED Strokes Per Minute SPM TYPE SIZE MINIMUM MAXIMUM Auger A40 All 1400 1950 Auger A30S All 1250 1550 Auger A30D All 1550 1850 Suggested Overload Setting 75 of Knife Speed NOTE The knife speed cannot be programmed outside the range s...

Page 111: ...windrower ensure that float engagement pin is installed in storage location C and not installed at hole location D CAUTION Check to be sure all bystanders have cleared the area b Start the engine and activate HEADER DOWN button on the GSL to fully retract header lift cylinders c Slowly drive windrower forward so that feet E on windrower enter boots B on the header Continue to drive slowly forward ...

Page 112: ...r is sufficient 4 Proceed to step e HYDRAULIC LINK WITHOUT SELF ALIGNMENT KIT M200 STD M150 OPTION 1 Relocate the pin at the frame linkage as required to position the hook over the header pin 2 Activate HEADER TILT cylinder switches on GSL to extend or retract center link cylinder so that the hook lines up with the header attachment pin 3 Push down on rod end of link cylinder J until hook engages ...

Page 113: ...from fall of raised header always engage header lift cylinder stops when working on or around raised header f Engage lift cylinder stops on both lift cylinders g Install pin A through each boot and foot and secure with hairpin IMPORTANT Ensure pin A is fully inserted and hairpin is installed behind bracket h Remove pin L from storage position in linkage and insert in hole M to engage float springs...

Page 114: ...m pin A and remove pin from left and right header boots B on header d Remove pin from location C to disengage float springs and insert in storage hole D Secure with hairpin 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 D and not installed at hol...

Page 115: ... HYDRAULIC LINK M200 STD M150 OPTION 1 Activate HEADER TILT cylinder switch on GSL to release load on center link cylinder H 2 Lift hook release J and lift hook K off header pin NOTE If optional center link lift cylinder is installed lift release J and then operate the link lift cylinder from the cab to disengage the center link from the header h Disconnect header drive hydraulics L and electrical...

Page 116: ...ched to the windrower the disc will operate at the original set point CROP CONDITION DISC RPM Alfalfa Heavy 2100 2300 Light 1800 2000 Sudan Sorghum Haygrazer Timothy Tall and Stemmy 2300 2500 Short Grass Dense 2500 Thin 2000 2200 Suggested Overload Setting 1300 rpm NOTE Higher engine rpm may be required to engage the R80 16 FT header Do not exceed 1800 rpm Display and set the desired disc speed as...

Page 117: ...ed type and shape of windrow depending on crop density dryness and maturity Refer to the R80 Rotary Disc Self Propelled Windrower Header Operator s Manual Form 169089 for more information The position can be controlled from the windrower cab with the REEL UP and REEL DOWN switches on the GSL The drums are hydraulically driven and the rotational speed can be varied from 0 to 1000 rpm from the windr...

Page 118: ...EDURES Wear close fitting clothing and cover long hair Never wear dangling items such as scarves or bracelets Wear protective shoes with slip resistant soles a hard hat protective glasses or goggles and heavy gloves If more than one person is servicing the machine at the same time be aware that rotating a driveline or other mechanically driven component by hand for example accessing a lube fitting...

Page 119: ...ditioning Compressor Lubricant High quality soft de ionized or distilled water as recommended by supplier 7 3 1 3 Lubricants LUBRICANT SPEC DESCRIPTION USE Grease SAE Multi Purpose High Temp Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base As Required Unless Otherwise Specified Engine Oil Cummins SAE 15W40 Compliant With SAE Specs For API Class SJ And CH ...

Page 120: ...lements increase torque values by 5 7 3 2 1 1 SAE Bolts BOLT DIA A in NC BOLT TORQUE SAE 5 SAE 8 lbf ft N m lbf ft N m 1 4 9 12 11 15 5 16 18 24 25 34 3 8 32 43 41 56 7 16 50 68 70 95 1 2 75 102 105 142 9 16 110 149 149 202 5 8 150 203 200 271 3 4 265 359 365 495 7 8 420 569 600 813 1 640 867 890 1205 Torque categories for bolts and capscrews are identified by their head markings 7 3 2 1 2 Metric ...

Page 121: ...ions as in reassembly 7 3 2 2 2 O Ring Type a Inspect O ring and seat for dirt or obvious defects b On angle fittings back off the lock nut until washer A bottoms out at top of groove B in fitting c Hand tighten fitting until back up washer A or washer face if straight fitting bottoms on part face C and O ring is seated d Position angle fittings by unscrewing no more than one turn e Tighten straig...

Page 122: ...e pounds per square inch psi x 6 8948 kilopascals kPa x 00689 megapascals MPa Torque pound feet or foot pounds lbf ft or ft lbf x 1 3558 newton meters N m pound inches or inch pounds lbf in or in lbf x 0 1129 newton meters N m Temperature degrees Fahrenheit F F 32 x 0 56 Celsius C Velocity feet per minute ft min x 0 3048 meters per minute m min feet per second ft s x 0 3048 meters per second m s m...

Page 123: ...nder hooks C and D stops it at approximately a 40 angle b To close hood 1 Pull down on strap B grasp the hood when within reach and lower until hood engages latch A c Open the hood at the highest position as follows 1 Open hood to lowest position 2 Remove strap from hooks C and D and allow hood to raise fully to approximately 65 d To close hood 1 Grasp the strap at B and loop under upper hook C 2 ...

Page 124: ...n release latch A and move platform forward until it stops and latch re engages 7 5 2 OPENING CLOSING PLATFORM FOR MAJOR SERVICING To improve access to the hydraulics plumbing and battery the platforms can be swung away from the windrower Right side cab forward platform is shown a Open platform as follows 1 Open engine compartment hood to lowest position IMPORTANT Failure to open hood will result ...

Page 125: ...AUTION Do not stand on the platform in the unlocked position It is unstable and may result in a fall 5 Swing link D under platform b Close platform as follows 1 Swing link D out from under platform all the way forward 2 Move platform front cab forward end inboard while moving it away from the walking beam 3 Position link D on bracket and install bolt and nut C Do not fully tighten 4 Move platform ...

Page 126: ...se the Maintenance Checklist provided to keep a record of scheduled maintenance Refer to Section 7 14 MAINTENANCE SCHEDULE 7 6 1 PROCEDURE DANGER Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine a Wipe grease fitting with a clean cloth before greasing to avoid injecting dirt and grit b Inject grease through ...

Page 127: ...tinued FORMED CASTER WHEEL BEARING 1 PLACE BOTH WHEELS 200 TOP LINK TWO FITTINGS BOTH SIDES High Temp Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base WALKING BEAM PIVOT FORKED CASTER SPINDLE BEARINGS TWO PLACES BOTH WHEELS CASTER PIVOT BOTH SIDES ...

Page 128: ...ould return to normal 4 If the engine does not shutdown the seat position switches require adjustment See your MacDon Dealer d With the windrower moving at less than 5 mph 8 km h 1 Stand up out of the seat 2 The CDM will flash NO OPERATOR on the upper line and ENGINE SHUTDOWN 5 4 3 2 1 0 on the lower line accompanied by a steady tone At 0 the engine shuts down 3 If the engine does not shutdown the...

Page 129: ...to either tighten or loosen the pivot The nut should be tightened to snug and then backed off turn c Tighten jam nut C d Check movement of GSL e Reinstall the control panel B with the five screws A 7 7 3 2 GSL Fore Aft Movement The GSL should remain as positioned by the operator and yet can be moved without excessive force The spring is set at the factory to 1 25 in 32 mm shown on the illustration...

Page 130: ...d bolts A for looseness and ball joints B for any perceptible play or movement g Check steering link bolts C for looseness and ball joints D for any perceptible play or movement h If bolts are loose 1 Back off jam nut E 2 Tighten inside nut F to 70 80 ft lbf 95 108 N m 3 Hold inside nut F and tighten jam nut E to 60 70 ft lbf 81 95 N m i If steering rod ball joints B or steering link ball joints D...

Page 131: ...teering chain being too tight or too loose If the chain tension requires adjustment proceed as follows b Swivel the Operator s station to position steering column close to the door c At the base of the steering column check dimension X at spring H It should be 0 625 inches 16 mm d Adjust dimension X as follows 1 Loosen nut J and turn nut K to achieve 0 625 inches 16 mm dimension 2 Tighten nut J ag...

Page 132: ...ust or replace switch as follows a Place GSL in N DETENT shutdown engine and remove key b Remove the five screws A securing control panel B to console remove panel and store in the tray c From inside the console pull switch support C so that rubber nuts D pull out of mounting holes and remove switch support from console d Adjust switch E as follows 1 Loosen screws F and rotate switch on support su...

Page 133: ...AND SERVICING Form 169017 169087 169095 131 Revision C f Position switch support C inside console and push rubber nuts D into holes g Check operation of switch h Reinstall control panel B with five screws A C D B A ...

Page 134: ... Element Cleaner Gun clean element with compressed air 3 Hold nozzle next to inner surface and move up and down pleats IMPORTANT Air pressure must not exceed 100 psi 700 kPa Do not direct air against outside of element as dirt might be forced through to inside 4 Repeat steps 1 to 3 to remove additional dirt as required e Inspect filter before installing as follows 1 Hold a bright light inside elem...

Page 135: ...r E and cover F and position on cab wall over opening e Secure to cab wall with knobs D 7 7 6 3 A C 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 Section 7 10 2 Cooling Box Maintenance 7 7 6...

Page 136: ...event damage to the system These switches do not require any regular servicing or maintenance so if problems occur and the switches are suspect contact your MacDon Dealer If the compressor cycles rapidly due to rapid pressure changes the CDM displays a warning CHECK A C SYSTEM Contact your Dealer 7 7 6 6 Refrigerant and Oil IMPORTANT Perform the following steps whenever the machine is first starte...

Page 137: ...p and nozzle inspection is recommended every 2000 hours See your MacDon Dealer 7 8 2 MANUALLY TURNING ENGINE To manually turn the engine with the flywheel an access hole is provided on the left cab forward side for a barring tool that is available from Cummins Manually turn engine as follows IMPORTANT Ensure nothing falls into gearbox oil reservoir DANGER Stop engine and remove key from ignition b...

Page 138: ... Reconnect the battery k Close hood and move maintenance platform back to working position 7 8 3 OIL LEVEL Check engine oil level frequently and watch for any signs of leakage NOTE During the break in period a higher than usual oil consumption should be considered normal Check the oil level as follows a Stop the engine and remove the key Wait about 5 minutes b Open engine compartment hood to lowes...

Page 139: ...E The engine should be warm prior to changing the oil a Stop the engine and remove the key b Place a drain pan of about 5 U S gallons 20 litres under the engine oil drain c Remove oil pan drain plug C and allow the oil to completely finish draining d Check the condition of the used oil If either of the following is evident have your MacDon Dealer correct the problem before starting the engine 1 Th...

Page 140: ...n drain plug C m Remove oil filler pipe cap B and add engine oil The engine requires 10 6 U S quarts 10 litres of SAE 15W40 Compliant with SAE Specs for API Class SJ and CH 4 Engine Oil n Operate the engine at low idle and check for leaks at the filter and drain plug o Stop the engine wait 5 minutes and check the oil level Add or remove oil to bring oil to HIGH level mark on dipstick p Close engin...

Page 141: ...uld activate when operating in extremely dirty conditions in which case the filter element should be cleaned Under normal operating conditions filter servicing should be performed at the specified interval Refer to Section 7 14 MAINTENANCE SCHEDULE 7 8 5 1 Air Filter Servicing DANGER Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could ...

Page 142: ...gs or at least every three years IMPORTANT The secondary inner element should be replaced every third time the primary element is changed g Clean inside of canister and cover with a damp cloth IMPORTANT Leave secondary element in place to prevent ingress of dirt into engine intake h Pat sides of primary element gently to loosen dirt Do not tap element against a hard surface i Using a Dry Element C...

Page 143: ...p and push end cap fully onto housing r Rotate end cap clockwise until catch G engages housing to prevent end cap from turning s Close engine compartment hood 7 8 5 2 Charge Air Cooling After the intake air passes through the air filter it passes through the turbocharger which boosts the pressure This process heats the air so it is passed through a cooler before entering the engine intake The cool...

Page 144: ...d engage an idling machine WARNING To avoid personal injury or death from explosion or fire do not smoke or allow flame or sparks near windrower when servicing a Open engine compartment hood to highest position b Locate filter A on vent line against hydraulic oil reservoir c Release hose tension clamps B and slide away from filter Pull hoses off filter d Position new filter through hole in frame a...

Page 145: ...ose fuel supply valve E under fuel tank c Change primary filter C as follows 1 Clean around the filter head F 2 Disconnect Water In Fuel WIF sensor G from bottom of filter 3 Turn drain valve H by hand counter clockwise until draining occurs and drain filter into a container 4 Remove filter C with a filter wrench 5 Clean gasket mating surface 6 Screw the new filter C onto the filter mount until the...

Page 146: ...t use a filter wrench to install the filter Over tightening can damage the gasket and filter e Open fuel valve E under fuel tank f Prime the system Refer to Section 7 8 6 5 System Priming g Close engine compartment hood 7 8 6 3 Draining Fuel Tank Draining the fuel tank is necessary to remove old or contaminated fuel To drain the tank refer to following illustrations and proceed as follows a Stop t...

Page 147: ...ted into the primary fuel filter The separator is equipped with a sensor G that detects water in the fuel and alerts the operator on the CDM Drain the water and sediment as follows from the separator daily or at any time the CDM Water in Fuel WIF light illuminates a Stop engine and remove key b Place a container under the filter to catch spilled fluid c Turn drain valve M by hand 1 to 2 turns coun...

Page 148: ...ttings Personal injury and property damage can result IMPORTANT Bleeding the fuel system is not recommended nor required Manual priming will be required if The fuel filter is replaced Injection pump is replaced High pressure fuel lines are replaced Engine is run until fuel tank is empty Prime the fuel system as follows a Stop the engine and remove the key b Open engine compartment hood to lowest p...

Page 149: ...the cooling system perform the following DANGER Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine a Stop engine and remove key b Move the left cab forward platform to the open position for access to the coolant tank and radiator Ensure the platform latch is engaged in open position c Raise engine compartment ...

Page 150: ...annually preferably before off season storage Tester should indicate protection to temperatures of 30 F 34 C b Replace the cap if spring is stuck c Close engine compartment hood and move maintenance platform to working position 7 8 7 3 Changing Coolant Coolant should be drained and the system flushed and filled with new coolant every 2000 hours or 2 years M150 Change coolant and flush the system a...

Page 151: ...lve F k Start engine and turn temperature control knob to high Run engine until normal operating temperature is reached l Stop engine and drain water out before rust or sediment settles See steps d to g m Close drain valves and fill system with a solution of clean water and a heavy duty radiator cleaner Follow instructions provided with cleaner n After using cleaner solution again flush system wit...

Page 152: ... could engage an idling machine a Check the lubricant level every 50 hours as follows 1 Park the windrower on level ground shutdown the engine and remove the key 2 Remove plug A The lubricant should be visible through the hole or slightly running out b Add lubricant as follows 1 Raise engine compartment hood to highest position 2 Remove breather cap B and add lubricant until it runs out at A Use S...

Page 153: ...ut 1 U S gallon 4 litres under the gearbox c Remove drain plug C and allow the oil to completely finish draining d Install the drain plug C and remove the check plug A e Unscrew breather cap B and add lubricant The gearbox will require 2 2 U S quarts 2 1 litres Add sufficient lubricant until it slightly runs out of hole A Use SAE 75W 90 API Service Class GL 5 Fully Synthetic Transmission Lubricant...

Page 154: ...low exhaust gases to escape to the cab c Dents or crushed portions of any tubing create exhaust flow restriction and increase back pressure significantly Even relatively small dents will cause decreased fuel economy and increased turbo wear If dents are relatively large increased bearing and cylinder wear will occur due to increased exhaust temperature d The exhaust system should be secured to eli...

Page 155: ... check tension and re adjust as required 7 8 10 2 A C Compressor Belt Replacement a Shutdown the engine and open engine compartment access hood to lowest level Refer to illustration opposite b Loosen compressor mounting hardware B and push compressor towards engine to release tension c Remove belt A d Install new belt A on pulleys e Pry compressor away from engine so that a force of 8 to 12 lbf 35...

Page 156: ...y from engine so that a force of 8 to 12 lbf 35 55 N deflects the belt A 3 16 inch 5 mm at mid span n Tighten compressor mounting hardware B o Re check tension and re adjust as required p Move maintenance platforms to working position and close engine compartment hood 7 8 11 ENGINE SPEED The maximum and idle engine speeds are factory set to the specifications See Section 4 SPECIFICATIONS If specif...

Page 157: ...e oil level frequently and watch for any signs of leakage NOTE During the break in period a higher than usual oil consumption should be considered normal Check the oil level as follows a Stop the engine and remove the key Wait about 5 minutes b Open engine compartment hood to lowest position c Remove dipstick by turning it counter clockwise to unlock and remove shown in previous column d Wipe clea...

Page 158: ...emove filter C with a filter wrench h Clean gasket mating surface i Apply a thin film of clean oil to the gasket on the new filter j Screw the new filter onto the filter mount until the gasket contacts the filter head k Tighten the filter an additional to turn by hand IMPORTANT Do not use a filter wrench to install the oil filter Over tightening can damage the gasket and filter l Install the oil p...

Page 159: ...equires cleaning NOTE The warning light could activate when operating in extremely dirty conditions in which case the filter element should be cleaned Under normal operating conditions filter servicing should be performed at the specified interval Refer to Section 7 14 MAINTENANCE SCHEDULE 7 9 4 1 Air Filter Servicing DANGER Stop engine and remove key from ignition before leaving Operator s seat f...

Page 160: ...cleanings or at least every three years IMPORTANT The secondary inner element should be replaced every third time the primary element is changed f Clean inside of canister and cover with a damp cloth IMPORTANT Leave secondary element in place to prevent ingress of dirt into engine intake g Pat sides of primary element gently to loosen dirt Do not tap element against a hard surface h Using a Dry El...

Page 161: ... engages housing to prevent end cap from turning r Close engine compartment hood 7 9 5 ASPIRATOR HOSE AND CHECK VALVE REPLACEMENT Inspect hose and valve for signs of overheating that may result if the check valve is not working properly Replace as follows a Remove plastic ties A securing hose assembly C to bracket on engine b Remove hose clamps B securing hose to muffler and to air cleaner Remove ...

Page 162: ... 169087 169095 160 Revision C d Assemble hose clamps B to hose and attach hose assembly to muffler and air filter e Ensure arrows on inlet side of check valve points up f Tighten clamps and install plastic ties A to hold valve in correct orientation A ...

Page 163: ...windrower when servicing a Open engine compartment hood to highest position b Locate filter A on vent line against hydraulic oil reservoir c Release hose tension clamps B and slide away from filter Pull hoses off filter d Position new filter through hole in frame and attach top hose onto filter IN marking should face down NOTE If filter has an arrow instead of an IN marking arrow should point up e...

Page 164: ...ove the tube and hand tighten drain 4 If equipped remove wiring harness from sensor H on bottom of glass bowl J 5 Hold glass bowl and remove screw K Remove glass bowl from filter 6 Remove filter C with a filter wrench 7 Discard filter and seals 8 Clean bowl 9 Lubricate O ring seal with clean engine oil and screw the new filter C onto the filter mount until the gasket contacts the filter head 10 Ti...

Page 165: ... is full and resistance is felt on the pump If engine does not start repeat this procedure h Close engine compartment hood i Remove the container and dispose of the fluid in a safe place 7 9 6 3 Separator A fuel water separator is incorporated into the primary fuel filter Drain the water and sediment as follows from the separator daily DANGER Stop engine and remove key from ignition before leaving...

Page 166: ... engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine a Stop the engine and remove the key b Open engine compartment hood to lowest position c Close fuel supply valve A d Place a drain pan of about 5 U S gallons 20 litres under the fuel supply line B e Loosen clamp C and pull hose B off fitting f Route hose to drain ...

Page 167: ...ction pump supply line will be vented automatically if the fuel filters are changed in accordance with instructions WARNING The fuel pump high pressure fuel lines and fuel rail contain extremely high pressure fuel Never loosen any fittings Personal injury and property damage can result IMPORTANT Bleeding the fuel system is not recommended nor required Manual priming may be required if The fuel fil...

Page 168: ...the cooling system perform the following DANGER Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine a Stop engine and remove key b Move the left cab forward platform to the open position for access to the coolant tank and radiator Ensure the platform latch is engaged in open position c Raise engine compartment ...

Page 169: ... annually preferably before off season storage Tester should indicate protection to temperatures of 30 F 34 C b Replace the cap if spring is stuck c Close engine compartment hood and move maintenance platform to working position 7 9 7 3 Changing Coolant Coolant should be drained and the system flushed and filled with new coolant every 3000 hours or 2 years Change coolant and flush the system as fo...

Page 170: ...hutoff valve C CAUTION To avoid personal injury from hot coolant do not remove plug until engine cools i Remove drain plug D in engine block so that coolant drains It is located at the forward right hand end on the block j When system is drained replace drain plug in block D and close radiator drain valve B k Fill system with clean water through the radiator filler pipe A and replace radiator cap ...

Page 171: ...lution again flush system with clean water See steps k to m Inspect radiator hoses and fittings for leaks q Close radiator drain valve B and replace block drain plug D r Fill system through radiator filler pipe A Use Ethylene Glycol with SCA equal parts with high quality soft de ionized or distilled water as recommended by the supplier System capacity is 5 3 U S Gallons 20 litres s Close radiator ...

Page 172: ...engage an idling machine a Check the lubricant level every 50 hours or weekly as follows 1 Park the windrower on level ground shutdown the engine and remove the key 2 Remove plug A The lubricant should be visible through the hole or slightly running out b Add lubricant as follows 1 Raise engine compartment hood to highest position 2 Remove breather cap B and add lubricant until it runs out at A Us...

Page 173: ...nder the gearbox c Remove drain plug C and allow the oil to completely finish draining d Install the drain plug C and remove the check plug A e Unscrew breather cap B and add lubricant The gearbox will require 2 2 U S quarts 2 1 litres Add sufficient lubricant until it slightly runs out of hole A Use SAE 75W 90 API Service Class GL 5 Fully Synthetic Transmission Lubricant SAE J2360 preferred f Rep...

Page 174: ...y allow exhaust gases to escape to the cab c Dents or crushed portions of any tubing create exhaust flow restriction and increase back pressure significantly Even relatively small dents will cause decreased fuel economy and increased turbo wear If dents are relatively large increased bearing and cylinder wear will occur due to increased exhaust temperature d The exhaust system should be secured to...

Page 175: ...rdware B 3 Pry compressor away from engine so that a force of 8 to 12 lbf 35 55 N deflects the belt A 3 16 inch 5 mm at mid span 4 Tighten compressor mounting hardware 5 Re check tension and re adjust as required 7 9 10 2 A C Compressor Belt Replacement a Shutdown the engine and open engine compartment access hood to lowest level Refer to illustration opposite b Loosen compressor mounting hardware...

Page 176: ... until fan belt D can be slipped off pulley E Release tensioner and remove wrench g Remove belt from flywheel pulley F and then fan pulley G Route belt around fan and remove belt h Install new belt D around fan and onto pulleys in G and F i Insert the drive end of a inch drive ratchet wrench into the belt tensioner C j Rotate tensioner clockwise until belt D can be slipped onto pulley E Release te...

Page 177: ...ngine and remove key b Raise engine compartment hood fully c If rotors A are plugged clean as follows 1 Remove nut B 2 Pivot rotor assembly C away from screen 3 Blow out debris from rotors A with compressed air d Push latch D and open screen assembly access door E Secure with rod F stored inside screen door e If duct G is plugged blow out debris with compressed air f Clean screen with compressed a...

Page 178: ...08 0 24 in 2 6 mm from screen near the center 3 Re tighten nut B 4 Loosen the two motor mount bolts H 5 Move motor rotor assembly J to obtain 0 04 0 32 in 1 8 mm gap between rotor to screen at full rotation of the rotor 6 Re tighten bolts H on motor mount j Close screen access door E and engage latch D k Lower engine compartment hood B C 0 08 0 24 in 2 6 mm H J 0 04 0 32 in 1 8 mm D E ...

Page 179: ...seat for any reason A child or even a pet could engage an idling machine a Stop engine and remove key b Raise engine compartment hood fully c Push latch A and open screen assembly access door B Secure with rod C stored inside the screen door d Rotate retainer D pull open condenser E and secure with support rod at F e Lift lever G and lower guard H The guard prevents the platform from inadvertently...

Page 180: ...K charge air cooler S air conditioning condenser E and cooling box T with compressed air k Slide oil cooler K back into cooling box l Close side access door J raise guard H and lock with lever G m Close side door N and top door Q and secure with retainers n Remove support rod at F swing condenser E back into position and secure with retainer D o Unhook support rod C in screen door and store at bas...

Page 181: ...der these conditions would be severely shocked When working around storage batteries remember that all of the exposed metal parts are live Never lay a metal object across the terminals because a spark or short circuit will result 7 11 1 1 Maintenance 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 a...

Page 182: ...5 F 52 C Follow all instructions and precautions furnished by the battery charger manufacturer Charge at recommended rates and times 7 11 1 4 Boosting A twelve volt battery can be connected in parallel to with the windrower battery Use heavy duty battery cables CAUTION Gas given off by batteries is explosive Keep sparks and flames away from batteries Make last connection and first disconnection at...

Page 183: ...d battery as gas given off by electrolyte is explosive Battery electrolyte causes severe burns Avoid contact with skin eyes or clothing Wear protective eyewear and heavy gloves WARNING If electrolyte is spilled or splashed on clothing or on the body neutralize it immediately with a solution of baking soda and water then rinse with clean water Electrolyte splashed into the eyes is extremely dangero...

Page 184: ...ps B on negative terminals and remove cable from batteries e Remove bolts C securing strap D to frame and remove strap f Lift batteries off holder E RATING GROUP CCA VOLT MAX DIMENSION Heavy Duty Off Road Vibration Resistant BCI 31A 750 12 13 x 6 81 x 9 44 in 330 x 173 x 240 mm NOTE Battery holder E can be removed from frame by simply lifting holder and pulling it away from frame g Position new ba...

Page 185: ...lternator wire See also Section 7 1 1 Welding Precautions e Always disconnect battery ground cable when working with the alternator or regulator f Never attempt to polarize alternator or regulator g If wires are disconnected from the alternator use the illustration below to ensure proper reconnection h Never ground the alternator field terminal or field circuit i Never connect or disconnect altern...

Page 186: ... engine and remove the key c Turn on the headlights A and switch to low beam d Align the headlights to the following specifications by turning adjusting screws B Adjustments are for low beam Light beams laterally centered on the direction of travel line from the headlights i e not skewed left or right Upper limit of the beam not higher than 49 inches 1263 mm above ground at a distance of 25 ft 7 5...

Page 187: ...as the oils or other chemicals from your skin will cause the bulb to fail prematurely e Align lugs on new bulb with slots G in body and push into place f Secure bulb with wire retainer E g Replace rubber insulator boot D h Push connector onto light bulb i Position headlight into light receptacle ensuring top is up and secure with screws C NOTE Aligning of light should not be necessary E F G E F D ...

Page 188: ...djust the lights with screws B 7 11 3 2 Bulb Replacement a Remove the two screws C and remove light assembly b Replace the bulb as described in Section 7 11 2 2 7 11 4 FLOOD LIGHTS FORWARD The forward floodlights are not adjustable Replace bulbs as follows a Shutdown engine and remove the key Turn off the lights b Hold onto the hand holds A on the cab front corners and stand on the header anti sli...

Page 189: ... E and screws D 7 11 5 FLOOD LIGHTS REAR DANGER Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine 7 11 5 1 Adjustment The rear floodlights are best adjusted with the machine in the field or the equivalent to suit operator preference a Shutdown engine and remove the key Turn on lights b Loosen bolts A and B c ...

Page 190: ...s up and secure with bezel K and screws C 7 11 6 RED AND AMBER 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 a Shutdown engine and remove the key Turn off the lights NOTE Hold onto the hand holds A on the cab front corners and stand on the header anti slip strips or stand on the maintenance ...

Page 191: ...from light B and remove light c Remove connector from light d Connect wiring harness to new light and install light with screws A 7 11 8 BEACONS IF INSTALLED a Shutdown engine and remove the key Turn off the beacons NOTE Hold onto the hand holds on the cab front corners and stand on the header anti slip strips or stand on the maintenance platform when accessing the red and amber lights b Turn lens...

Page 192: ...r chemicals from your skin will cause the bulb to fail prematurely f Connect harness to new lamp place lamp in socket and line up flat side on lamp with recess in socket g Place retainer over lamp and pinch tabs to secure retainer to socket h Line up the three lugs one is longer in the base with slots in lens and seat the lens against the rubber seal i Turn the lens clockwise to lock it in place ...

Page 193: ... turn clockwise until it locks g Push gauge into console h Locate bracket C onto back of gauge and secure with nut B Tighten nut to 75 96 in oz 530 678 mN m i Replace gauge access hole decal A 7 11 10 DOME LIGHT a Shutdown engine b Remove two screws A from plastic lens and remove lens c Replace bulb d Reinstall plastic lens with screws A 7 11 11 AMBIENT LIGHT a Shutdown engine b Push against tabs ...

Page 194: ...remove key b Move right cab forward side platform rearward c Remove wing nut A and remove fuse box cover B d Refer to decal on inside of cover for identification of fuses and circuit breakers See illustration on next page 7 11 13 1 Checking Replacing Fuses a To check fuse pull fuse C out of receptacle and visually examine b To replace fuse insert new fuse into receptacle IMPORTANT Replacement fuse...

Page 195: ...MAINTENANCE AND SERVICING Form 169017 169087 169095 193 Revision C 7 11 13 3 Fuse Box Decal ...

Page 196: ...age an idling machine a Stop engine and remove key b Move right cab forward side platform rearward c To check condition of fuse pull tab A and open cover B d Visually examine fuse C for indications of melting e To remove fuse C remove two nuts D and pull fuse free from holder Existing wiring may need to be pulled off the stud first f Install new fuse on studs and any existing wiring that was remov...

Page 197: ...of it with unused diesel fuel or unused commercial petroleum cleaning solvent for ten seconds minimum Do not use water water soluble cleaners or compressed air IMPORTANT The components in this system are built to very close tolerances and have been adjusted at the factory Do not attempt to service these components except to maintain proper oil level change oil and filters and to adjust relief pres...

Page 198: ... 10 2 Cooling Box Maintenance 7 12 4 HYDRAULIC OIL FILTERS NOTE Change hydraulic oil filters after the first 50 hours of operation and every 500 hours thereafter Filter A part 112419 and filter B part 110474 can be obtained from your MacDon Dealer The hydraulic system contains two filters Change hydraulic oil filters as follows DANGER Stop engine and remove key from ignition before leaving Operato...

Page 199: ...nsator valve may require adjusting Contact your Windrower Dealer or refer to the Technical Service Manual for your Windrower WINDROWER MODEL HEADER MODEL APPLICATION SYSTEM SUGGESTED OVERLOAD WARNING SETTING psi kPa WINDROWER PRESSURE COMP SETTING psi kPa M150 D60 and A40D Reel Draper Pressure 3000 20684 3200 22063 M150 D60 and A40D Knife Conditioner Pressure 4000 27579 4200 28958 M150 R80 Disc Pr...

Page 200: ...ing Operator s seat for any reason A child or even a pet could engage an idling machine a Lower header to ground stop engine and remove key b Move left cab forward side platform rearward c Loosen jam nut A on needle valve and turn screw B clockwise to decrease the drop rate or counter clockwise to increase the drop rate d Tighten jam nut A e Close platform and engine compartment hood f Check drop ...

Page 201: ...for leakage c Check the charge pressure relief valve Refer to following section d If charge pressure still cannot be maintained do not operate the windrower Contact your Windrower Dealer 7 12 6 2 Charge Pump Pressure Incorrect charge pressure settings may result in the inability to build required system pressure and or inadequate loop flushing flows Correct charge pressure must be maintained under...

Page 202: ...f pressure g Remove pressure gauge hose and reinstall cap A to fitting 7 12 7 HOSES AND LINES Check hydraulic hoses and lines daily for signs of leaks WARNING Avoid high pressure fluids Escaping fluid can penetrate the skin causing serious injury Relieve pressure before disconnecting hydraulic lines Tighten all connections before applying pressure Keep hands and body away from pin holes and nozzle...

Page 203: ...emove install or make repairs to a tire on a rim unless you have the proper equipment and experience to perform the job Take the tire and rim to a qualified tire repair shop If the tire is not in correct position on the rim or if too full of air the tire bead can loosen on one side causing air to leak at high speed and with great force An air leak of this nature can thrust the tire in any directio...

Page 204: ... API Service Class GL 5 Extreme Pressure Gear Lubricant After first change use SAE 75W 90 API Service Class GL 5 Fully Synthetic Transmission Lubricant SAE J2360 preferred c Replace plugs and tighten d Change the lubricant as follows 1 Rotate the wheel so that plug A is located at the bottom 2 Place a large enough container about 2 quarts U S 2 litres under the drain plug A 3 Remove plugs A and B ...

Page 205: ...ne and remove key d Jack up windrower under leg jack point and raise windrower wheel slightly off ground e Undo wheel nuts A and remove wheel f To install new tire ensure that air valves are on outside and tire tread point forward For Turf tires diamond tread be sure arrow on sidewall points in forward rotation g Position wheel on hub and install wheel nuts A h Tighten nuts A to 220 ft lbf 300 N m...

Page 206: ...d wheel rim Never weld a wheel rim Make sure all the air is removed from a tire before removing the tire from the rim Never use force on an inflated or partially inflated tire Make sure the tire is correctly seated before inflating to operating pressure Do not remove install or make repairs to a tire on a rim unless you have the proper equipment and experience to perform the job Take the tire and ...

Page 207: ...S lb kg 7 5X16 A 10 38 200 91 10X16 B 18 69 380 170 16 5X16 1 C 41 158 830 377 Weights are given for typical calcium chloride and water mixtures Weight is reduced by 20 if only water is used for areas that do not require antifreeze protection HEADER DESCRIPTION RECOMMENDED BALLAST RECOMMENDED TIRE SIZE APPLICABLE WINDROWER LEVEL GROUND HILLS TYPE SIZE PER TIRE BOTH TIRES PER TIRE BOTH TIRES U S Ga...

Page 208: ... remove key before performing any of the following checks and or adjustments a Remove the caster wheel as follows 1 Park windrower on level ground and block all wheels 2 Place GSL in N DETENT Shutdown engine and remove key 3 Raise end of walking beam using a jack 4000 lb 1816 kg capacity or other suitable lifting device until the wheel is slightly off the ground 4 Remove the eight bolts C attachin...

Page 209: ...capacity or other suitable lifting device until the wheel is slightly off the ground 4 Undo the six wheel bolts E and remove wheel from hub b Install the caster wheel as follows 1 Position wheel on hub and install wheel bolts E 2 Torque nuts E to 120 ft lbf 163 N m using the tightening sequence as shown on previous page 3 Lower windrower and remove jack 7 13 2 6 Caster Wheels Anti Shimmy Dampeners...

Page 210: ...ds etc CAUTION Carefully follow safety messages given under Section 7 1 PREPARATION FOR SERVICING and Section 7 2 RECOMMENDED SAFETY PROCEDURES 7 14 1 BREAK IN INSPECTIONS BREAK IN INSPECTIONS HOURS ITEM CHECK EVERY 25 Road or 1 in Field Drive Wheel Nuts Torque 220 ft lbf 300 N m Repeat Checks Until Torque Stabilizes 5 A C Belt Tension Caster Wheel Nuts Torque 120 ft lbf 163 N m Caster Wheel Anti ...

Page 211: ...ter Pivot 3 Grease Top Lift Link Pivots 4 Grease Forked Caster Spindle Bearings 5 Clean Cab Fresh Air Intake Filter 6 Check Gear Box Oil Level 100 HOURS OR ANNUALLY 1 Clean Cab Air Return Filter 200 HOURS OR ANNUALLY 1 Check Drive Wheel Lubricant Level 2 Grease Formed Caster Wheel Hub Bearings 3 Check Wheel Nut Torque 500 HOURS 1 Change Engine Oil And Filter or Annually 2 Change Fuel Filters 3 Cha...

Page 212: ...ED BUT IS AT THE OWNER OPERATOR S DISCRETION A C Condenser Charge Air Cooler 9 Engine Oil Level 9 Engine Coolant Level 9 Fuel Tank 9 Fuel Filter Water Trap 9 Hydraulic Hoses And Lines Hydraulic Oil Cooler 9 Hydraulic Oil Level Radiator 9 Tire Inflation ANNUALLY 9 A C Blower 9 Antifreeze Concentration 9 Battery Charge 9 Battery Fluid Level S Fuel Tank Vent Line Filter 9 Steering Control Rod Ball Jo...

Page 213: ...ers 9 Engine Valve Tappet Clearance 1 st M200 ONLY S Engine Air Cleaner Filter Element M200 ONLY S Crankcase Breather M200 ONLY S Gearbox Lubricant S Hydraulic Oil Filters 9 Safety Systems or Annually 1000 HOURS S Drive Wheel Lubricant S Engine Air Cleaner Filter Element M150 ONLY 9 Engine Valve Tappet Clearance 2000 HOURS S Engine Coolant M150 ONLY 9 General Inspection S Hydraulic Oil 3000 HOURS ...

Page 214: ...y electrolyte level 7 11 1 Poor battery connection Clean and tighten loose connections Faulty starter Contact MacDon Dealer Wiring shorted circuit breaker open Check continuity of wiring and breaker manual reset 7 11 13 Loose electrical connection at fuel pump Ensure connector at pump is fully pushed in ECM fuse 1 of 2 blown ECM Ignition relay faulty Neutral Logic relay faulty Replace 7 11 13 Faul...

Page 215: ...check thermostat See Engine Overheats below Improper valve clearance Contact MacDon Dealer Faulty injectors Engine Temperature Below Normal Defective thermostat Remove and check thermostat Warning Alarm Sounds Engine overheated Check coolant level 7 8 7 7 9 7 Check thermostat Low engine oil pressure Check oil level 7 8 3 7 9 2 Low transmission oil pressure 7 12 1 Engine Overheats Low coolant level...

Page 216: ... Engine out of time Air in fuel system Engine Emits White Exhaust Improper type of fuel Consult your fuel supplier and use proper type fuel for conditions 7 3 1 Cool engine Warm engine up to normal operating temperature 6 3 5 2 Defective thermostat Remove and check thermostat Engine out of time Contact MacDon Dealer Starter Cranks Slowly Or Will Not Operate Low battery output Check battery charge ...

Page 217: ...rcuit breaker Check circuit breaker 7 11 13 Defective relay Replace relay Poor ground on lights Clean and tighten ground wires Turn Signals Or Indicators Showing Wrong Direction Reversed wires Contact MacDon Dealer No Current To Cab Circuit breaker tripped Breaker automatically resets Broken or disconnected wire Contact MacDon Dealer Battery disconnect switch is off Turn on switch 7 11 1 2 8 3 HYD...

Page 218: ...alarm wiring Faulty sender Wheels Lack Pulling Ability On A Grade Or Pulling Out Of A Ditch Insufficient torque at drive wheels Move speed range control to field position and reduce ground speed 6 3 6 Loose or worn controls Check controls 7 7 3 Air in system Use proper oil 7 3 1 3 Check oil level and leaks 7 12 1 Check hydraulic oil filters 7 12 4 Brakes binding or not releasing fully Check pressu...

Page 219: ...More Than The Other Leakage at pump or motor Contact MacDon Dealer Wheels not in same speed range Faulty relief valve Repair or replace valve 7 12 6 2 Excessive Noise From Drive System Hydraulic line clamps loose Tighten clamps Mechanical interference in steering or ground speed linkage Adjust repair replace 7 7 3 7 7 4 Brakes binding or not releasing fully Check pressure min 200 psi on brake rele...

Page 220: ...0 1 Defective thermostat in engine water outlet manifold Replace thermostat Heater temperature control defective Replace control No thermostat in engine water outlet manifold Install thermostat Odour From Air Louvers Plugged drainage hose Blow out hose with compressed air Dirty filters Clean filters 7 7 6 1 7 7 6 2 Air Conditioning Not Cooling Low refrigerant level Add refrigerant Switch contacts ...

Page 221: ...culation over condenser coil fins clogged with dirt or insects Clean condenser 7 10 2 Evaporator fins clogged Clean evaporator fins under cab floor 7 7 6 4 Too little refrigerant in system Clogged expansion valve Clogged receiver drier Excessive moisture in system Air in system Blower motor sluggish in operation Contact MacDon Dealer Thermostat defective or improperly adjusted Replace thermostat A...

Page 222: ...system Incorrect super heat adjustment in expansion valve Contact MacDon Dealer Thermostat defective Defective blower switch or blower motor Partially open improper ground or loose connection in compressor clutch coil Windows Fog Up High humidity Run A C to dehumidify air and heater to control temperature 5 10 3 8 8 OPERATOR S STATION SYMPTOM PROBLEM SOLUTION SECTION Rough Ride Seat suspension not...

Page 223: ... spring tension for float Installation instructions are included 9 8 WINDSHIELD SHADES Retractable sun shades for front and rear windows Installation instructions are included 9 9 DISC HEADER VALVE Required for attaching a R80 Disc Header to M150 Installation instructions are included 9 10 AM FM RADIO Available for installation into pre wired cab Speakers are factory installed Refer to M150 and M2...

Page 224: ...rovide installation and support services Cabs have been prepared with access routing knock outs to enable easy wiring harness installation and display mounting The GSL has been pre wired with an auto steer engage switch 9 19 LIGHTING AND MARKING KIT FOR CAB FORWARD ROAD TRAVEL Allows the windrower to travel in the cab forward mode on public roads and comply with vehicle lighting regulations The ki...

Page 225: ...le 17 Cooler 25 Daily Check 54 Deck Shift Switch 32 Dimensions 14 Disc Header attachment 109 detaching 112 disc speed set point 114 disc speed switch 31 Display set up 47 Display Warnings 42 Double Windrowing 87 Draper Header attachment 88 deck shift 100 detaching 91 draper speed 97 knife speed 99 reel speed 94 Drive Wheels 201 bolt torque 201 lubricant 202 removal installation 203 Driving cab for...

Page 226: ...eight control 85 levelling 81 lift cylinder stops 77 monitoring 33 on off switch 29 operation 77 position switch 31 programming 44 return to cut 85 reverse 82 reverse switch 29 stand 90 troubleshooting 216 Header Control Switches 30 32 Header Controls 29 Headlights alignment 184 Heater controls 24 shut off valve 23 Height Control 85 Hub Locks 76 Hydraulic System 195 charge pump pressure 199 oil ch...

Page 227: ... replace 188 replace 189 Tire Inflation caster wheels 204 drive wheels 201 Torques 118 Towing header 68 tow pole 70 Towing Windrower 75 76 Traction Drive System GSL adjustment 127 hub locks 76 park brake 130 park brake switch 130 steering links 128 troubleshooting 216 217 Training Seat 19 Transporting 66 Troubleshooting air conditioning 218 electrical 215 engine 212 header drive 216 hydraulics 215...

Page 228: ...t detected short circuit open circuit E 40 E140 H I G H R A N G E V 5 A High range solenoid V5A fault detected short circuit open circuit E 41 E141 R E E L A F T V 2 C Reel aft solenoid V2C fault detected short circuit open circuit E 42 E142 R E E L F O R E V 4 C Reel fore solenoid V4C fault detected short circuit open circuit E 43 E143 R E E L U P D O W N V 4 B Reel up down solenoid V4B fault det...

Page 229: ... Erratic Intermittent or Incorrect 3 Red 131 91 Accelerator Pedal or Lever Position Sensor Circuit Voltage Above Normal or Shorted to High Source 4 Red 132 91 Accelerator Pedal or Lever Position Sensor Circuit Voltage Below Normal or Shorted to Low Source 8 154 91 Abnormal frequency pulse width or period 12 154 91 Bad Device or component 19 Red 287 SAE J1939 Multiplexing Accelerator Pedal or Lever...

Page 230: ... 172 Intake Manifold Air Temperature Sensor Circuit Voltage Above Normal or Shorted to High Source 4 Amber 154 172 Intake Manifold Air Temperature Sensor Circuit Voltage Below Normal or Shorted to Low Source 15 None 2964 539 Intake Manifold Temperature High Data Valid but Above Normal Operational Range Least Severe Level 16 Amber 488 539 Intake Manifold 1 Temperature Data Valid but Above Normal Op...

Page 231: ... Moderately Severe Level 18 Amber 441 Battery 1 Voltage Low Data Valid but Below Normal Operational Range Moderately Severe Level Ambient Air Temperature 171 3 Amber 249 Ambient Air Temperature Sensor Circuit Voltage Above Normal or Shorted to High Source 4 Amber 256 Ambient Air Temperature Sensor Circuit Voltage Below Normal or Shorted to Low Source Fuel Temperature 174 3 Amber 263 Engine Fuel Te...

Page 232: ... 434 Power Lost without Ignition Off Data Erratic Intermittent or Incorrect Controller 1 629 12 Red 111 Engine Control Module Critical internal failure Bad intelligent Device or Component Calibration Memory 630 2 Amber 341 268 Engine Control Module data lost Data Erratic Intermittent or Incorrect 13 Red 342 Electronic Calibration Code Incompatibility Out of Calibration 31 Amber 2217 ECM Program Me...

Page 233: ...roperly or Out of Adjustment 8 142 342 Abnormal signal frequency Intake Air Heater 1 729 3 Amber 2555 Intake Air Heater 1 Circuit Voltage Above Normal or Shorted to High Source 4 Amber 2556 Intake Air Heater 1 Circuit Voltage Below Normal or Shorted to Low Source Internal Sensor Voltage Supply 1043 3 Amber 387 Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit Voltage Above Normal o...

Page 234: ...84 31 None 211 Additional Auxiliary Diagnostic Codes logged Condition Exists Control Module Identification Input State 1563 2 Amber 1256 Control Module Identification Input State Error Data Erratic Intermittent or Incorrect Accelerator Pedal Position 2623 3 Amber 1239 Accelerator Pedal or Lever Position Sensor 2 Circuit Voltage Above Normal or Shorted to High Source 4 Amber 1241 Accelerator Pedal ...

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MacDon M150, Operator'S Manual

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