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MacDon M205 2012 Operator'S Manual Download Page 200

MAINTENANCE AND SERVICING 

 

169469/169470/169471

 

198

 

Revision E

 

7.12.2.2 Ballast 

Requirements 

Fluid ballasting of rear caster tires is 
recommended to provide adequate machine 
stability when using large headers on the 
windrower. Also, the stability of machine varies 
with different attachments, windrower options, 
terrain and Operator’s driving technique.  

Ballast capability per tire is at a maximum fill of 
75% or when fluid is level with valve stem when 
the stem is positioned at 12 o’clock. Fluid can be 
added to any level up to maximum fill.  Always add 
an equal amount of fluid on both sides. 

Tire Size 

Fluid 

per

 tire at 

75% fill 

US Gal. (Liters) 

Total weight of 

both

 tires 

lb (kg) * 

7.5X16

 

(A) 

10 (38)

 

200 (91)

 

10X16 

(B) 

18 (69)

 

380 (170)

 

16.5X16.1 

(C) 

41 (158)

 

830 (377)

 

* Weights are given for typical calcium chloride 
and water mixtures. Weight is reduced by 20% if 
only water is used (for areas that do not require 
anti-freeze protection). 

 

Header Description 

Recommended Ballast 

Recommended Tire 

Size 

Level Ground 

Hills 

Type Size 

Per

 tire

 

Both

 tires 

Per

 tire 

Both

 tires 

U.S. Gal. 

(Liters)

 

lb (kg) *

 

U.S. Gal. 

(Liters)

 

lb (kg) *

 

A, R Series 

All Options 

All 

0 0 0 0 

A,B,C 

D Series 

25 ft and Down 

0 

0 

0 

0 

A,B,C 

30 ft Single or  

Split Reel W/O Conditioner 

0 0 

10 

(38)

 

200 (91)

 

A,B,C 

35 ft Single Reel 

30 ft Split Reel. 

Steel Fingers and 

Conditioner 18 

(69)

 

380 (170)

 

30 (115)

 

630 (288)

 

Level Ground – B, C 

Hills - C 

35 ft Split Reel (5 or 6 Bat) 

40 ft 

30 (115)

 

630 (288)

 

41 (158)

 

830 (377)

 

C 

 
* If only water is used, increase volume of water by 20% (up to maximum allowable fill per tire) to compensate. 

 

Summary of Contents for M205 2012

Page 1: ...M205 Self Propelled Windrower OPERATOR S MANUAL Part 169469 Rev E 25 ...

Page 2: ...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: ...n 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 the Table of Contents and the Index to guide you to specific areas Study the Table of Contents to familiarize yourself with how the material is organized Keep this manual handy for frequent reference an...

Page 4: ...ilizer 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 frame near the walking beam ENGINE SERIAL NO ______________________YEAR_____ Serial Number Plate is located on the top face of the engine cylinder head cover ...

Page 5: ...Transmission 26 5 3 SEAT ADJUSTMENTS 26 5 4 TRAINING SEAT 27 5 5 SEAT BELTS 27 5 6 STEERING COLUMN ADJUSTMENT 27 5 7 LIGHTS 28 5 7 1 Cab forward Lighting Field 28 5 7 2 Engine forward Lighting Road 29 5 7 3 Cab forward Lighting Road Optional 29 5 7 4 Beacon Lighting Export N A Optional 30 5 7 5 HID Lighting Optional 30 5 8 WINDSHIELD WIPERS 31 5 9 REAR VIEW MIRRORS 31 5 10 CAB TEMPERATURE 31 5 10 ...

Page 6: ...reak In Period 62 6 3 3 Pre Season Check 63 6 3 4 Daily Check 63 6 3 5 Engine Operation 64 6 3 6 Driving The Windrower 68 6 3 7 Adjustable Caster Tread Width 74 6 3 8 Transporting 76 6 3 9 Storage 86 6 4 HEADER OPERATION 87 6 4 1 Header Lift Cylinder Stops 87 6 4 2 Header Flotation 88 6 4 3 Levelling 91 6 4 4 Header Drive 92 6 4 5 Header Angle 93 6 4 6 Cutting Height 95 6 4 7 Double Windrowing 97 ...

Page 7: ... 8 ENGINE 143 7 8 1 General Engine Inspection 143 7 8 2 Manually Turning Engine 144 7 8 3 Oil Level 145 7 8 4 Changing Oil and Oil Filter 146 7 8 5 Air Intake System 147 7 8 6 Fuel System 151 7 8 7 Engine Cooling System 155 7 8 8 Gearbox 158 7 8 9 Exhaust System 160 7 8 10 Belts 161 7 8 11 Engine Speed 163 7 9 COOLING BOX 164 7 9 1 Cooling Box Screen 164 7 9 2 Rotor To Screen Clearance 165 7 9 3 C...

Page 8: ...TS 214 9 1 AM FM RADIO 214 9 2 AUTO STEER 214 9 3 BOOSTER SPRING KIT 214 9 4 COMPLETION KIT FOR AUGER and DRAPER HEADER DRIVES 214 9 5 COMPLETION KIT FOR AUGER HEADER DRIVE and CONDITIONER REVERSER 214 9 6 COMPLETION KIT FOR DRAPER HEADER REEL DRIVE 214 9 7 COOLING KITS 214 9 8 DOUBLE WINDROW ATTACHMENT 214 9 9 FAN AIR BAFFLE KIT 214 9 10 HID AUXILLIARY LIGHTING 214 9 11 INTERNAL BOOSTER SPRING KI...

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

Page 10: ...E Close to Radiator Cap MD 166461 F Fan Shroud Top MD 166450 G Fan Shroud Middle MD 166451 H Fan Shroud Bottom MD 166452 J Frame Opening MD 166233 K Platform L of Step MD 166425 L Platform R of Step MD 166441 M Frame at Valve Block MD 166466 N Lift Linkage MD 166438 O Inner Post MD 166457 P Inner Post MD 166234 Q Inner Post MD 166463 R Neutral Interlock MD 166425 S Frame MD 166425 Safety Sign Loca...

Page 11: ...SAFETY 169469 169470 169471 9 Revision E ...

Page 12: ...cont d Safety Sign Locations RH Side A Hazard Sign on Seat MD 115148 B Lift Linkage MD 166439 C Frame MD 166455 D Frame MD 166456 E Cab Frame MD 184372 F Platform MD 166425 G Shroud MD 166451 H Shroud MD 166452 J Hydraulic Reservoir MD 174436 K Wiper Cover MD 166465 ...

Page 13: ...SAFETY 169469 169470 169471 11 Revision E Safety Sign Locations cont d ...

Page 14: ...om Operator s seat Do not try to start engine with someone under or near machine 2 MD 166234 Run over hazard WARNING The training seat is provided for an experienced Operator of the machine when a new Operator is being trained The training seat is not intended as a passenger seat or for use by children Use the seatbelt whenever operating the machine or riding as a trainer Keep all other riders off...

Page 15: ...e mechanical locks before going under unit 6 MD 166441 Loss of control hazard CAUTION To prevent machine damage and or loss of control it is essential that the machine be equipped such that weights are within the specified limits 7 MD 166450 Hot surface hazard WARNING To avoid injury keep a safe distance from hot surface 8 MD 166451 Rotating fan hazard WARNING To avoid injury stop engine before op...

Page 16: ...s off the machine vii Keep all shields in place and stay clear of moving parts viii Disengage header drive put transmission in neutral and wait for all movement to stop before leaving Operator s position ix Shut off engine and remove key from ignition before servicing adjusting lubricating cleaning or unplugging machine x Engage locks to prevent lowering of header or reel before servicing in the r...

Page 17: ...nd wait for all movement to stop before leaving Operator s position ix Shut off engine and remove key from ignition before servicing adjusting lubricating cleaning or unplugging machine x Engage locks to prevent lowering of header or reel before servicing in the raised position xi Use slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited by law Machine...

Page 18: ...ng down well in advance iii Do not rapidly accelerate or decelerate while turning iv Limit speed to maximum 20 mph 32 km h when towing a header To ensure steering control refer to Operator s manual for adding weight to drive wheels v When traveling on steep slopes 1 Reduce speed and lower header 2 Move ground speed lever to slow end of range 3 Shift high low speed control to low range vi With head...

Page 19: ... Provide a first aid kit for use in case of emergencies Keep a fire extinguisher on the machine Be sure the extinguisher is properly maintained and be familiar with its proper use Keep young children away from machinery at all times Be aware 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 fa...

Page 20: ...lippery 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 volatil...

Page 21: ...e Windrow Attachment ECM Engine Control Module Engine Forward Windrower operation with the Operator and engine facing in the direction of travel GSL Ground Speed Lever GVW Gross Vehicle Weight Header A machine that cuts and lays crop into a windrow and is attached to a self propelled windrower ISC Intermediate Speed Control Mower Conditioner A machine that cuts and conditions hay and is pulled by ...

Page 22: ...ge 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 Planetary Gearbox Ratio 30 06 1 Wheel Motor Displacement Low Range 4 15 cu in 68 cc Mid Range 3 01 cu in 50 cc High Range 1 93 cu in 32 cc SYSTEM CAPACITIES Fuel Tank 97 U S Gallons 367 L Cooling 7 9 U S Gallons 30 L Hydraulic Reservoir 17 2 U S Gallons 65...

Page 23: ...28 280 Btu h 8 288 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 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 Header Drive Load Gauge TIRE OPTIONS Size Drive 18 4 26 Bar 18 4...

Page 24: ...adial 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 158 3 4020 120 6 3064 Inner Inner 123 3124 131 9 3352 146 6 3724 23 1 26 and 580 70R26 Turf Tires Inner Outer 127 2 3230 139 1 3532 150 3810 Outer Outer 134 2 3410 146 1 3712 157 1 3990 142 9 3630 158 3 4020 120 6 3064 Inner Inner 120 1 3050 131 9 3352 142 9 3630 CASTER TIRES 7 5 16SL Mi...

Page 25: ...PRODUCT DESCRIPTION 169469 169470 169471 23 Revision E WINDROWER DIMENSIONS cont d ENGINE FORWARD TREAD CASTERS WHEEL BASE CAB FORWARD 45 7 in 1 160 mm TREAD HUBS TIRES WHEEL BASE 133 in 3 378 mm ...

Page 26: ...AND RAILS DOOR WINDSHIELD WIPER MIRROR MAINTENANCE PLATFORM TAIL LIGHT ENGINE FORWARD TAIL LIGHT ENGINE FORWARD CENTER LINK TURN SIGNAL HAZARD LIGHTS MAINTENANCE PLATFORM FIELD ROAD LIGHTS DRIVE WHEEL TURN SIGNAL HAZARD LIGHTS MIRROR WALKING BEAM DOOR ENGINE COMPARTMENT HOOD FIELD ROAD LIGHTS WINDSHIELD WIPER TAIL LIGHTS CAB FORWARD OPTIONAL CASTER WHEEL HORN ...

Page 27: ...ardless 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 particular Operator as follows a To adjust fore aft and height pull lever A and slide console fore or aft to desired position Release lever to lock console b To adjust only fore aft loosen nuts B under c...

Page 28: ...econds the lower display will flash NO OPERATOR 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 ...

Page 29: ...curely 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 buc...

Page 30: ...rd 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 modes 5 7 1 CAB FORWARD LIGHTING FIELD HIGH LOW LIGHTS Controls High Low Beam For Road Lights High Low LIGHTS Controls field and transport lights Field Off Road BEACON Controls Beacons On Cab Standard for Export ...

Page 31: ...h is in the ROAD position The hazard lights must be activated with the switch on the Cab Display Module 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 ENGINE FORWARD TAIL BRAKE LIGHTS RED TURN SIGNALS HAZARDS AMBER HIGH LOW ROAD FRONT EN...

Page 32: ...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 the road 5 7 5 HID LIGHTING OPTIONAL Activated with field light switch BEACON LIGHTS AMBER ...

Page 33: ...tor 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...

Page 34: ...to run The HIGH pressure switch opens and stops the compressor when the pressure rises to 315 335 psi 2 172 2 310 kPa When the pressure falls to 220 280 psi 1 517 1 930 kPa the switch closes and allows the compressor to run If the air conditioning system is shut down by either switch locate the source of the problem and correct it before operating the system 5 11 INTERIOR LIGHTS Two interior light...

Page 35: ...9471 33 Revision E 5 12 OPERATOR AMENITIES CIGARETTE LIGHTER UTILITY TRAY UNDER ARMREST AUXILIARY POWER UTILITY TRAY ASHTRAY CUPHOLDER MANUAL STORAGE CASE COAT HOOK WINDOW SHADES OPTIONAL AUXILIARY POWER 3 GROUND 2 BATTERY 1 12V SWITCHED ...

Page 36: ...2 ANTENNA MOUNTING A roof mounted antenna base for installing a magnetic antenna is available as an option from your Dealer Order MD 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 and RH rear cab r...

Page 37: ...FULL Push Lever Forward OPERATING See Section 6 3 6 CLOSED Pull Lever Back IGNITION SWITCH ACC Fully Counterclockwise OFF All Electrical Systems Off RUN Clockwise START Fully Clockwise To Crank Engine Release and Switch Returns to RUN REMOVE KEY WHEN WINDROWER NOT IN USE KEY ALSO LOCKS DOORS FUEL Indicates Fuel Level in Tank E Empty F Full ENGINE TEMPERATURE Indicates Engine Coolant Temperature No...

Page 38: ...tral 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 TURN SIGNALS Activates Turn Signals on Windrower and Header Momentary Switches on Monitor REVERSE AUTO STEER ENGAGEMENT SWITCH Engages Auto Steer System If co...

Page 39: ... for detailed 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 not engage header with engine at full rpm 5 17 2 HEADER DRIVE REVERSE BUTTON NOTE The optional hydraulic reversing kit must be installed on draper headers with a conditioner and on auger headers R...

Page 40: ...odule 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 Cab Display Module CDM programming and on 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 ...

Page 41: ...ed 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 the following header functions 5 17 4 1 Deck Shift Float Preset Switch Draper Header with Deck Shift Option Controls deck shifting for double windrowing options with a draper header Draper Header with F...

Page 42: ...ler Switch If Installed Double Windrow Attachment DWA deck is raised or lowered if switch is installed and programmed It may be used in lieu of the DWA switches on the Ground Speed Lever GSL Swath Roller Roller is raised or lowered when switch is pressed DWA DOWN DWA UP SWATH ROLLER DOWN SWATH ROLLER UP ...

Page 43: ...yor Speed to Ground Speed Push On Push Off Illuminates In On Position SELECT SWITCH Allows Operator To Select Display Item Bottom Line See Pages 42 48 RETURN TO CUT HEIGHT SWITCH Allows Cutting Height Pre Set Push On Push Off FLOAT SWITCH HEADER LEFT SIDE Same As Above NOTE HEADER MUST BE ENGAGED HAZARD WARNING LIGHTS SWITCH Activates Hazard Warning Lights Cancels Turn Signal TURN SIGNAL SWITCHES ...

Page 44: ...or Ground Speed Lever 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 Cutterbar and Ground...

Page 45: ...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 C or F HYD OIL Hydraulic Oil Temperature VOLTS Engine E...

Page 46: ...r and Ground If sensor disabled HEIGHT and SENSOR flash alternately HEADER ANGLE TILT SENSOR If Sensor Disabled Angle Setting 00 0 10 0 Header Relative To Ground If sensor disabled ANGLE and SENSOR flash alternately L FLOAT R FLOAT SENS DISABLED If Sensor Disabled Left and Right Float Setting 0 0 10 0 If sensor disabled does not flash C or F HYD OIL Hydraulic Oil Temperature If sensor disabled OIL...

Page 47: ...ed 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 C or F HYD OIL Hydraulic Oil Temperature LOAD If Metric Bar Graph Representing Hydraulic Operating Pressure Full Scale Is Pre Programmed...

Page 48: ...EADER 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 C or F HYD OIL Hydraulic Oil Temperature LOAD If Metric Bar Graph Representing Hydraulic Operating Pressure Full Scale Is Pre Programmed Overload Pressure 2 500 5...

Page 49: ...tal 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 Operating Pressure Fu...

Page 50: ...essed On CDM See Note 2 HAZARDS Indicates Hazard Warning Lights Are On When Is Pressed On CDM ROAD GEAR With Hi Range Selected On Console Switch Engine forward Only See Note HEADER REVERSE Header Drive Running In Reverse HEADER ENGAGED Header Drive Engaged NOTE 1 If road light kit is not installed CDM will display LEFT STOP LAMP as a malfunction in CAB FORWARD mode 2 If road light kit is not insta...

Page 51: ... 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 221 227 ENGINE PREHEAT Illuminates Yellow Wait To Start Engine STOP Illuminates Red Stop Engine Immediately Refer to ...

Page 52: ...oud Tone For 10 Seconds 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 TEMPERATURE 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 None Header S...

Page 53: ...evel 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 OPERATOR NOT IN PARK ENGINE SHUTDOWN Continuous Tone Operator Not Detected In Seat With Header Engaged or Out Of Neutral Detent with Machine Moving at 5 mph 8 km h Engine Shutdown After 5 Seconds NO OPERATOR Continuous...

Page 54: ... 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 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 t...

Page 55: ... L2 X 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 X x x x I S C R P M E N D When the programming mode is entered the header ID will be displayed on the top line of the CDM using the last 4 display positions 500 to 100 range offset from set point 300 is default For Disc Headers only Pressing SELECT will go to the next line 1 L1 menu selection The turn signal arrow keys a...

Page 56: ...R S P E E D L2 X x x x 5 7 5 1 H R S E N A B L E D L2 X 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 X x x x 5 7 5 1 H R S E N A B L E D L2 X 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 X x x x 5 7 5 1 H R S E N A B L E D L2 X 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 X x x x 5 7 5 1 H R S E N A B L E D L2 X x x x 6 4 8 6 H R S L O C...

Page 57: ... T H O L D L2 X x x x H D R T I L T C O M P L E T E If NO then jump to The display will indicate the sensor being calibrated 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...

Page 58: ... D I S A B L E L1 C x x x H E A D E R H T S E N S O R L2 X x x x E N A B L E D I S A B L E L1 C x x x H E A D E R T I L T S E N S O R L2 X x x x E N A B L E D I S A B L E L1 C x x x H E A D E R F L O A T S E N S O R L2 X x x x E N A B L E D I S A B L E L1 C x x x O V E R L O A D P R E S S U R E L2 X x x x E N A B L E D I S A B L E The operator can select any of the three items requiring calibratio...

Page 59: ... A T E R E E L H T L2 X x x x D O W N U P L1 C x x x A C T I V A T E H D R T I L T L2 X x x x I N O U T L1 C x x x K N I F E D R V S P D X X X X L2 X x x x D 0 P 0 L1 C x x x D R A P E R D R V S P D X X X X L2 X x x x D 0 P 0 L1 C x x x R E E L D R V S P D X X X X L2 X x x x D 0 P 0 L1 C x x x D I S C D R V S P D X X X X L2 X x x x D 0 P 0 L1 C x x x A C T I V A T E D W A D R V L2 X x x x D 0 P 0 ...

Page 60: ... D R A P E R L2 X x x x 2 5 F T D K D R A P E R L2 X x x x 3 0 F T D K D R A P E R L2 X x x x 3 5 F T D K D R A P E R L2 X x x x 4 0 F T D K D R A P E R L1 C x x x E X I T F O R C E H E A D E R L2 X x x x N O Y E S S E L E C T H E A D E R T Y P E L1 C x x x E X I T D I A G N O S T I C L2 X x x x N O Y E S V I E W E R R O R C O D E S L1 C x x x E X I T S E T U P L2 X x x x N O Y E S W I N D R O W E...

Page 61: ... 500 Thin 2 000 2 200 Suggested Overload Setting 1 300 rpm 5 18 7 ENGINE ERROR CODES The Cab Display Module CDM displays Error Codes when there is a fault with one of the several sensors that monitor and control engine operation to assist the Operator or technician in locating a specific problem with engine operation Refer to the Appendix for the Error Codes 5 18 8 CAB DISPLAY MODULE CDM AND WINDR...

Page 62: ...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 instru...

Page 63: ...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 64: ...od artificial light 6 3 2 BREAK IN PERIOD The windrower is ready for normal operation However there are several items to check and watch out for during the first 150 hours In addition to the following perform the items specified in to section 7 13 1 Break In Inspections DANGER Before investigating an unusual sound or attempting to correct a problem place Ground Speed Lever GSL in N DETENT shut off...

Page 65: ...2 Remove plastic bags and or tape from all sealed openings air cleaner intake exhaust pipe fuel tank 3 Charge battery and install Be sure terminals are clean and cables are connected securely 4 Adjust tension on A C compressor belt See Section 7 8 10 1 Tension 5 Cycle A C switch to distribute A C refrigerant oil c Perform annual maintenance See Section 7 13 MAINTENANCE SCHEDULE 6 3 4 DAILY CHECK a...

Page 66: ...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 maintained ...

Page 67: ...rt wait at least two minutes before trying again After the third 15 second crank attempt allow solenoid to cool for 10 minutes before further cranking attempts If engine still does not start refer to Section 9 Troubleshooting WARNING If starter engages with steering wheel unlocked ground speed lever out of Neutral or header clutch engaged DO NOT START ENGINE See your Dealer h Cold Start engine tem...

Page 68: ...wn 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 counterclockwise to OFF position 6 3 5 5 Fueling WARNING To avoid personal inj...

Page 69: ...psi 52 kPa a continuous loud tone will sound and the CDM display will flash ENGINE OIL PRESS Shut down 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...

Page 70: ...f this type of steering is different than conventional steering mechanisms CAUTION With the engine running moving the ground speed lever out of N DETENT unlocks steering Any movement of steering wheel will then cause the machine to move even if the ground speed lever has not been moved forward or rearward from the Neutral position Hydrostatic steering is more sensitive than mechanical steering Ste...

Page 71: ...ion A child or even a pet could engage an idling machine o Turn off wipers o Turn off lights unless required for inspection purposes o Release seat belt o Raise armrest and steering wheel for easier exit and re entry o Lock the cab door when leaving the windrower unattended When the door is locked it can still be opened from inside the cab Swing away platforms and stairs A are provided on both sid...

Page 72: ... is fastened 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 2 250 2 340 rpm at G CAUTION Check again to be sure all bystanders have cleared the area f Slowly move the GSL A forwar...

Page 73: ...area c Move the Ground Speed Lever 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 Speed Lever 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 ...

Page 74: ... up a ramp up a hill or up out of a ditch 1 Move the GSL A closer to eutral 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 is opposite to n...

Page 75: ...this 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 posi...

Page 76: ...d steering wheel locked DANGER Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine a Raise rear of windrower slightly so that most of the weight is off the casters using a jack or other lifting device under the frame where shown NOTE Lifting device should have a lifting capacity of at least 5 000 lb 2 270 kg b ...

Page 77: ...nstalled 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 lb ft 447 N m 3 Tighten and torque bottom bolts C to 330 lb ft 447 N m g Lower windrower to ground IMPORTANT Re torque bolts after first 5 and 10 hours of operation A B C ...

Page 78: ...CAUTION Check local laws for width regulations 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 See Section 5 7 3 Do not drive windrower on a road or highway at night or in conditions whic...

Page 79: ...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 heade...

Page 80: ...pment without brakes do not exceed 20 mph 32 km h CAUTION To tow a header for transporting with a M205 Self Propelled Windrower the header must be equipped with the appropriate equipment to comply with all local regulations Before each towing trip a pre trip inspection must all be conducted to verify that all signal lighting and safety equipment is installed and functioning properly Do NOT exceed ...

Page 81: ...le A at the top of the lift arms for additional lift height for transport wheel deployment DANGER To avoid bodily injury from fall of raised header always engage header lift cylinder stops when working on or around raised header d Raise header to full height stop engine and engage safety locks on lift cylinders e Deploy header slow speed transport system See header operator s manual f Remove float...

Page 82: ...itch to header as follows 1 Position end G of the aft section onto front wheel hook H 2 Push down until latch J captures the end G 3 Secure latch J with clevis pin K 4 Remove the L pin from end L of aft section if installed 5 Position end M of the forward section into end L of the aft section 6 Lower forward section into aft section 7 Fully insert L pin N in upper hole and turn pin to lock it Secu...

Page 83: ...ed in storage location C and NOT installed at hole location B o Drive windrower so that windrower lift arms are positioned into the weight box pockets p 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 q Route the weight box harness R to the elec...

Page 84: ...ower lift arms until the lift arm floats up away from the linkage at the rear of the lift arm u Attach slow speed transport hitch to the weight box tongue with drawbar pin secure using lynch pin Attach safety chain v Connect hitch harness to electrical socket at front of weight box w Remove the temporary lift pins A should be loose in lift arm and place into storage holes on weight box HEADER TILT...

Page 85: ... 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 pins...

Page 86: ...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 attaching header to windrower Disengage lift cylinder locks n Start engine lower weight box onto blocks and back away o Attach header to windrower Refer to Section 6 5 1 Header Attachment p Convert header into...

Page 87: ... may roll on a sloped surface Before disengaging final drives attach windrower to towing vehicle After towing engage drives and ensure Ground Speed Lever GSL is in N DETENT before detaching from towing vehicle IMPORTANT Failure to disengage final drives before towing will result in serious transmission damage IMPORTANT Do NOT exceed 16 mph 26 km h when towing windrower IMPORTANT Do NOT use this to...

Page 88: ...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 Repaint all worn or chipped painted surfaces to prevent rust i Lubricate the windrower thoroughly leaving excess grease on fittings to keep moisture out of bearings App...

Page 89: ...th 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 switch...

Page 90: ...r 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 the spri...

Page 91: ...NDER 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 shut down the engine and remove the key 3 Tur...

Page 92: ...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 and f to set the float i Select a third preset with the float preset switch j Repeat steps e and f to set ...

Page 93: ...ember 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 94: ...tch to engage header drive A slight delay between switch on and operating speed is normal 3 Push switch 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 standard for rotary disc headers Reverses knife and conditioner on D Series draper headers Reverses reel...

Page 95: ...te HEADER TILT UP switch on Ground Speed Lever 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 TILT DOWN switch on GSL handle so that cylinder extends The CDM display will show a reading on the lower line of increasing value between 00 0 and 10 0 c The header til...

Page 96: ...469 169470 169471 94 Revision E 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 B C ...

Page 97: ...e See 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 off 2 Adjust the header to the desired cutting height with the HEADER UP or HEADER DOWN switches on the Ground Speed Lever GSL CDM displays between 00 0 and 10 0 3 Adjust the header angle with th...

Page 98: ...isplayed 5 Press or to change value on lower line Working range is 4 0 to 9 5 OFF disables the feature 6 Press PROGRAM to exit programming mode when finished entering desired values b Use the AUTO RAISE HEIGHT feature as follows IMPORTANT The windrower must be running with the header engaged at the cutting height and the RETURN TO CUT switch activated 1 Double click HEADER UP switch on the Ground ...

Page 99: ...efer to MacDon M Series Windrower Double Windrow Attachment Manual MD 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 Double Windrow Attachment DWA UP and DOWN switches on the Ground Speed Lever GSL or with the rocker switch on the Operator s console depending on how the windrower Cad Di...

Page 100: ... 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 attached to windrower ensure that float engagement pin is installed in storage location A and NOT installed at hole location B a If not installed attach draper header boots supplied with header to windrower li...

Page 101: ... 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 legs and header nudges forward e Check that linkages are properly engaged in header legs contacting support plates f Adjust the position of the center link cylinder with the REEL UP and REEL DOWN switches...

Page 102: ... 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 Remove pin from storage position K in linkage and insert in hole L to engage float springs Secure with hairpin m Disengage lift cylinder stops Refer to Section 6 4 1 Header Lift Cylinder Stops n Start eng...

Page 103: ... loaded 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 header lift linkages without a header or weight box attached to windrower ensure that float engagement pin is installed in storage location E and NOT installed at hole location D f Disengage l...

Page 104: ... 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 from header NOTE If hay conditioner is installed watch clearances on both sides n Reinstall pin A into header leg and secure with hairpin M H HEADER TILT UP HEADER TILT DOWN REEL UP REEL DOWN A ...

Page 105: ...n the Ground Speed Lever 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 and can be activated during programming the Cab Display Module CDM 6 5 5 REEL HEIGHT Press and hold the switch for the desired up or down movement of the reel IMPORTANT Under certain conditions with reel...

Page 106: ...nd reduces 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 Check to be sure all bystanders have cleared the area NOTE DISPLAY will flash MIN REEL MPH or KPH to prompt the Operator to change the minimum set point or increase ground speed if Ground Speed P...

Page 107: ...ndrower 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 Set the speed of the reel independently of ground speed as follows CAUTION Check to be sure all bystanders have cleared the area NOTE This procedure can also be used to change the draper speed on the go...

Page 108: ...setting 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 S...

Page 109: ... 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 110: ...eader code is detected the CDM displays NO HEADER and the knife speed reverts to a range from 0 1 400 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 1 500 1 900 20 and 25 1 400 1 700 30 1 200 1 600 35 1...

Page 111: ...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 will indi...

Page 112: ...pplied 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 header 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 lo...

Page 113: ...Lower the center link onto the header with REEL DOWN switch until it locks into position handle is down IMPORTANT Hook release must be down to enable self locking mechanism If the release is open up manually push it down after hook engages header pin Check that center link is locked onto header by pulling upward on rod end of cylinder f Raise the header fully with the HEADER UP switch on the GSL S...

Page 114: ...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 engage float springs Secure with lynch pin m Disengage lift cylinder stops n Start engine and activate HEADER DOWN switch on GSL to lower header fully Stop engine and remove key o Connect header drive hydra...

Page 115: ... header boots B on header d Lower stand C by pulling pin D inverting stand and re locating on bracket Reinsert pin D and secure with hairpin e Remove pin 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 ...

Page 116: ...ase 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 header operator s manual l Slowly back windrower away from header m Reinstall pins A in header boots B HEADER TILT UP HEADER TILT DOWN REEL UP REEL DOWN G H B A J K ...

Page 117: ...eel Speed 6 6 3 2 A30 D Headers On A30 Series auger headers the auger speed is fixed to the knife speed NOTE The auger speed can be independently changed from the knife speed by changing the drive sprocket Refer to A30 S A30 D and A40 D Self Propelled Windrower Headers Operator s Manual Display the auger speed as follows DISPLAY SELECTOR DISPLAY HEADER INDEX ENGAGE HEADER HEADER INDEX SWITCH OFF O...

Page 118: ...RTANT Windrower can be moving but must be less than minimum reel speed a Display will flash MIN REEL mph or kph to prompt the Operator to change the minimum set point or increase ground speed if Ground Speed Plus Index is less than the minimum reel speed set point 6 6 4 1 1 3 Reel Index Set Reel Index as follows while driving windrower at normal operating speed and greater than minimum reel speed ...

Page 119: ...e is detected the CDM displays NO HEADER and the knife speed reverts to a range from 800 1 000 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 D All 1 400 1 950 Auger A30 D All 1 550 1 950 Suggested Overload Setting 75 of Knife Speed NOTE The knife speed cannot be programmed outside the range s...

Page 120: ...lled 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 with the kit See above 6 7 1 HEADER ATTACHMENT a Remove hairpin from pin A and remove pin from on left and right header boots B on header IMPORTANT To prevent damage to the lift system when lowering header...

Page 121: ...on the hook above the header attachment pin e Lower the center link onto the header with REEL DOWN switch until it locks into position handle is down IMPORTANT Hook release must be down to enable self locking mechanism If the release is open up manually push it down after hook engages header pin Check that center link is locked onto header by pulling upward on rod end of cylinder f Raise the heade...

Page 122: ...erted and hairpin is installed 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 HEADER DOWN switch on GSL to lower header fully Stop engine and remove key l Connect header drive hydraulics and electrical harness to header Refer to your rotary disc header operat...

Page 123: ...ge 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 hole location C e Disengage lift cylinder stops f Start engine choose a level area and lower header to the gro...

Page 124: ...169469 169470 169471 122 Revision E 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 Reinstall pins A in header boots B A B ...

Page 125: ...te at the original set point Crop Condition Disc rpm Alfalfa Heavy 2 100 2 300 Light 1 800 2 000 Sudan Sorghum Haygrazer Timothy Tall and Stemmy 2 300 2 500 Short Grass Dense 2 500 Thin 2 000 2 200 Suggested Overload Setting 1 300 rpm NOTE Higher engine rpm may be required to engage the R85 headers Do NOT exceed 1 800 rpm NOTE Desired disc speed will only be maintained above 1 500 rpm engine Disc ...

Page 126: ...e 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 will cause driv...

Page 127: ...ne Glycol With SCA Equal Parts With Water Engine Coolant A C Refrigerant R134A Refrigerant Cab A C System A C Compressor Oil SP 15 Compressor Oil Cab A C 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...

Page 128: ... increase torque values by 5 7 3 2 1 1 SAE Bolts Bolt dia A in NC BOLT TORQUE SAE 5 SAE 8 lb ft N m lb 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 1 205 Torque categories for bolts and cap screws are identified by their head markings 7 3 2 1 2 Metric Bolts B...

Page 129: ...bly 7 3 2 3 O Ring Boss ORB Hydraulic Fittings a Inspect O ring and seat for dirt or obvious defects b On angle fittings back off the lock nut until washer A bottoms out at top of groove B in fitting c Hand tighten fitting until back up washer A or washer face if straight fitting bottoms on part face C and O ring is seated d Position angle fittings by unscrewing no more than one turn e Tighten str...

Page 130: ...ead tube or hose nut until hand tight The nut should turn freely until it is bottomed out Torque fitting further to the specified number of F F F T Flats From Finger Tight or to a given torque value in the table shown in the opposite column NOTE If available always hold the hex on the fitting body to prevent unwanted rotation of fitting body and hose when tightening the fitting nut e When assembli...

Page 131: ...er square inch psi x 6 8948 kilopascals kPa x 00689 megapascals MPa Torque pound feet or foot pounds lb ft x 1 3558 newton meters N m pound inches or inch pounds lbf in or in lbf x 0 1129 Temperature degrees Fahrenheit F F 32 x 0 56 Celsius C Velocity feet per minute ft min x 0 3048 meters per minute m min feet per second ft s x 0 3048 meters per second m s miles per hour mph x 1 6063 kilometers p...

Page 132: ...further b To close hood 1 Grasp the strap at B and loop under upper hook C IMPORTANT Failure to hook strap may result in it becoming entangled with the screen cleaners or the latch 2 Pull down on strap B grasp the hood when within reach and lower until hood engages latch A c Open the hood at the highest position as follows 1 Open hood to lowest position 2 Remove strap from hooks C and D and allow ...

Page 133: ...OR 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 lowest position IMPORTANT Failure to open hood will result in damage to the hood when the platform is repositioned b Unlock latch A and move platform B toward open position but do not lock in full aft po...

Page 134: ... and use the Maintenance Checklist provided to keep a record of scheduled maintenance Refer to Section 7 13 MAINTENANCE SCHEDULE 7 6 1 LUBRICATION 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 Lubricant Spec Description Use Grease SAE Multi Purpose High Temperature Extreme Pressure EP2 Pe...

Page 135: ...d FORMED CASTER WHEEL BEARING 1 PLACE BOTH WHEELS FORKED CASTER SPINDLE BEARINGS TWO PLACES BOTH WHEELS TOP LINK TWO FITTINGS BOTH SIDES WALKING BEAM PIVOT CASTER PIVOT BOTH SIDES High Temperature Extreme Pressure EP2 Performance With 1 Max Molybdenum Disulphide NLGI Grade 2 Lithium Base ...

Page 136: ...he 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 shut down the Operator presence system requires adjustment See your M...

Page 137: ...nut D to either tighten or loosen the pivot The nut should be tightened to snug and then backed off 1 2 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 Ground Speed Lever 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...

Page 138: ...k steering rod bolts 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 Back off jam nut E 2 Tighten inside nut F to 70 80 lb ft 95 108 N m 3 Hold inside nut F and tighten jam nut E to 60 70 lb ft 81 95 N m f If steering link ball joints B or steering rod ba...

Page 139: ...steering 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 A It should be 5 8 inches 16 mm d Adjust dimension as follows 1 Loosen nut B and turn nut C to achieve 5 8 inches 16 mm dimension 2 Tighten nut B against...

Page 140: ...pushes plunger Adjust or replace switch as follows a Place GSL in N DETENT shut down 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 s...

Page 141: ...E AND SERVICING 169469 169470 169471 139 Revision E 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 142: ...rd surface 2 Using a Dry 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 60 psi 414 kPa Do NOTdirect 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 d Inspect filter before installing as follows 1 Hold a br...

Page 143: ...aner 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 frequent cleaning may be necessary in severe conditions Cleaning the condenser can be done at the same time as the radiator oil cooler and charge air cooler Refer to Section 7 9 COOLING BOX 7 7 6 4 A C E...

Page 144: ...ese 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 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 started after storage for more than one we...

Page 145: ...ean Straw and chaff on a hot engine are a fire hazard Never use gasoline naphtha or any other volatile material for cleaning purposes These materials are toxic and or flammable 7 8 1 GENERAL ENGINE INSPECTION Engine inspection should be performed by your MacDon Dealer Refer to your engine manual for further information Owner s Manual QSB4 5 and QSB6 7 Engine Cummins 4021531 supplied with your mach...

Page 146: ...tform 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 Open engine compartment hood to lowest position See Section 7 4 ENGINE COMPARTMENT HOOD e Clean area around the plastic cap on access hole B Remove the cap f Insert the tool C into the flywheel housin...

Page 147: ...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 Add oil as follows if level is below the LOW mark Two U S quarts 1 9 liters will raise the level from LOW to HIGH CAUTION Do not fill above the HIGH mark 1 Remove filler cap by turning it counterclockw...

Page 148: ...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 1 2 to 3 4 turn by hand IMPORTANT Do not use a filter wrench to install the oil filter Over tightening can damage the gasket and filter l Install the oil pan drain plug A m Remove oil filler pipe ca...

Page 149: ... requires cleaning NOTE Over servicing the filter element increases the risk of dirt being ingested by the engine and severely damaging the engine Filter servicing should only be performed when the CDM indicates ENGINE AIR FILTER or at the specified interval Refer to Section 7 13 MAINTENANCE SCHEDULE 7 8 5 1 Air Filter Servicing DANGER Stop engine and remove key from ignition before leaving Operat...

Page 150: ...nto canister seal first and push until seal is seated inside canister IMPORTANT When replacing safety filter re insert new filter as soon as possible to prevent dirt from entering engine intake i Insert new primary filter element K into canister over safety element and push into place ensuring that element is firmly seated in canister j Position end cap F onto filter housing with aspirator pointin...

Page 151: ...ghten loose clamps n If spring type clamps M require tightening use a gauge as shown o Constant torque type clamps N should be tightened to achieve gap as shown p Clamp O should be tightened to 25 40 in lbf 2 8 N m q Close engine compartment hood M HOLD 0 018 in 0 46 mm GAUGE BETWEEN MIDDLE COILS AND TIGHTEN CLAMP UNTIL GAUGE IS SNUG REMOVE GAUGE M 0 157 02 in 4 0 5 mm O N ...

Page 152: ...ety elements IMPORTANT The air cleaner s primary outer filter element should be replaced after three cleanings or at the specified interval Refer to Section 7 13 MAINTENANCE SCHEDULE IMPORTANT The safety inner element should be replaced every third time the primary element is changed 6 Clean element with compressed air and a Dry Element Cleaner Gun 7 Hold nozzle next to inner surface and move up a...

Page 153: ...tion See Section 7 4 ENGINE COMPARTMENT HOOD b Locate filter A on vent line against hydraulic oil reservoir c Release hose tension clamps B and slide away from filter Pull hoses off filter d Position new filter through hole in frame and attach top hose onto filter IN marking should face down NOTE If filter has an arrow instead of an IN marking arrow should point up e Attach lower hose to filter an...

Page 154: ...o 3 4 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 Place a container under the filter to catch split fluid 3 Remove filter D with a filter wrench 4 Clean gasket mating surface IMPORTANT Do not pre fill filter with fuel Pre filling can contaminate the...

Page 155: ...n or fire do not smoke or allow flame or sparks near windrower when servicing a Stop engine and remove key b Open engine compartment hood to lowest position See Section 7 4 ENGINE COMPARTMENT HOOD c Close fuel supply valve A d Place a 5 U S gallon 20 liter drain pan under the fuel supply hose B at primary filter e Loosen clamp C and pull hose B off fitting f Route hose to drain pan and open valve ...

Page 156: ...fold Small amounts of air introduced by changing filters or injection pump supply line will be vented automatically if the fuel filters are changed in accordance with instructions WARNING The fuel pump high pressure fuel lines and fuel rail contain extremely high pressure fuel Never loosen any fittings Personal injury and property damage can result IMPORTANT Bleeding the fuel system is not recomme...

Page 157: ...he 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 right 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 hood to lowest position See...

Page 158: ...rably 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 2 000 hours or 2 years Change coolant and flush the system as follows CAUTION ...

Page 159: ...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 system with a solution of clean water and a heavy duty radiator cleaner Follow instructions provided with cleaner o After using cleaner solution again flush system with clean water Inspect radiator ho...

Page 160: ...ne a Check the lubricant level every 50 hours as follows 1 Park the windrower on level ground shut down 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 See Section 7 4 ENGINE COMPARTMENT HOOD 2 Remove breather cap B and add lubricant until it runs ou...

Page 161: ...under the gearbox c Remove drain plug C and allow the oil to completely finish draining d Install the drain plug C and remove the check plug A e Unscrew breather cap B and add lubricant The gearbox will require 2 2 U S quarts 2 1 liters Add sufficient lubricant until it slightly runs out of hole A Use SAE 75W 90 API Service Class GL 5 Fully Synthetic Transmission Lubricant SAEJ2360 preferred f Ins...

Page 162: ...exhaust system may allow exhaust gases to escape to the cab c Dents or crushed portions of any tubing create exhaust flow restriction and increase back pressure significantly Even relatively small dents will cause decreased fuel economy and increased turbo wear If dents are relatively large increased bearing and cylinder wear will occur due to increased exhaust temperature d The exhaust system sho...

Page 163: ...rdware 5 Re check tension and re adjust as required 7 8 10 2 A C Compressor Belt Replacement a Shut down 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 ...

Page 164: ...nstall new belt D around fan and onto pulleys in order 3 2 1 i Insert the drive end of a 1 2 inch drive ratchet wrench into the belt tensioner C j Rotate tensioner counterclockwise until belt D can be slipped onto pulley E Release tensioner and remove wrench k Check that belt is properly seated in all pulley grooves l Install A C compressor belt A on pulleys m Pry compressor away from engine so th...

Page 165: ...ranty See also Section 6 3 5 3 Engine Intermediate Speed Control ISC 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 in the cab should move the throttle sensor the full range between slow speed stop and full rpm stop without contacting the console at either position If the throttle l...

Page 166: ...ed Service rotors and screen as follows a Stop engine and remove key b Raise engine compartment hood fully See Section 7 4 ENGINE COMPARTMENT HOOD c If rotors A are plugged clean as follows 1 Remove nut B 2 Pivot rotor assembly C away from screen 3 Blow out debris from rotors A with compressed air d Push latch D and open screen assembly access door E Secure with rod F stored inside screen door e I...

Page 167: ...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 motor mount bolts D 5 Move motor duct assembly E to obtain 0 04 0 32 in 1 8 mm gap to screen at full rotation of the duct 6 Re tighten nuts D on motor mount c Close screen access door F and engage latch ...

Page 168: ...fer to illustrations below and proceed as follows DANGER Stop engine and remove key from ignition before leaving Operator s seat for any reason A child or even a pet could engage an idling machine a Stop engine and remove key b Raise engine compartment hood fully See Section 7 4 ENGINE COMPARTMENT HOOD c Push latch A and open screen assembly access door B Secure with rod C stored inside the screen...

Page 169: ...an be very easily bent which may interfere with its function Exercise caution when cleaning h Clean radiator M through access holes in cooling box with compressed air i Clean oil cooler A C condenser N charge air cooler O fuel cooler P and cooling box Q with compressed air j Inspect all lines and coolers for evidence of leaks and damage k Slide oil cooler F back into cooling box continued next pag...

Page 170: ... l Close side access door E and lock with lever D m Close top door K and secure with wing nut K n Unhook support rod C in screen door and store in screen door o Close screen door B until latch engages pin A p Lower hood and hood latch will lock hood D E K L A B C ...

Page 171: ...onditions 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 10 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 Check batt...

Page 172: ...ctions for proper hook up and use of battery charger v Turn off charger prior to hook up to avoid dangerous sparks Wear proper eye protection vi If the electrolyte is accessible verify that plates are covered before charging Distilled water may be added after charging to bring levels to proper height then charge for additional 30 minutes to mix If electrolyte levels are low but battery is not acce...

Page 173: ...ine starts disconnect cable from windrower ground first and then disconnect the other cables g Replace rubber cover on boost post A 7 10 1 5 Adding Electrolyte WARNING Keep all smoking materials sparks and flames away from electrolyte container and battery as gas given off by electrolyte is explosive Battery electrolyte causes severe burns Avoid contact with skin eyes or clothing Wear protective e...

Page 174: ...sing Platform for Major Servicing c Remove red plastic cover from positive cable clamps A Loosen the clamps and remove cable from batteries d Loosen clamps B on negative terminals and remove cable from batteries e Remove bolts C securing strap D to frame and remove strap f Lift batteries off holder E NOTE Battery holder E can be removed from frame by simply lifting holder and pulling it away from ...

Page 175: ...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 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 alternat...

Page 176: ...gine and remove the key c Turn headlights A ON 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 3 4 inches 1 263 mm above ground at a distance of 25 ft 7 5 m...

Page 177: ...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 C ...

Page 178: ... engage an idling machine 7 10 3 1 Adjustment The field lights are best adjusted with the machine in the field or equivalent to suit Operator preference a Hold onto the hand holds A on the cab front corners and stand on the header anti slip strips b Adjust the lights with screws B 7 10 3 2 Bulb Replacement a Remove the two screws C and remove light assembly b Replace the bulb as described in Secti...

Page 179: ...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 glass of the halogen bulb as the oils or other chemicals from your skin will cause the bulb to fail prematurely g Match slots on new bulb E with lugs G in optical unit and insert bulb into unit h Secure bu...

Page 180: ... 10 5 2 Bulb Replacement a Shut down engine and remove the key Turn lights OFF b Remove the two screws C and remove light bezel D c Remove light from receptacle d Pinch the wire retainer E and lift away from hooks e Remove bulb F from body and pull wire from connector G IMPORTANT Do not touch the glass of the halogen bulb as the oils or other chemicals from your skin will cause the bulb to fail pr...

Page 181: ...ve 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 for red tail lights and 1156 for amber lights e Reinstall lens with screws B 7 10 7 RED TAIL LIGHTS IF INSTALLED DANGER Stop engine and remove key from ignition before leaving Operator s seat for any r...

Page 182: ...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 counterclockwise to unlock lens from base and remove lens c Pinch retainer and remove it from lamp socket d Pull lamp out of socket e Disconnect harness from lamp continued next page ...

Page 183: ... 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 184: ...wise 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 LIGHT a Shut down engine b Remove two screws E from plastic lens and remove lens c Replace bulb d Reinstall plastic lens with screws E 7 10 11 AMBIENT LIGHT a Shut down engine b Push against tabs F with a ...

Page 185: ...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 illustration next page 7 10 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 186: ...MAINTENANCE AND SERVICING 169469 169470 169471 184 Revision E 7 10 13 3 Fuse Box Decal ...

Page 187: ...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 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 existin...

Page 188: ... the inside of it with unused diesel fuel or unused commercial petroleum cleaning solvent for ten seconds minimum Do not use water water soluble cleaners or compressed air IMPORTANT The components in this system are built to very close tolerances and have been adjusted at the factory Do not attempt to service these components except to maintain proper oil level change oil and filters and to adjust...

Page 189: ...e add mark on the dipstick 7 11 2 HYDRAULIC OIL COOLER The hydraulic oil cooler is located inside the cooling box behind the radiator It should be cleaned daily with compressed air Refer to Section 7 9 3 Cooling Box Maintenance 7 11 3 CHANGING HYDRAULIC OIL NOTE Change hydraulic oil every 1 500 hours a Stop engine and remove key b Open engine compartment hood to highest position c Place a suitable...

Page 190: ...anged at any other time a vacuum must be applied to the supply tank to prevent the oil from running out of the filter head when the filter is removed a Stop engine and remove key b Open engine compartment hood to highest position c Clean around head of the filter d Unscrew the filter with a filter wrench e Clean the gasket surface of the filter head f Apply a thin film of clean oil to the filter g...

Page 191: ...filter 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 filter after the first 50 hours of operation and every 500 hours thereafter Filter part MD 112419 can be obtained from your Dealer a Stop engine and remove key b Move left cab forward platform out to...

Page 192: ...rive capacity problems develop the pressure relief valve may require adjusting Contact your windrower Dealer or refer to the technical manual for your windrower Header Model Application System Windrower Differential Relief Setting header attached psi bar R80 R85 Disc Pressure 5 500 379 D60 D65 and A40D Reel Draper Pressure 2 900 200 D60 D65 and A40D Knife Conditioner Pressure 4 000 275 7 11 5 2 Fl...

Page 193: ...g 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 knob A on needle valve and then turn knob B clockwise to decrease the drop rate or counterclockwise to increase the drop rate d Tighten jam nut A e Close platform and engine compartment hood f Check drop ra...

Page 194: ...on 7 11 1 Oil Level b Check the hoses and lines for leakage c Check the charge pressure relief valve Refer to following section d If charge pressure still cannot be maintained do NOT operate the windrower Contact your windrower Dealer 7 11 6 2 Charge Pump Pressure Incorrect charge pressure settings may result in the inability to build required system pressure and or inadequate loop flushing flows ...

Page 195: ...nds and body away from pin holes and nozzles which eject fluids under high pressure If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result Use a piece of cardboard or paper to search for leaks IMPORTANT Keep hydraulic coupler tips and connectors clean Dust dirt water and foreign material are the m...

Page 196: ...ot remove install or make repairs to a tire on a rim unless you have the proper equipment and experience to perform the job Take the tire and rim to a qualified tire repair shop If the tire is not in correct position on the rim or if too full of air the tire bead can loosen on one side causing air to leak at high speed and with great force An air leak of this nature can thrust the tire in any dire...

Page 197: ...e Pressure Gear Lubricant After first change use SAE 75W 90 API Service Class GL 5 Fully Synthetic Transmission Lubricant SAE J2360 preferred 4 Replace plugs and tighten b Change the lubricant as follows 1 Rotate the wheel so that one of the plugs A is located at the bottom 2 Place a large enough container about 2 quarts US 2 liters under the drain plug A 3 Remove top plug B and drain lubricant Id...

Page 198: ...o 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 h Tighten nuts to 220 lb ft 300 N m using the tightening sequence shown above NOTE To avoid damage to wheel rims do not over tighten wheel nuts i Repeat sequence three times j Lower win...

Page 199: ...heel rim Never weld a wheel rim Make sure all the air is removed from a tire before removing the tire from the rim Never use force on an inflated or partially inflated tire Make sure the tire is correctly seated before inflating to operating pressure Do not remove install or make repairs to a tire on a rim unless you have the proper equipment and experience to perform the job Take the tire and rim...

Page 200: ...h tires lb kg 7 5X16 A 10 38 200 91 10X16 B 18 69 380 170 16 5X16 1 C 41 158 830 377 Weights are given for typical calcium chloride and water mixtures Weight is reduced by 20 if only water is used for areas that do not require anti freeze protection Header Description Recommended Ballast Recommended Tire Size Level Ground Hills Type Size Per tire Both tires Per tire Both tires U S Gal Liters lb kg...

Page 201: ...remove key before performing any of the following checks and or adjustments a Remove the caster wheel as follows 1 Park windrower on level ground and block all wheels 2 Place GSL in N DETENT shut down engine and remove key 3 Raise end of walking beam using a jack 4 000 lb 1 816 kg capacity or other suitable lifting device until the wheel is slightly off the ground 4 Remove the eight bolts C attach...

Page 202: ... capacity or other suitable lifting device until the wheel is slightly off the ground 4 Undo the six wheel bolts A and remove wheel from hub b Install the caster wheel as follows 1 Position wheel on hub and install wheel bolts A 2 Torque bolts A to 120 lb ft 163 N m using the tightening sequence shown on previous page 3 Lower windrower and remove jack 7 12 2 6 Caster Wheels Anti Shimmy Dampeners E...

Page 203: ...Section 7 1 PREPARATION FOR SERVICING and Section 7 2 RECOMMENDED SAFETY PROCEDURES 7 13 1 BREAK IN INSPECTIONS BREAK IN INSPECTIONS HRS ITEM CHECK Every 25 Road or 1 in Field Drive Wheel Nuts Torque 220 lb ft 300 N m Repeat Checks Until Torque Stabilizes 5 A C Belt Tension Caster Wheel Nuts Torque 120 lb ft 163 172 N m Caster Wheel Anti Shimmy Dampener Bolts Inboard Bolt Torque 100 lb ft 135 N m ...

Page 204: ...ts 2 Grease Walking Beam Center Pivot 3 Grease Top Lift Link Pivots 4 Grease Forked Caster Spindle Bearings 5 Clean Cab Fresh Air Intake Filter 6 Check Gear Box Oil Level 100 HOURS OR ANNUALLY 1 Clean Cab Air Return Filter 250 HOURS OR ANNUALLY 1 Change Engine Oil and Filter 2 Change Engine Air Cleaner Primary Filter Element CDM displays ENGINE AIR FILTER 3 Check Drive Wheel Lubricant Level 4 Grea...

Page 205: ...el 7 8 3 Engine Coolant Level 7 8 9 1 Fuel Tank 7 8 6 Fuel Filter Water Trap 7 8 6 Hydraulic Hoses and Lines 7 11 7 Hydraulic Oil Cooler 7 11 2 Hydraulic Oil Level 7 11 1 Radiator 7 8 7 Tire Inflation 7 12 11 ANNUALLY A C Blower 7 7 6 Antifreeze Concentration 7 8 7 Battery Charge 7 10 1 Battery Fluid Level 7 10 1 Fuel Tank Vent Line Filter 7 8 6 Steering Linkages 7 7 4 50 HOURS Cab Fresh Air Intak...

Page 206: ...d Hydraulic Oil Filters 7 11 4 Safety Systems or Annually 7 7 2 1000 HOURS Drive Wheel Lubricant 7 12 13 Engine Valve Tappet Clearance 7 8 1 1500 HOURS OR BI ANNUALLY Hydraulic Oil and Filters 7 11 2000 HOURS OR BI ANNUALLY Engine Coolant 7 8 7 3 General Inspection 7 8 1 5000 HOURS OR BI ANNUALLY Engine Valve Tappet Clearance 7 8 1 WHICHEVER OCCURS FIRST IT IS RECOMMENDED THAT ANNUAL MAINTENANCE B...

Page 207: ... 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 manual reset 7 10 13 1 Loose electrical connection at fuel pump Ensure connector at pump is fully pushed in ECM fuse 1 of 2 blown Replace 7 10 13 2 ECM Ignition relay faulty Neutral Logic relay faulty Faulty injectors Conta...

Page 208: ...e Engine Overheats 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 Check thermostat Low engine oil pressure Check oil level 7 8 3 Low transmission oil pressure 7 11 1 Engine Overheats Low coolant level Fill reserve tank to proper level Ch...

Page 209: ...uel system Engine Emits White Exhaust Improper type of fuel Consult your fuel supplier and use proper type fuel for conditions 7 3 1 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 7 10 1 1 Controls not in N...

Page 210: ... 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 switch ON 7 10 1 2 8 3 HYDRAULICS SYMPTOM PROBLEM SOLUTION SECTION Header or Reel Not Lifting Contaminant in relief valve Clean relief valve at cy...

Page 211: ...ls 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 11 1 Check hydraulic oil filters 7 11 4 Brakes binding or not releasing fully Check pressure min 200 psi 1 379 kPa on bra...

Page 212: ...lve 7 11 6 2 Excessive Noise From Drive System Hydraulic line clamps loose Tighten clamps Air in system Check lines for leakage Mechanical interference in steering or ground speed linkage Adjust repair replace 7 7 3 and 7 7 4 Brakes binding or not releasing fully Check pressure min 200 psi on brake release valve Faulty pump or motor Contact MacDon Dealer Hydraulic Oil Filter Leaks At Seal Not prop...

Page 213: ...lace control No thermostat in engine water outlet manifold Install thermostat Odor From Air Louvers Plugged drainage hose Blow out hose with compressed air Dirty filters Clean filters 7 7 6 1 and 7 7 6 2 Air Conditioning Not Cooling Low refrigerant level Add refrigerant Switch contacts in thermostat burned excessively or sensing element defective Replace thermostat Clutch coil burned out or discon...

Page 214: ...ittle air circulation over condenser coil fins clogged with dirt or insects Clean condenser 7 9 3 Evaporator fins clogged Clean evaporator fins under cab floor 7 7 6 4 Too little refrigerant in system Contact MacDon Dealer Clogged expansion valve Clogged receiver drier Excessive moisture in system Air in system Blower motor sluggish in operation Thermostat defective or improperly adjusted Replace ...

Page 215: ...sture in system Contact MacDon Dealer Incorrect super heat adjustment in expansion valve Thermostat defective Defective blower switch or blower motor Partially open improper ground or loose connection in compressor clutch coil Windows Fog Up High humidity Run A C to dehumidify air and heater to control temperature 5 10 3 8 8 OPERATOR S STATION SYMPTOM PROBLEM SOLUTION SECTION Rough Ride Seat suspe...

Page 216: ... both auger and draper headers 9 6 COMPLETION KIT FOR DRAPER HEADER REEL DRIVE Used together with Completion Kit for Auger and Draper Header Drives 9 4 to allow operation of a draper header Includes reel fore aft plumbing 9 7 COOLING KITS There are three cooling kits available Hood air scoop Intake air pre cleaner and Air cooler radiator sweeps 9 8 DOUBLE WINDROW ATTACHMENT Allows auger header win...

Page 217: ...8 TOWING HARNESS The towing harness is used together with the weight box if towing a D Series draper header behind the windrower is desired 9 19 WARNING BEACONS Roof mounted rotating warning beacons Available for installation into pre wired cab including switch The beacons are standard equipment for export windrowers and optional for North America 9 20 WEIGHT BOX The weight box allows engine forwa...

Page 218: ...torque 199 removal installation 199 200 tread adjustment 74 CDM 41 CDM Displays 42 CGVW 78 Charge Filter 189 Charge Pressure 192 Circuit Breakers 183 Clamps 149 151 153 160 172 Compressor Oil 125 Console 25 Cooling Box 166 Daily check 63 Deck Shift Switch 39 Definitions 19 Disc Header attachment 118 detaching 121 disc speed set point 123 disc speed switch 39 disc speeds 59 Display set up 55 Displa...

Page 219: ... 158 Greasing 132 Ground Speed control lever 36 range switch 36 Hazard Lights 36 179 Header angle adjustment 93 attaching draper 98 detaching draper 101 drive 92 drop rate 96 191 engage 92 float adjustment 88 float switch 39 flotation 88 functions 41 height control 95 levelling 91 lift cylinder stops 87 monitoring 41 on off switch 37 operation 87 position switch 39 programming 52 return to cut 95 ...

Page 220: ... symbols 7 Safety Filter 148 Seat Adjustment 26 Seat Belts 27 maintenance 134 Separator 154 Serial Number 2 Servicing preparation 124 Sight Glass 187 Signal Lights 179 Specifications 20 Starting Engine 64 Steering chain 137 column adjust 27 links 136 Storage fuel and lubricants 125 windrower 86 Swath Roller 97 switch 40 Symbol Definitions 60 Tail Lights bulb replace 179 replace 179 Tire Inflation ...

Page 221: ...ve solenoid fault detected short circuit open circuit E 32 E132 H E A D E R U P D O W N P 5 7 Header up down solenoid fault detected short circuit open circuit E 33 E133 S C R E E N C L E A N E R S Screen cleaner output fault detected short circuit open circuit E 34 E134 R I G H T S T O P L A M P Right stop lamp output fault detected short circuit open circuit E 35 E135 L E F T S T O P L A M P Lef...

Page 222: ...ned on x x x x S x x F x x C Engine code configuration Canbus C E N T E R S T E E R I N G GSL or Pintal switches not closed with the key on engine off N O T I N P A R K GSL or Pintal switches not closed with the key on engine off B R A K E O N Engine running GSL out of PARK brake is still engaged P L A C E G S L I N T O N GSL or Pintal switches not closed with the key on engine off B R A K E S W F...

Page 223: ...lse Width or Period 1 Red 147 Accelerator Pedal or Lever Position Sensor Circuit Abnormal Frequency Pulse Width or Period 2 Red 1242 Accelerator Pedal or Lever Position Sensor 1 and 2 Data Erratic Intermittent 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 ...

Page 224: ...essure Data Valid but Above Normal Operational Range Moderately Severe Level Turbocharger 1 Speed 103 10 Amber 2345 Turbocharger speed invalid rate of change detected Abnormal Rate of Change 16 Amber 595 Turbocharger 1 Speed High Data Valid but Above Normal Operational Range Moderately Severe Level 18 Amber 687 Turbocharger 1 Speed Low Data Valid but Below Normal Operational Range Moderately Sever...

Page 225: ...etering Rail 1 Pressure High Data Valid but Above Normal Operational Range Moderately Severe Level 18 Amber 559 Injector Metering Rail 1 Pressure Low Data Valid but Below Normal Operational Range Moderately Severe Level Key Switch 158 2 439 Data erratic intermittent or incorrect Cylinder Power 166 2 None 951 Cylinder Power Imbalance Between Cylinders Data Erratic Intermittent or Incorrect Alternat...

Page 226: ...e Switch 558 2 Amber 431 Accelerator Pedal or Lever Idle Validation Circuit Data Erratic Intermittent or Incorrect 2 155 Data erratic intermittent or incorrect 4 Amber 551 Accelerator Pedal or Lever Idle Validation Circuit Voltage Below Normal or Shorted to Low Source 13 Red 432 Accelerator Pedal or Lever Idle Validation Circuit Out of Calibration System Diagnostic code 1 611 3 Amber 2185 Sensor S...

Page 227: ...cuit 6 N A Injector Current High 7 Amber 1142 Injector Cylinder 3 Mechanical System Not Responding Properly or Out of Adjustment Injector Cylinder 04 654 5 Amber 332 Injector Solenoid Cylinder 4 Circuit Current Below Normal or Open Circuit 6 N A Injector Current High 7 Amber 1143 Injector Cylinder 4 Mechanical System Not Responding Properly or Out of Adjustment Injector Cylinder 05 655 5 Amber 323...

Page 228: ...e Turbocharger 1Compressor Inlet Temperature 1172 3 Amber 691 Turbocharger 1 Compressor Inlet Temperature Sensor Circuit Voltage Above Normal or Shorted to High Source 4 Amber 692 Turbocharger 1 Compressor Inlet Temperature Sensor Circuit Voltage Below Normal or Shorted to Low Source Turbo Wastegate 1188 7 177 Turbo Wastegate not responding Exhaust Gas Pressure 1209 3 Amber 2373 Exhaust Gas Pressu...

Page 229: ...1 2789 15 None 2346 Turbocharger Turbine Inlet Temperature Calculated Data Valid but Above Normal Operational Range Least Severe Level Coolant Pressure 2981 3 Amber 2115 Coolant Pressure 2 Circuit Voltage Above Normal or Shorted to High Source 4 Amber 2116 Coolant Pressure 2 Circuit Voltage Below Normal or Shorted to Low Source 18 Amber 2117 Coolant Pressure 2 Data Valid but Below Normal Operation...

Page 230: ...NOTES 169469 169470 169471 228 Revision E ...

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