MacDon M205 2010 Operator'S Manual Download Page 2

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This Manual contains instructions for “SAFETY”, “OPERATION”, and “MAINTENANCE/SERVICE” for your new MacDon

Model M205 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

Summary of Contents for M205 2010

Page 1: ...M205 Self Propelled Windrower OPERATOR S MANUAL Revision C Part 169469 25...

Page 2: ...elf 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 h...

Page 3: ...on about the machine If you follow the instructions given in this manual your M205 Windrower will work well for many years If you require more detailed service information check with your dealer Use t...

Page 4: ...abilizer Wheel Option if installed and the Combine Adapter on the lines below WINDROWER SERIAL NO __________________YEAR_____ Serial Number Plate is located on the left cab forward side of the main fr...

Page 5: ...rward Lighting Road Optional 24 5 7 4 Beacon Lighting Export N A Optional 25 5 8 WINDSHIELD WIPERS 26 5 9 REAR VIEW MIRRORS 26 5 10 CAB TEMPERATURE 26 5 10 1 Heater Shut Off Valve 26 5 10 2 Air Distri...

Page 6: ...6 5 5 Reel Height 97 6 5 6 Reel Speed 98 6 5 7 Draper Speed 100 6 5 8 Knife Speed 102 6 5 9 Deck Shift Optional 103 6 6 A SERIES HEADER OPERATION 104 6 6 1 Header Attachment 104 6 6 2 Header Detachmen...

Page 7: ...7 10 10 Dome Light 177 7 10 11 Ambient Light 177 7 10 12 Turn Signal Indicators 177 7 10 13 Circuit Breakers and Fuses 178 7 11 HYDRAULIC SYSTEM 181 7 11 1 Oil Level 181 7 11 2 Hydraulic Oil Cooler 1...

Page 8: ...WINDSHIELD SHADES 208 9 10 AM FM RADIO 208 9 11 PRESSURE SENSOR KIT 208 9 12 WEIGHT BOX 208 9 13 TOWING HARNESS 208 9 14 SWATH ROLLER 208 9 15 WARNING BEACONS 208 9 16 AUTO STEER 208 9 17 LIGHTING AN...

Page 9: ...st unsafe practices CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It is also used as a reminder of good safety practices 3 3 SAFETY SIG...

Page 10: ...9469 169470 169471 8 Revision C Safety Sign Locations continued LIFT LINKAGES 163561 FRONT OF PLATFORM 134070 BELOW DOOR HANDLE 32744 IN CAB 32744 BEHIND DOOR ON SILL LH SIDE ONLY 160396 BEHIND DOOR O...

Page 11: ...SAFETY Form 169469 169470 169471 9 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 12: ...SAFETY Form 169469 169470 169471 10 Revision C Safety Sign Locations continued ON FRAME 110986 ON COOLER TOP DOOR EXHAUST COVER 139668 ON FAN SHROUD 134068 ON FRAME 42130...

Page 13: ...SAFETY Form 169469 169470 169471 11 Revision C Safety Sign Locations continued ON DRINK COOLER 160429 INSIDE FRAME 32743 ON FRAME 110986 ON LIFT LINKAGE 163562...

Page 14: ...de 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 f...

Page 15: ...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 S...

Page 16: ...Attachment ECM Engine Control Module Engine Forward Windrower operation with the operator and engine facing in the direction of travel GSL Ground Speed Lever Header A machine that cuts and lays crop...

Page 17: ...erse Cab Fwd 6 mph 9 6 km h Transport Engine Fwd 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 167 L min Final Drive Type...

Page 18: ...tioning 28 280 Btu h 8288 W Electrical Outlets One Live Two On Ignition One Live Keyed Mirrors One Inside Transport Two Outside Field Radio Two Speakers and Antenna Factory Installed Radio Dealer Inst...

Page 19: ...142 9 3630 158 3 4020 120 6 3064 Inner Inner 123 3124 131 9 3352 142 1 3610 600 65R28 Radial Tire Inner Outer 130 1 3305 139 1 3532 153 7 3904 Outer Outer 137 2 3484 146 1 3712 160 9 4084 142 9 3630 1...

Page 20: ...PRODUCT DESCRIPTION Form 169469 169470 169471 18 Revision C WINDROWER DIMENSIONS cont d CAB FORWARD 45 7 in 1160 TREAD HUBS TIRES WHEEL BASE 133 in 3378 mm ENGINE FORWARD TREAD CASTERS WHEEL BASE...

Page 21: ...AL HAZARD LIGHTS MIRROR WALKING BEAM DOOR ENGINE COMPARTMENT HOOD FIELD ROAD LIGHTS WINDSHIELD WIPER TAIL LIGHTS CAB FWD CASTER WHEEL HORN HEADER LIFT LEG FIELD ROAD LIGHTS OPERATOR S STATION HEADER F...

Page 22: ...gardless of the direction of travel 5 1 OPERATOR CONSOLE The console contains controls to operate the windrower as well as amenities for the operator The console position is adjustable to suit each pa...

Page 23: ...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 positi...

Page 24: ...ecurely fasten your seat belt and ensure trainer s seat belt is fastened if occupied The seat belt can help insure your safety if it is used and maintained Never wear a seat belt loosely or with slack...

Page 25: ...engine forward mode The position of the operator s station automatically determines the lighting IMPORTANT Red and amber reflector tape is applied to be visible in both engine forward and cab forward...

Page 26: ...en the switch 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...

Page 27: ...9469 169470 169471 25 Revision C 5 7 4 BEACON LIGHTING EXPORT N A OPTIONAL The beacon lights are functional when the ignition and the beacon switches are on The beacons must be used when driving on th...

Page 28: ...ator 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 h...

Page 29: ...pens and stops the compressor when the pressure rises to 315 335 psi 2172 2310 kPa When the pressure falls to 220 280 psi 1517 1930 kPa the switch closes and allows the compressor to run If the air co...

Page 30: ...rm 169469 169470 169471 28 Revision C 5 12 OPERATOR AMENITIES CIGARETTE LIGHTER UTILITY TRAY UNDER ARMREST UTILITY TRAY ASHTRAY CUPHOLDER AUXILIARY POWER MANUAL STORAGE CASE COOLER AUXILIARY POWER GRO...

Page 31: ...ANTENNA MOUNTING A roof mounted antenna base for installing a magnetic antenna is available as an option from your dealer Order part 160288 or see illustration for part dimensions for a homemade versi...

Page 32: ...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 Engi...

Page 33: ...utral 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...

Page 34: ...etailed operating procedures of all header controls 5 17 1 HEADER ENGAGE SWITCH Engages and disengages header drive IMPORTANT Always move throttle lever back to idle before engaging header drive Do no...

Page 35: ...ngs in the CDM B top line read out for each of the header controls Press switch to scroll through settings 5 17 3 2 Reel Position Switches The reel position switches perform functions depending on CDM...

Page 36: ...peed is limited in INDEX HEADER SPEED mode Rotary Header Conditioner speed automatically adjusts when disc speed is changed 5 17 4 CONSOLE HEADER SWITCHES The operator s console contains switches for...

Page 37: ...veyor Speed to Ground Speed Push On Push Off Illuminates In On Position SELECT SWITCH Allows Operator To Select Display Item Bottom Line See Pages 36 41 RETURN TO CUT HEIGHT SWITCH Allows Cutting Heig...

Page 38: ...h 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 To...

Page 39: ...ut 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 Dist...

Page 40: ...trokes Per Minute HEADER HEIGHT HEIGHT SENSOR If Sensor Disabled Distance Setting 00 0 10 0 Between Cutterbar Ground HEADER ANGLE TILT SENSOR If Sensor Disabled Angle Setting 00 0 10 0 Header Relative...

Page 41: ...abled Knife Speed In Strokes Per Minute HEADER HEIGHT HEIGHT SENSOR Sensor Disabled Distance Setting 00 0 10 0 Between Cutterbar Ground HEADER ANGLE TILT SENSOR Sensor Disabled Angle Setting 00 0 10 0...

Page 42: ...ute HEADER HEIGHT HEIGHT SENSOR Sensor Disabled Distance Setting 00 0 10 0 Between Cutterbar Ground HEADER ANGLE TILT SENSOR Sensor Disabled Angle Setting 00 0 10 0 Header Relative To Ground L FLOAT R...

Page 43: ...otal 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 Ground HEADER ANGLE T...

Page 44: ...e 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...

Page 45: ...en 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 Attentio...

Page 46: ...nds Repeats Every 30 Minutes Until Condition Is Corrected Engine Air Filter Requires Servicing ENGINE OIL PRESSURE Continuous Loud Tone Until Oil Pressure Is Regained Low Engine Oil Pressure ENGINE TE...

Page 47: ...Hydraulic Oil Level Header Shuts Down Automatically If Engaged Header On Switch Must Be Moved To OFF Position and Then To ON Position To Restart The Header NO HEADER None Header Is Not Detected NO OPE...

Page 48: ...e programming mode accordingly a Turn ignition key to RUN or start the engine Refer to paragraph 6 3 5 Engine Operation b Press PROGRAM and SELECT on CDM to enter programming mode Header ID code is di...

Page 49: ...0 6 5 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...

Page 50: ...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...

Page 51: ...OPERATOR S STATION Form 169469 169470 169471 49 Revision C continued next page...

Page 52: ...ibrated 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 wi...

Page 53: ...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...

Page 54: ...2 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...

Page 55: ...2000 Sudan Sorghum Haygrazer Timothy Tall Stemmy 2300 2500 Short Grass Dense 2500 Thin 2000 2200 Suggested Overload Setting 1300 rpm 5 18 7 ENGINE ERROR CODES The CDM displays Error Codes when there i...

Page 56: ...t 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...

Page 57: ...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...

Page 58: ...only in daylight or good artificial light 6 3 2 BREAK IN PERIOD The windrower is ready for normal operation However there are several items to check and watch out for during the first 150 hours In add...

Page 59: ...2 Remove plastic bags and or tape from all sealed openings air cleaner intake exhaust pipe fuel tank 3 Charge battery and install Be sure terminals are clean and cables are connected securely 4 Adjus...

Page 60: ...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 d...

Page 61: ...at least two minutes before trying again After the third 15 second crank attempt allow solenoid to cool for 10 minutes before further cranking attempts If engine still does not start refer to Trouble...

Page 62: ...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...

Page 63: ...low 7 5 psi 52 kPa a continuous 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...

Page 64: ...cally 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 me...

Page 65: ...s locked in the straight ahead position o Fully lower header and reel o Disengage header drives o Stop engine and remove key from ignition A child or even a pet could engage an idling machine o Turn o...

Page 66: ...tened 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...

Page 67: ...ave cleared the area c Move the GSL A rearward to desired speed d Steer as shown 6 3 6 3 Engine forward Operation a Swivel operator s station to engine forward position as follows 1 Place ground GSL A...

Page 68: ...ing 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...

Page 69: ...l 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...

Page 70: ...ing wheel locked DANGER Stop engine and remove key from ignition before leaving operator s seat for any reason A child or even a pet could engage an idling machine a Raise rear of windrower slightly s...

Page 71: ...installed at the back inboard locations e Install bottom bolts C f Tighten bolts as follows 1 Snug bottom bolts C 2 Tighten and torque back bolts B to 330 ft lbf 447 N m 3 Tighten and torque bottom bo...

Page 72: ...AUTION 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...

Page 73: ...efer 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...

Page 74: ...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 hydraul...

Page 75: ...of hook k Use the HEADER TILT switches to release load on the cylinder if necessary l Raise the center link off the header using the REEL UP switch on the GSL m Slowly back windrower away from header...

Page 76: ...lly insert L pin N in upper hole and turn pin to lock it Secure with ring pin O 8 Make the electrical connection at the joint Q and at the header wheel P IMPORTANT To prevent damage to the lift system...

Page 77: ...rness to connector r Raise lift arms fully shut off engine and remove key from ignition s Move float pins from storage location C to engaged position B t Start engine and press HEADER DOWN switch on G...

Page 78: ...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 eng...

Page 79: ...d to windrower ensure that float engagement pin is installed in storage location H and not installed at hole location G m Remove pins J securing lift linkages to weight box and retain pins for attachi...

Page 80: ...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 ma...

Page 81: ...tive 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...

Page 82: ...eath 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 I...

Page 83: ...eader 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 so...

Page 84: ...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...

Page 85: ...ift 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...

Page 86: ...member 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 Sto...

Page 87: ...ch to disengage header drive b Reverse the header operation as follows NOTE The optional hydraulic reversing kit must be installed for auger and draper with conditioner equipped windrowers It is stand...

Page 88: ...te 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 op...

Page 89: ...9469 169470 169471 87 Revision C 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 lif...

Page 90: ...Section 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...

Page 91: ...E HEIGHT is displayed 6 Press or to change value on lower line Range is 4 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...

Page 92: ...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 Manua...

Page 93: ...Kit Number Base Kit B5491 Completion B5496 Coupler B5497 6 5 1 HEADER ATTACHMENT IMPORTANT To prevent damage to the lift system when lowering header lift linkages without a header or weight box attac...

Page 94: ...o fully retract header lift cylinders d Slowly drive windrower forward so that boots D enter header legs G Continue to drive slowly forward until lift linkages contact support plates in the header leg...

Page 95: ...HEADER OPERATION D SERIES Form 169469 169470 169471 93 Revision C continued next page...

Page 96: ...r leg engaging U bracket in lift linkage on both sides and secure with hairpin k Raise header stand H to storage position by pulling pin J and lifting stand into uppermost position Release pin J l Rem...

Page 97: ...pin C Release pin to lock stand e Remove pin from location D to disengage float springs and insert in storage hole E Secure with lynch pin IMPORTANT To prevent damage to the lift system when lowering...

Page 98: ...h on GSL to release load on center link cylinder k Lift release M l Operate the link lift cylinder with REEL UP switch on GSL to disengage the center link from the header m Slowly back windrower away...

Page 99: ...function switches on the GSL Press and hold the switch for the desired fore or aft movement of the reel The switches also control adjustments to the optional Double Windrow Attachment DWA conveyor an...

Page 100: ...es noise in the cab Ground cutting speed can be maintained using this feature a Set Reel Minimum Speed as follows IMPORTANT Windrower can be moving but must be less than minimum reel speed CAUTION Che...

Page 101: ...indrower is operating at 8 mph with Header Index on and set at 1 0 Display shows 9 0 1 0 REEL IND where 9 0 8 1 0 is the reel speed in mph and 1 0 is the header index setting 6 5 6 2 Reel Only Speed S...

Page 102: ...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...

Page 103: ...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...

Page 104: ...O 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 eac...

Page 105: ...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...

Page 106: ...supplied with the kits Kit Description Kit Number Base Kit B5491 Completion B5492 Coupler B5497 6 6 1 HEADER ATTACHMENT a Remove hairpin from pin A and remove pin from left and right header boots B on...

Page 107: ...EL DOWN switches and HEADER TILT switches on the GSL to position the hook above the header attachment pin e Lower the center link onto the header with REEL DOWN switch until it locks into position han...

Page 108: ...stand to storage position by inverting stand and re locating on bracket as shown Reinsert pin F and secure with lynch pin l Remove pin H from storage position in linkage and insert in hole J to engag...

Page 109: ...boots B on header d Lower stand C by pulling pin D inverting stand and re locating on bracket Reinsert pin D and secure with hairpin e Remove pin from linkage E to disengage float springs and insert i...

Page 110: ...ease H j Operate the link lift cylinder with REEL UP switch on GSL to disengage the center link from the header k Disconnect header drive hydraulics J and electrical harness K Refer to the Auger Heade...

Page 111: ...eed can be independently changed from the knife speed by changing the drive sprocket Refer to A30 S A30 D A40 D Self Propelled Windrower Headers OPERATOR S MANUAL Display the auger speed as follows EN...

Page 112: ...he auger initially set the speed of the reel and auger as follows Subsequent adjustments to reel speed do not affect auger speed YES 15 00 85 00 ENGAGE HEADER HEADER INDEX SWITCH OFF ON GSL PRESS SLOW...

Page 113: ...hence 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 HEADER INDEX SWITCH OFF DONE ON GSL PR...

Page 114: ...lays 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...

Page 115: ...installed and the installation of a separate motor and hose bundle is necessary If required obtain kit number B5456 from your MacDon dealer and install it in accordance with the instructions supplied...

Page 116: ...the REEL UP and REEL DOWN switches and HEADER TILT switches on the GSL to position the hook above the header attachment pin e Lower the center link onto the header with REEL DOWN switch until it lock...

Page 117: ...talled behind bracket i Remove pin F from storage position in linkage and insert in hole G to engage float springs Secure with hairpin j Disengage lift cylinder stops k Start engine and activate HEADE...

Page 118: ...gage 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 windrow...

Page 119: ...169469 169470 169471 117 Revision C j Disconnect header drive hydraulics and electrical harness Refer to your Rotary Disc Header Operator s Manual k Slowly back windrower away from header l Re instal...

Page 120: ...ginal set point CROP CONDITION DISC RPM Alfalfa Heavy 2100 2300 Light 1800 2000 Sudan Sorghum Haygrazer Timothy Tall Stemmy 2300 2500 Short Grass Dense 2500 Thin 2000 2200 Suggested Overload Setting 1...

Page 121: ...ose 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 glove...

Page 122: ...Air Conditioning Compressor Oil SP 15 Compressor Oil Cab Air Conditioning Compressor Lubricant High quality soft de ionized or distilled water as recommended by supplier 7 3 1 3 Lubricants LUBRICANT...

Page 123: ...ts 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...

Page 124: ...s 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 ti...

Page 125: ...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...

Page 126: ...urther b To close hood 1 Grasp the strap at B and loop under upper hook C IMPORTANT Failure to hook strap may result in it becoming entangled with the screen cleaners or the latch 2 Pull down on strap...

Page 127: ...MAJOR SERVICING To improve access to the hydraulics plumbing or battery the platforms can be swung away from the windrower Left side cab forward platform shown a Open engine compartment hood to lowes...

Page 128: ...ll e Close platform as follows 1 Swing link C all the way forward 2 Move platform front cab forward end inboard while moving it away from the walking beam 3 Position link C on bracket and install bolt...

Page 129: ...Maintenance Checklist provided to keep a record of scheduled maintenance Refer to Section 7 13 MAINTENANCE SCHEDULE 7 6 1 PROCEDURE DANGER Stop engine and remove key from ignition before leaving opera...

Page 130: ...ed WALKING BEAM PIVOT High Temp Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base FORMED CASTER WHEEL BEARING 1 PLACE BOTH WHEELS CASTER PIVOT BOTH SIDES FORK...

Page 131: ...s not shut down 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 o...

Page 132: ...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...

Page 133: ...lts A for looseness and ball joints B for any perceptible play or movement d Check steering link bolts C for looseness and ball joints D for any perceptible play or movement e If bolts are loose 1 Bac...

Page 134: ...ering 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...

Page 135: ...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...

Page 136: ...E SERVICE Form 169469 169470 169471 134 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...

Page 137: ...ment 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 outs...

Page 138: ...ner 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 and more freq...

Page 139: ...prevent damage to the system These switches do not require any regular servicing or maintenance so if problems occur and the switches are suspect contact your dealer If the compressor cycles rapidly...

Page 140: ...a hot engine are a fire hazard Never use gasoline naphtha or any other volatile material for cleaning purposes These materials are toxic and or flammable 7 8 1 GENERAL ENGINE INSPECTION Have the over...

Page 141: ...form on right cab forward side of machine to open position to allow access to the battery c Remove red plastic covers A from positive cable clamps Loosen the clamps and remove cable from batteries d O...

Page 142: ...ick by turning it counterclockwise to unlock and remove d Wipe clean reinsert in engine and remove e Oil level should be between LOW and HIGH marks f Replace dipstick and turn it clockwise to lock g A...

Page 143: ...ad B g Remove filter C h Clean gasket mating surface i Apply a thin film of clean oil to the gasket on the new filter j Screw the new filter onto the filter mount until the gasket contacts the filter...

Page 144: ...es 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 sho...

Page 145: ...r holes Discard any element which shows the slightest hole 2 Be sure outer screen is not dented Vibration would quickly wear a hole in the filter 3 Be sure filter gasket is in good condition If gasket...

Page 146: ...t tap element against a hard surface l Using a Dry Element Cleaner Gun clean element with compressed air m Hold nozzle next to inner surface and move up and down pleats IMPORTANT Air pressure must not...

Page 147: ...ng to prevent end cap from turning v 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 J which boosts the p...

Page 148: ...on See Section 7 4 ENGINE COMPARTMENT HOOD b Locate filter A on vent line against hydraulic oil reservoir c Release hose tension clamps B and slide away from filter Pull hoses off filter d Position ne...

Page 149: ...l to turn by hand IMPORTANT Do not use a filter wrench to install the filter Over tightening can damage the gasket and filter c Change secondary filter D as follows 1 Clean around the filter head J 2...

Page 150: ...hen servicing a Stop the engine and remove the key b Open engine compartment hood to lowest position See Section 7 4 ENGINE COMPARTMENT HOOD c Close fuel supply valve A d Place a 5 U S gallon 20 litre...

Page 151: ...d Small amounts of air introduced by changing filters or injection pump supply line will be vented automatically if the fuel filters are changed in accordance with instructions WARNING The fuel pump h...

Page 152: ...e 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 r...

Page 153: ...ably 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 work...

Page 154: ...perature control knob to high Run engine until normal operating temperature is reached m Stop engine and drain water out before rust or sediment settles See steps d to h n Close drain valves and fill...

Page 155: ...e 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...

Page 156: ...der 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...

Page 157: ...xhaust system may allow exhaust gases to escape to the cab c Dents or crushed portions of any tubing create exhaust flow restriction and increase back pressure significantly Even relatively small dent...

Page 158: ...rdware 5 Recheck 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...

Page 159: ...tall new belt D around fan and onto pulleys in order 3 2 1 i Insert the drive end of a inch drive ratchet wrench into the belt tensioner C j Rotate tensioner counterclockwise until belt D can be slipp...

Page 160: ...seals will void the engine warranty 7 8 11 1 Throttle Adjustment The engine speed is controlled with the throttle lever that is connected to an electronic sensor inside the console The throttle lever...

Page 161: ...ged Service rotors and screen as follows a Stop engine and remove key b Raise engine compartment hood fully See Section 7 4 ENGINE COMPARTMENT HOOD c If rotors A are plugged clean as follows 1 Remove...

Page 162: ...f necessary adjust clearance as follows 1 Loosen nut B on motor support C 2 Move support in or out until duct is 0 08 0 24 in 2 6 mm from screen near the center 3 Re tighten nut B 4 Loosen the two mot...

Page 163: ...NGER Stop engine and remove key from ignition before leaving operator s seat for any reason A child or even a pet could engage an idling machine a Stop engine and remove key b Raise engine compartment...

Page 164: ...can be very easily bent which may interfere with its function Exercise caution when cleaning i Clean radiator O through access holes in cooling box with compressed air j Clean oil cooler A C condenser...

Page 165: ...lever F n Close top door N and secure with wing nut M o Loosen knob D and lower fuel cooler E to original position Tighten knob p Unhook support rod C in screen door and store in screen door q Close...

Page 166: ...r 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 o...

Page 167: ...52 C Follow all instructions and precautions furnished by the battery charger manufacturer Charge at recommended rates and times 7 10 1 4 Boosting A twelve volt battery can be connected in parallel to...

Page 168: ...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...

Page 169: ...s 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 R...

Page 170: ...ernator 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...

Page 171: ...gine and remove the key c Turn on the headlights A and switch to lo beam d Align the headlights to the following specifications by turning adjusting screws B Adjustments are for lo beam Light beams la...

Page 172: ...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 rubbe...

Page 173: ...age an idling machine 7 10 3 1 Adjustment The field lights are best adjusted with the machine in the field or the equivalent to suit operator preference a Hold onto the hand holds A on the cab front c...

Page 174: ...s B and remove light bezel C d Remove light from receptacle e Pinch the wire retainer D and lift away from hooks f Remove bulb E from body and pull wire from connector F IMPORTANT Do not touch the gla...

Page 175: ...5 2 Bulb Replacement a Shutdown engine and remove the key Turn off the lights b Remove the two screws C and remove light bezel D c Remove light from receptacle d Pinch the wire retainer E and lift awa...

Page 176: ...e two screws B from lens and remove lens c Push and twist light bulb D to remove from socket d Install new bulb D in socket ensuring that bulb base is properly engaged in socket Use Bulb Trade 1157 fo...

Page 177: ...OTE 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 counter clockwis...

Page 178: ...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...

Page 179: ...kwise 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 10 10 DOME LIGH...

Page 180: ...y b Move right cab forward side platform rearward cab forward 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 i...

Page 181: ...MAINTENANCE SERVICE Form 169469 169470 169471 179 Revision C 7 10 13 3 Fuse Box Decal...

Page 182: ...t could engage an idling machine a Stop engine and remove key b Move right cab forward side platform rearward cab forward c To check condition of fuse pull tab A and open cover B d Visually examine fu...

Page 183: ...ing 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 f...

Page 184: ...and tighten drain plug g Add oil to the tank to the required level through the filler pipe Refer to previous section 7 11 4 HYDRAULIC OIL FILTERS Change hydraulic oil filters as follows DANGER Stop en...

Page 185: ...lter Over tightening can damage gasket and filter 7 11 4 3 Return Filter NOTE The return filter is a part of the hydraulics package required to run a draper or auger header NOTE Change hydraulic oil f...

Page 186: ...the pressure relief valve may require adjusting Contact your Windrower Dealer or refer to the Technical Service Manual for your Windrower HEADER MODEL APPLICATION SYSTEM SUGGESTED OVERLOAD WARNING SET...

Page 187: ...perator 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 knob A on...

Page 188: ...n 7 11 1 Oil Level b Check the hoses and lines for leakage c Check the charge pressure relief valve Refer to following section d If charge pressure still cannot be maintained do not operate the windro...

Page 189: ...ds and body away from pin holes and nozzles which eject fluids under high pressure If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with thi...

Page 190: ...not remove install or make repairs to a tire on a rim unless you have the proper equipment and experience to perform the job Take the tire and rim to a qualified tire repair shop If the tire is not i...

Page 191: ...Pressure Gear Lubricant After first change use SAE 75W 90 API Service Class GL 5 Fully Synthetic Transmission Lubricant SAE J2360 preferred 4 Replace plugs and tighten b Change the lubricant as follow...

Page 192: ...gine and remove key d Jack up windrower under leg jack point and raise windrower wheel slightly off ground e Undo wheel nuts and remove wheel f To install new tire ensure that air valves are on outsid...

Page 193: ...eel 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 correc...

Page 194: ...rs TOTAL WEIGHT OF BOTH TIRES lb kg 7 5X16 A 10 38 200 91 10X16 B 18 69 380 170 16 5X16 1 C 41 158 830 377 Weights are given for typical calcium chloride and water mixtures Weight is reduced by 20 if...

Page 195: ...ove 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 eng...

Page 196: ...pacity or other suitable lifting device until the wheel is slightly off the ground 4 Undo the six wheel bolts A and remove wheel from hub b Install the caster wheel as follows 1 Position wheel on hub...

Page 197: ...7 1 PREPARATION FOR SERVICING and Section 7 2 RECOMMENDED SAFETY PROCEDURES 7 13 1 BREAK IN INSPECTION BREAK IN INSPECTIONS HRS ITEM CHECK Every 25 Road or 1 in Field Drive Wheel Nuts Torque 220 ft l...

Page 198: ...r Leaks 50 HOURS 1 Grease Caster Pivots 2 Grease Walking Beam Center Pivot 3 Grease Top Lift Link Pivots 4 Grease Forked Caster Spindle Bearings 5 Clean Cab Fresh Air Intake Filter 6 Check Gear Box Oi...

Page 199: ...NORMALLY REQUIRED BUT IS AT THE OWNER OPERATOR S DISCRETION A C Condenser Charge Air Cooler Engine Oil Level Engine Coolant Level Fuel Tank Fuel Filter Water Trap Hydraulic Hoses and Lines Hydraulic O...

Page 200: ...viced By 500 HOURS Engine Oil and Filter or Annually Fuel Filters Gearbox Lubricant Charge System and Return if applicable Hydraulic Oil Filters Safety Systems or Annually 1000 HOURS Drive Wheel Lubri...

Page 201: ...ctrolyte level 7 10 1 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 manu...

Page 202: ...d check thermostat See Engine Overheats Improper valve clearance Contact MacDon dealer Faulty injectors Engine Temperature Below Normal Defective thermostat Remove and check thermostat Warning Alarm S...

Page 203: ...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 tempera...

Page 204: ...n 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 wir...

Page 205: ...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 Loos...

Page 206: ...pump or motor Contact MacDon dealer Wheels not in same speed range Faulty relief valve Repair or replace valve 7 11 6 2 Excessive Noise From Drive System Hydraulic line clamps loose Tighten clamps Me...

Page 207: ...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 F...

Page 208: ...culation over condenser coil fins clogged with dirt or insects Clean condenser 7 9 3 Evaporator fins clogged Clean evaporator fins under cab floor 7 7 6 4 Too little refrigerant in system Contact MacD...

Page 209: ...ystem Contact MacDon dealer Incorrect super heat adjustment in expansion valve Thermostat defective Defective blower switch or blower motor Partially open improper ground or loose connection in compre...

Page 210: ...tension for float Installation instructions are included 9 9 WINDSHIELD SHADES Retractable sun shades for front and rear windows Installation instructions are included 9 10 AM FM RADIO Available for...

Page 211: ...VEL Allows the windrower to travel in the cab forward mode on public roads and comply with vehicle lighting regulations The kit includes red tail lights SMV markings hardware and installation instruct...

Page 212: ...ead adjustment 67 CDM 35 CDM Displays 36 Charge Filter 180 Circuit Breakers 175 Compressor Oil 117 Console 20 Cooler 28 Daily check 56 Deck Shift Switch 34 Definitions 14 Disc Header attachment 110 de...

Page 213: ...attaching draper 90 detaching draper 93 drive 84 drop rate 88 182 engage 84 float adjustment 80 float switch 34 flotation 80 functions 35 height control 87 levelling 83 lift cylinder stops 79 monitor...

Page 214: ...gnal Lights 171 Specifications 15 Starting Engine 57 Steering Chain 129 Steering Column Adjust 22 Steering Links 128 Storage fuel and lubricants 117 windrower 78 Symbol Definitions 53 Tail Lights bulb...

Page 215: ...eader drive solenoid V10 fault detected short circuit open circuit E 39 E139 M I D R A N G E V 5 B M200 Mid range solenoid V5B fault detected short circuit open circuit E 40 E140 H I G H R A N G E V 5...

Page 216: ...nt or Incorrect 3 Red 131 Accelerator Pedal or Lever Position Sensor Circuit Voltage Above Normal or Shorted to High Source 4 Red 132 Accelerator Pedal or Lever Position Sensor Circuit Voltage Below N...

Page 217: ...nifold Air Temperature Sensor Circuit Voltage Above Normal or Shorted to High Source 4 Amber 154 Intake Manifold Air Temperature Sensor Circuit Voltage Below Normal or Shorted to Low Source 15 None 29...

Page 218: ...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...

Page 219: ...2 Amber 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 Calib...

Page 220: ...aft sensors Mechanical System Not Responding Properly or Out of Adjustment 8 142 Abnormal signal frequency Intake Air Heater 1 729 3 Amber 2555 Intake Air Heater 1 Circuit Voltage Above Normal or Shor...

Page 221: ...al Instructions J1939 Error 1484 31 None 211 Additional Auxiliary Diagnostic Codes logged Condition Exists Control Module Identification Input State 1563 2 Amber 1256 Control Module Identification Inp...

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MacDon M205 2010, Operator'S Manual

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Summary of Contents for M205 2010

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