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214603

360

Revision A

1000846

A

Figure 5.132: Headlight Assembly

7.

Replace rubber insulator boot (A).

8.

Push connector onto light bulb.

1000845

A

Figure 5.133: Headlight

9.

Position headlight into light receptacle, ensuring top is
up, and secure with screws (A). To align the headlights,
refer to

Aligning Headlights, page 360

Aligning Headlights

DANGER

To avoid bodily injury or death from unexpected startup of the machine, always stop the engine and
remove the key from the ignition before leaving the operator

’

s seat for any reason.

NOTE:

Header should be attached and raised to maintain proper windrower stance.

1.

Position windrower in engine-forward mode on level ground so that headlights are positioned 7.5 m (25 ft.) in
front of a vertical surface.

2.

Shut down engine and remove key.

MAINTENANCE AND SERVICING

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Summary of Contents for M205

Page 1: ...M205 Self Propelled Windrower Operator s Manual 214603 Revision A 2018 Model Year Original Instruction The harvesting specialists ...

Page 2: ... 57 to 1 06 m s2 as measured on a representative machine during typical operations and analyzed in accordance with ISO 5008 During the same operations the weighted root means square hand arm vibration was less than 1 45 m s2 when analyzed in accordance with ISO 5349 These acceleration values depend on the roughness of the ground the speeds at which the windrower is operated the operator s experien...

Page 3: ...Declaration of Conformity 1025029 ...

Page 4: ...1025030 ...

Page 5: ...ne function and machine life and may result in a hazardous situation If you follow the instructions given here your M205 Windrower will work well for many years Use this manual in conjunction with your header operator s manual A manual storage case is provided in the cab Keep this manual handy for frequent reference and to pass on to new Operators or Owners Call your Dealer if you need assistance ...

Page 6: ... corner field lights remain on when the auto road light feature is activated 3 7 1 Field Light Cab Forward page 50 Driving on the Road page 179 Changed swath roller to swath compressor Double Windrow Attachment DWA Swath Compressor Switch if installed page 75 Added topic 3 19 12 Calibrating the Swath Compressor Sensor page 131 Added topic Converting from Transport Mode to Field Operation page 189 ...

Page 7: ... 369 Updated fuse box decal to MD 167962 Fuse Box Decal page 381 Changed wheel drive lubricant from 80W 140 to 75W 90 8 2 Recommended Fuel Fluids and Lubricants page 460 Added swath compressor to options and attachments chapter 7 3 11 Swath Compressor page 447 Added Recommended Fluids and Lubricants to the inside back cover Removed Pre cleaner and Sweeps kit B6422 from Options and Attachments chap...

Page 8: ...e lines below 1013874 A Machine Serial Number Location The windrower serial number plate A is located on the left side of the main frame near the walking beam Windrower model number Windrower serial number Year of manufacture 1005633 A Engine Serial Number Location The engine serial number plate A is located on top of the engine cylinder head cover Engine serial number Date of manufacture 214603 i...

Page 9: ...2 Understanding Safety Signs 17 Chapter 2 Product Overview 27 2 1 Definitions 27 2 2 Specifications 30 2 3 Windrower Dimensions 34 2 4 Component Location 37 Chapter 3 Operator s Station 39 3 1 Operator Console 39 3 2 Operator Presence System 41 3 2 1 Header Drive 41 3 2 2 Engine and Transmission 41 3 3 Operator s Seat Adjustments 42 3 3 1 Adjusting Fore Aft Position 42 3 3 2 Adjusting Seat Suspens...

Page 10: ...ency Exit 61 3 13 Operator Amenities 62 3 14 Radio 64 3 14 1 AM FM Radio 64 3 14 2 Mounting the Antenna 64 3 15 Horn 66 3 16 Engine Controls and Gauges 67 3 17 Windrower Controls 68 3 18 Header Controls 70 3 18 1 Header Drive Switch 70 3 18 2 Header Drive Reverse Button 70 3 18 3 Ground Speed Lever GSL Header Switches 71 Display Selector Switch 72 Reel Position Switches 72 Header Position Switches...

Page 11: ...g the Double Windrow Attachment DWA 98 Setting the Header Cut Width 101 Activating the Swath Compressor 102 Displaying Reel Speed 104 Setting the Windrower s Tire Size 105 Setting the Engine Intermediate Speed Control ISC RPM 106 Clearing Sub Acres 107 3 19 8 Activating Cab Display Lockouts 107 Activating the Header Tilt Control Lockout 108 Activating the Header Float Control Lockout 109 Activatin...

Page 12: ... the Cab Display Module CDM 152 Activating the Hydraulic Purge Using the Cab Display Module CDM 154 3 19 15 Engine Error Codes 156 3 19 16 Cab Display Module CDM and Windrower Control Module WCM Fault Codes 156 Chapter 4 Operation 157 4 1 Owner Operator Responsibilities 157 4 2 Symbol Definitions 158 4 2 1 Engine Functions 158 4 2 2 Windrower Operating Symbols 159 4 2 3 Header Functions 160 4 3 Op...

Page 13: ...Auto Raise Height Feature 212 4 4 9 Header Drop Rate 212 4 4 10 Using the Double Windrowing Attachment 213 Engaging and Disengaging the Double Windrow Attachment DWA 214 Adjusting Double Windrow Attachment DWA Draper Speed 214 4 4 11 Swath Compressor Option 215 Using the Swath Compressor 215 4 5 Attaching and Detaching Headers 217 4 5 1 Attaching Header Boots 217 4 5 2 Attaching a D Series or D1 S...

Page 14: ...Shift Control 272 Deck Shift 272 Setting Float Options with Deck Shift 273 4 7 Operating with an A Series Header 275 4 7 1 Auger Speed 276 Auger Speed on A30D Headers 276 Setting the Auger Speed on A40D Headers 276 4 7 2 Reel Speed 277 Reel Speed on A30D Headers 277 Reel Speed on A40D Headers 277 4 7 3 Knife Speed 280 4 8 Operating with an R Series Header 281 4 8 1 Disc Speed 282 Setting Disc Spee...

Page 15: ...r Filter 305 Cleaning Return Air Cleaner Filter 306 5 7 3 Air Conditioning Condenser 307 5 7 4 Air Conditioning A C Evaporator Core 307 Removing Air Conditioning A C Cover 307 Cleaning Air Conditioning A C Evaporator Core 308 Installing Air Conditioning A C Cover 309 5 7 5 Air Conditioning A C Compressor 310 Servicing the Air Conditioning Compressor 310 5 8 Engine 311 5 8 1 General Engine Inspecti...

Page 16: ...Screen 342 5 8 7 Gearbox 343 Checking Lubricant Level and Adding Lubricant 343 Changing Lubricant 344 5 8 8 Exhaust System 345 5 8 9 Belts 345 Tensioning Alternator Fan Belt 345 Replacing Fan Belt 345 Tensioning Air Conditioner A C Compressor Belt 347 Replacing Air Conditioner A C Compressor Belt 347 5 8 10 Engine Speed 348 Throttle Adjustment 348 5 9 Electrical System 349 5 9 1 Preventing Electri...

Page 17: ...acing Fuses 379 Replacing Circuit Breakers and Relays 380 Fuse Box Decal 381 Inspecting and Replacing 125A Main Fuses 382 5 10 Hydraulic System 384 5 10 1 Checking and Filling Hydraulic Oil 385 5 10 2 Hydraulic Oil Cooler 386 5 10 3 Changing the Hydraulic Oil 386 5 10 4 Changing Hydraulic Oil Filters 387 Charge Oil Filter 387 Removing Charge Oil Filter 387 Installing Charge Oil Filter 389 Return O...

Page 18: ... 1 Maintenance Schedule Record 415 Chapter 6 Troubleshooting 421 6 1 Engine Troubleshooting 421 6 2 Electrical Troubleshooting 427 6 3 Hydraulics Troubleshooting 429 6 4 Header Drive Troubleshooting 430 6 5 Traction Drive Troubleshooting 431 6 6 Steering and Ground Speed Control Troubleshooting 435 6 7 Cab Air Troubleshooting 436 6 8 Operator s Station Troubleshooting 441 Chapter 7 Options and Att...

Page 19: ...449 8 1 Recommended Torques 449 8 1 1 Torque Specifications 449 SAE Bolt Torque Specifications 449 Metric Bolt Specifications 451 Metric Bolt Specifications Bolting into Cast Aluminum 453 Flare Type Hydraulic Fittings 454 O Ring Boss ORB Hydraulic Fittings Adjustable 455 O Ring Boss ORB Hydraulic Fittings Non Adjustable 457 O Ring Face Seal ORFS Hydraulic Fittings 458 Tapered Pipe Thread Fittings ...

Page 20: ......

Page 21: ...dicates important safety messages in this manual and on safety signs on the machine This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Carefully read and follow the safety message accompanying this symbol Why is safety important to you Accidents disable and kill Accidents cost Accidents can be avoided ...

Page 22: ...tly hazardous situation that if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation that if not avoided could result in death or serious injury It may also be used to alert against unsafe practices CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It may be used to alert against unsafe p...

Page 23: ...goggles Heavy gloves Wet weather gear Respirator or filter mask 1000005 Figure 1 3 Safety Equipment Be aware that exposure to loud noises can cause hearing impairment or loss Wear suitable hearing protection devices such as earmuffs or earplugs to help protect against loud noises 1010391 Figure 1 4 Safety Equipment Provide a first aid kit for use in case of emergencies Keep a fire extinguisher on ...

Page 24: ...machine function and or safety It may also shorten machine s life To avoid bodily injury or death from unexpected startup of machine ALWAYS stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1000009 Figure 1 7 Safety around Equipment Keep service area clean and dry Wet or oily floors are slippery Wet spots can be dangerous when working with elect...

Page 25: ...nnecting machine Make sure all components are tight and that steel lines hoses and couplings are in good condition before applying pressure to hydraulic systems Keep hands feet clothing and hair away from all moving and or rotating parts Clear area of bystanders especially children when carrying out any maintenance repairs or adjustments Install transport lock or place safety stands under frame be...

Page 26: ...ssure Makeshift repairs will fail suddenly and create hazardous and unsafe conditions 1001207 Figure 1 12 Hydraulic Pressure Hazard Wear proper hand and eye protection when searching for high pressure hydraulic leaks Use a piece of cardboard as a backstop instead of hands to isolate and identify a leak If injured by a concentrated high pressure stream of hydraulic fluid seek medical attention imme...

Page 27: ... tires that have defects Replace wheel rims that are cracked worn or severely rusted Never weld a wheel rim Never use force on an inflated or partially inflated tire Make sure tire is correctly seated before inflating to operating pressure If tire is not correctly positioned on rim or is overinflated tire bead can loosen on one side causing air to escape at high speed and with great force An air l...

Page 28: ...ctor immediately If electrolyte is spilled or splashed on clothing or body neutralize it immediately with a solution of baking soda and water then rinse with clear water 1000017 Figure 1 18 Safety around Batteries WARNING To avoid injury from spark or short circuit disconnect battery ground cable before servicing any part of electrical system Do NOT operate engine with alternator or battery discon...

Page 29: ...age spikes associated with welding can cause damage to electronic components Before welding on any part of windrower or an attached header disconnect all electronic module harness connections as well as battery cables Refer to your Dealer for proper procedures SAFETY ...

Page 30: ...rt switch or to controls do NOT start engine or move controls Consult with person who attached warning tag before engine is started Start engine from operator s compartment Always start engine according to procedure that is described in Starting Engine section of operator s manual Knowing correct procedure will help to prevent major damage to engine components and prevent personal injury To ensure...

Page 31: ...his engine has a comprehensive programmable engine monitoring system The ECM has the ability to monitor engine operating conditions If conditions exceed the allowable range the ECM will initiate immediate action The following actions are available for engine monitoring control Warning Derate Shut down The following monitored engine operating conditions have the ability to limit engine speed and or...

Page 32: ...sure repair part also bears current safety sign Replacement safety signs are available from your MacDon Dealer Parts Department 1 10 1 Installing Safety Decals 1 Clean and dry installation area 2 Decide on exact location before you remove decal backing paper 3 Remove smaller portion of split backing paper 4 Place decal in position and slowly peel back remaining paper smoothing decal as it is appli...

Page 33: ... Cover MD 166450 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 Left of Step MD 166425 L Platform Right of Step MD 166441 M Frame at Multifunction Manifold MD 166466 N Lift Linkage MD 166438 P Inner Post MD 166457 Q Inner Post MD 166234 R Inner Post MD 166463 S Neutral Interlock MD 166425...

Page 34: ...214603 14 Revision A Figure 1 21 Safety Signs Left Cab Forward Side 1011019 A B C D E F G H J K L M N P Q R T S U SAFETY ...

Page 35: ...C D E F G H J K L M 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 L Rim MD 166454 M Window MD 167504 SAFETY ...

Page 36: ...214603 16 Revision A Figure 1 23 Safety Signs Right Cab Forward Side 1011020 A B C D E F G H J K L M SAFETY ...

Page 37: ... near machine 1000700 Figure 1 25 MD 166234 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 seat belt whenever operating the machine or riding as a trainer Keep all other riders off the machine 1000685 Figure 1 26 MD 16...

Page 38: ...66438 MD 166438 Crushing hazard DANGER Rest header on ground or engage safety props before going under unit 1000691 Figure 1 28 MD 166439 MD 166439 Crushing hazard DANGER Rest header on ground or engage safety props before going under unit SAFETY ...

Page 39: ...al that the machine be equipped such that weights are within the specified limits 1000688 Figure 1 30 MD 166450 MD 166450 Hot surface hazard WARNING To avoid injury keep a safe distance from hot surface 1000696 Figure 1 31 MD 166451 MD 166451 Rotating fan hazard WARNING To avoid injury stop the engine and remove the key before opening engine hood SAFETY ...

Page 40: ... of moving parts Disengage header drive put transmission in Neutral and wait for all movement to stop before leaving operator s position Stop the engine and remove the key from the ignition before servicing adjusting lubricating cleaning or unplugging machine Engage locks to prevent lowering of header or reel before servicing in the raised position Use slow moving vehicle emblem and flashing warni...

Page 41: ...214603 21 Revision A 1000693 Figure 1 34 MD 166456 MD 166456 Battery acid hazard WARNING Corrosive and poisonous battery acid Acid can severely burn your body and clothing SAFETY ...

Page 42: ...e put transmission in Neutral and wait for all movement to stop before leaving operator s position Stop the engine and remove the key from the ignition before servicing adjusting lubricating cleaning or unplugging machine Engage locks to prevent lowering of header or reel before servicing in the raised position Use slow moving vehicle emblem and flashing warning lights when operating on roadways u...

Page 43: ...arning lights unless prohibited by law If width of attached header impedes other vehicle traffic remove header and install MacDon approved weight box Refer to operator s manual for safe procedure to tow header 1000702 Figure 1 38 MD 166465 MD 166465 Loss of control hazard WARNING To avoid serious injury or death from loss of control Do not make abrupt changes in steering direction Anticipate turns...

Page 44: ...y punctures skin causing serious injury gangrene or death If injured seek emergency medical help Immediate surgery is required to remove oil Do not use finger or skin to check for leaks Lower load or relieve hydraulic pressure before loosening fittings 1014916 Figure 1 40 MD 166843 MD 166843 Steering control WARNING To avoid serious injury or death from loss of control Do not make abrupt changes i...

Page 45: ...rgency exit ATTENTION To exit the machine via the secondary door follow the arrow on the running man sign 1000920 Figure 1 43 MD 174436 MD 174436 High pressure oil hazard WARNING Do not go near leaks High pressure oil easily punctures skin causing serious injury gangrene or death If injured seek emergency medical help Immediate surgery is required to remove oil Do not use finger or skin to check f...

Page 46: ...214603 26 Revision A 1004138 Figure 1 44 MD 190546 MD 190546 Slippery surface WARNING Do not use this area as a step or platform Failure to comply could result in serious injury or death SAFETY ...

Page 47: ...s for M Series Windrower DK Double knife DKD Double knife drive DDD Double draper drive DWA Double Windrow Attachment ECM Engine control module Engine forward Windrower operation with Operator and engine facing in direction of travel FFFT Flats from finger tight Finger tight Finger tight is a reference position where sealing surfaces or components are making contact with each other and fitting has...

Page 48: ...irective by the European Union to restrict use of certain hazardous substances such as hexavalent chromium used in some yellow zinc platings rpm Revolutions per minute SAE Society of Automotive Engineers Screw A headed and externally threaded fastener that threads into preformed threads or forms its own thread into a mating part SDD Single draper drive Self Propelled SP Windrower Self propelled ma...

Page 49: ... Ultra low sulphur diesel Washer A thin cylinder with a hole or slot located in the center that is to be used as a spacer load distribution element or a locking mechanism WCM Windrower control module Windrower Power unit of a self propelled header PRODUCT OVERVIEW ...

Page 50: ... rating 29H or 31A heavy duty off road vibration resistant Minimum CCA per battery cold cranking amps 750 Alternator 130 amp Egress lighting Standard Starter Wet type Working lights 11 Traction Drive Type Hydrostatic 3 speed electric shift Speed Field cab forward Low range 0 18 km h 11 mph mid range 0 26 km h 16 mph Speed Reverse cab forward 9 6 km h 6 mph Speed Transport engine forward High range...

Page 51: ...eader 41 369 kPa 6000 psi 2 Maximum pressure1 Knife drive differential 27 579 31 026 kPa 4000 4500 psi 2 Maximum pressure1 Reel draper drive differential 22 063 24 132 kPa 3200 3500 psi 2 Maximum pressure1 Double Windrow Attachment DWA drive 22 063 24 132 kPa 3200 3500 psi 2 Maximum pressure1 Conveyor draper Reel Auger A40 22 063 24 132 kPa 3200 3500 psi 2 Maximum pressure1 Supercharge 1655 2068 k...

Page 52: ... 800 mm 31 5 in blade Windshield wiper Rear 560 mm 22 in blade Heater 7038 W 24 000 Btu h Air conditioning 8288 W 28 280 Btu h 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 ...

Page 53: ... Header up to 12 2 m 40 ft R80 R85 Rotary Disc NOTE Specifications and design are subject to change without notice or obligation to revise previously sold units Weights do not include options Figure 2 1 Hydraulic Pumps Orientation 1020618 A B C D A Piston Pump Disc Drive Knife Drive Reel Draper Drive B Gear Pump Outboard Lift Tilt and Reel Fore Aft Circuits C Gear Pump Middle 4 Draper Control D Se...

Page 54: ...6 bar and turf narrow track5 Inner outer shipping 3144 123 3 4 3571 140 9 16 3644 143 7 16 18 4 x 26 bar and turf narrow track5 Outer outer 3324 130 7 8 3751 147 11 16 3824 150 5 8 18 4 x 26 bar and turf narrow track5 Inner inner 2964 116 11 16 3391 133 1 2 3464 136 3 8 18 4 x 26 bar and turf wide track5 Inner outer shipping 3319 130 11 16 3571 140 9 16 3819 150 3 8 18 4 x 26 bar and turf wide tra...

Page 55: ...16 3571 140 9 16 3758 147 15 16 600 65R28 radial tire Outer outer 3319 130 11 16 3751 147 11 16 3938 155 1 16 600 65R28 radial tire Inner inner 2959 116 1 2 3391 133 1 2 3578 140 7 8 23 1 26 and 580 70R26 turf tires Inner outer shipping 3203 126 1 8 3571 140 9 16 3793 149 5 16 23 1 26 and 580 70R26 turf tires Outer outer 3383 133 3 16 3751 147 11 16 3973 156 7 16 23 1 26 and 580 70R26 turf tires I...

Page 56: ...asters E mm in 7 5 16SL Minimum 2448 96 7 16 3032 118 15 16 7 5 16SL Maximum 3448 135 11 16 4032 158 3 4 10 16 formed caster Minimum 2448 96 7 16 3032 118 15 16 10 16 formed caster Maximum 3448 135 11 16 4032 158 3 4 10 16 forked caster Minimum 2448 96 7 16 3014 118 11 16 10 16 forked caster Maximum 3448 135 11 16 4014 158 16 5 x 16 1 Minimum 2448 96 7 16 3014 118 11 16 16 5 x 16 1 Maximum 3448 13...

Page 57: ...22542 A B C D E F G H F K L M N J J A Header Lift Leg B Header Float Springs C Operator s Station D Windshield Wiper E Turn Signal Hazard Lights F Taillight Engine Forward G Field Road Lights H Handholds J Beacon K Mirror L Door M Maintenance Platform N Center Link PRODUCT OVERVIEW ...

Page 58: ... K L M N P A Caster Wheel B Walking Beam C Taillights Cab Forward Option D Engine Compartment Hood E Windshield Wiper F Field Lights G Horn H Turn Signal Hazard Lights J Mirror K Door L Drive Wheel M Maintenance Platform N Engine Air Precleaner Export P Headlights PRODUCT OVERVIEW ...

Page 59: ...dless of the direction of travel 3 1 Operator Console 1000570 A B C D C E Figure 3 1 Operator Console A Ignition B Cab Display Module CDM C Header Controls D Ground Speed Lever GSL E Throttle The console contains controls to operate the windrower as well as amenities for the Operator The console position is adjustable to suit each Operator 1000572 A Figure 3 2 Console Fore Aft 1 Adjusting fore aft...

Page 60: ...214603 40 Revision A 1000571 A Figure 3 3 Console Fore Aft 2 Adjusting only fore aft a Loosen nuts A under console b Move console as required c Tighten nuts A OPERATOR S STATION ...

Page 61: ... position 3 2 2 Engine and Transmission If the HEADER DRIVE switch is engaged the engine will not start If the windrower is moving 8 km h 5 mph or slower and the Operator leaves the seat the CDM will flash NO OPERATOR on the upper line and ENGINE SHUT DOWN 5 4 3 2 1 0 on the lower line accompanied by a steady tone When the countdown reaches 0 the engine shuts down If the windrower is moving 8 km h...

Page 62: ...t 3 3 1 Adjusting Fore Aft Position 1000573 A Figure 3 4 Fore Aft Position 1 Pull lever A up to release 2 Move seat forward or rearward 3 Release lever A 3 3 2 Adjusting Seat Suspension and Height Controls suspension stiffness and seat height 1000574 A B Figure 3 5 Seat Suspension and Height INCREASE Press upper switch A DECREASE Press lower switch B OPERATOR S STATION ...

Page 63: ...ampening 1000579 A Figure 3 6 Vertical Dampener INCREASE Turn knob A counterclockwise DECREASE Turn knob A clockwise 3 3 4 Adjusting the Armrest 1000575 A Figure 3 7 Armrest Raise armrest A for easier access to seat Lower armrest A after seat belt is buckled OPERATOR S STATION ...

Page 64: ...seat fore aft isolator 1000578 A Figure 3 8 Fore Aft Isolator Lock LOCK Push lever A down UNLOCK Pull lever A up 3 3 6 Adjusting Seat Tilt 1000577 A Figure 3 9 Seat Tilt 1 Pull lever A up to release 2 Position seat back as desired 3 Release lever A OPERATOR S STATION ...

Page 65: ...0 Armrest Angle INCREASE Rotate knob A clockwise DECREASE Rotate knob A counterclockwise 3 3 8 Adjusting Lumbar Support Adjusts the stiffness of seat back 1007710 A Figure 3 11 Lumbar Support INCREASE Rotate knob A upward DECREASE Rotate knob A downward OPERATOR S STATION ...

Page 66: ... a new Operator The training seat is NOT intended as a passenger seat or for use by children Use the seat belt whenever operating the machine or riding as a Trainer Keep all other riders off the machine 1000581 A B Figure 3 12 Training Seat in Storage Position For storage lift seat B and secure with latch A 1000580 A B Figure 3 13 Training Seat To lower seat lift latch A and lower seat B OPERATOR ...

Page 67: ...fastened 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 To fasten seat belt 1006291 A B C Figure 3 14 Seat Belt 1 Pull belt with metal eye A at right side completely across your body 2 Push metal eye A into buckle B until it locks 3 Adjust the position of the belt as low on your body as possi...

Page 68: ...t each particular Operator and to make it easier to get in and out of the seat 1000582 A Figure 3 15 Steering Column 1 Hold onto the steering wheel lift handle A and move the steering wheel up or down to desired position 2 Release handle A to lock the steering wheel position OPERATOR S STATION ...

Page 69: ...OFF CLEARANCE The field road A high low beam B and beacon light C switches are located on a panel in the cab headliner The hazard turn signal switch is located on the cab display module CDM The position of the operator s station cab forward mode or engine forward mode automatically determines the lighting IMPORTANT Red and amber reflector tape is positioned so as to be visible in both engine forwa...

Page 70: ... turn on the remaining field lights are disabled 1000585 A Figure 3 19 Cab Forward Front View The two innermost lights in the field light group A at the front of the cab are adjustable Refer to Adjusting Field Lights page 362 1000586 A B Figure 3 20 Cab Forward Rear View The two field lights A at the rear of the cab are adjustable Refer to Adjusting Rear Floodlights page 369 NOTE When the engine i...

Page 71: ...8 A B Figure 3 22 Engine Forward Rear View Red taillights A on the mirror supports Amber turn signals and hazard lights B on mirror supports rear view 1000589 A B Figure 3 23 Engine Forward Front View Amber turn signals and hazard lights A on mirror supports front view Headlights B in hood with low high switch The two headlights in the hood are adjustable Refer to Aligning Headlights page 360 OPER...

Page 72: ...rd 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 regulations Refer to 7 1 4 Lighting and Marking for Cab Forward Road Travel page 443 or see your MacDon Dealer NOTE If the red tail lighting kit is not installed travelling...

Page 73: ...be turned off by engaging the header drive 3 7 5 Beacon Light Optional MD B5582 1000593 A Figure 3 28 Cab Forward Front View 1010285 B Figure 3 29 Beacon Light Switch The beacon lights A are functional when the ignition and the beacon switch B are ON The beacons MUST be used when driving on the road where required by law The beacons will also turn on automatically when the auto road light feature ...

Page 74: ...gaged Transmission is in either mid or high range Moving the ground speed lever GSL out of neutral brake off will switch the white lights from field work lights to road lights if the switch is in the field road lights position 3 7 7 HID Auxiliary Lighting Optional Two optional high intensity discharge HID lights MD B5596 provide additional lighting during field operation 1005500 A Figure 3 30 HID ...

Page 75: ...on A 1010283 B Figure 3 31 Field Light Switch except Russia 1022644 B Figure 3 32 Field Light Switch Russia Optional HID auxiliary lighting is activated with the light switch B in the FIELD position OPERATOR S STATION ...

Page 76: ... 8 Windshield Wipers 1022567 A B Figure 3 33 Wiper Controls A Rear Wiper B Front Wiper The windshield wiper controls are located in the cab headliner The illustration shows the controls in cab forward mode OPERATOR S STATION ...

Page 77: ...adjustable mirrors A provide a rear view when the windrower is in cab forward mode A single interior mounted mirror B provides a rear view in the engine forward mode The mirror light assembly A is designed to fold back if accidentally struck A detent type lock keeps it in place OPERATOR S STATION ...

Page 78: ...hut Off 1000596 A Figure 3 35 Heater Shut Off Valve A shut off valve A at the engine allows the cab heater to be isolated from the engine coolant The valve must be OPEN to provide heat to the cab but can be CLOSED for maximum cooling 3 10 2 Air Distribution 1000598 A B C Figure 3 36 Adjustable Air Vents A Vent B Open Close C Direction Cab air distribution is controlled through adjustable air vents...

Page 79: ...e 1 Ensure heater shut off valve at engine is OPEN Refer to 3 10 1 Heater Shut Off page 58 2 Turn blower switch to the first position turn temperature control switch to MAXIMUM heating and A C control to OFF 3 Start the engine and operate at low idle until the engine is warm 4 Click A C switch from OFF to ON for 1 second then back to OFF for 5 to 10 seconds Repeat this step ten times Refrigerant O...

Page 80: ...nsity LED light A is located directly overhead to provide ambient lighting if desired It functions only when the key is in the RUN position An ON OFF switch is located on the light The other interior light B is located on the headliner switch panel and the push ON push OFF button is located on the light It functions at any time OPERATOR S STATION ...

Page 81: ...gency exit window indicated by the emergency exit decal A is located beside the operator s station To open the emergency exit window follow these steps 1011937 A B C Figure 3 40 Emergency Exit Window 1 Release the window latch A 2 Remove the latch pin B 3 Push window open C OPERATOR S STATION ...

Page 82: ...eld Shades Windshield Shades Optional Retractable window shades A can be installed for the front and rear windows Refer to 7 1 7 Windshield Shades page 444 for ordering information 1010329 A B C D E Figure 3 43 Auxiliary Power Outlets A Auxiliary Power Outlet B Auxiliary Power Outlet C Battery Terminal D Ground Terminal E Switched Terminal Auxiliary Outlets Two auxiliary power outlets are located ...

Page 83: ...e 3 44 Operator s Manual Storage Manual Storage A manual storage case A is located under the training seat 1000608 A Figure 3 45 Coat Hook Coat Hook A coat hook A is located above the training seat left of the Operator OPERATOR S STATION ...

Page 84: ...rocedures refer to the M155 and M205 Self Propelled Windrower Unloading and Assembly Instructions North American Shipments or M Series Self Propelled Windrower Unloading and Assembly Instructions for Container Shipments Operating instructions are supplied with the radio 3 14 2 Mounting the Antenna An optional base for a magnetic roof mounted antenna is available from your Dealer IMPORTANT Antenna ...

Page 85: ...ckout A is located on the exterior right cab forward rear corner post of the cab under the roof between the horn and the light 1000611 Figure 3 49 Template for Antenna Mount To make your own mount refer to dimensions template Use 11 GA or 3 0 mm steel sheet OPERATOR S STATION ...

Page 86: ... is activated by pushing button A located on the panel in the headliner Sound the horn three times prior to starting the engine 1000612 A Figure 3 51 Horn Location The horn A is located outside the cab on the rear right cab forward corner of the cab under the roof OPERATOR S STATION ...

Page 87: ...ART Fully clockwise to crank engine Release and switch returns to RUN NOTE Remove key when windrower is not in use the key also locks doors Engine Coolant Temperature Gauge B Normal Running 82 104 C 180 220 F NOTE For information about temperature warnings and alarms refer to Display Warnings and Alarms page 87 Fuel Gauge C E Empty F Full Throttle D controls engine speed FULL Push lever forward OP...

Page 88: ...ked in center R Reverse C HAZARD WARNING LIGHTS activate signals on windrower and header Push ON Push OFF D GROUND SPEED RANGE SWITCH shifts transmission speed range High range 0 37 km h 23 mph ENGINE FORWARD ONLY Mid range 0 25 7 km h 16 mph CAB FORWARD ONLY Low range 0 17 7 km h 11 mph E N Detent 1009722 A Figure 3 54 GSL Autosteer Control A AUTOSTEER ENGAGEMENT SWITCH engages disengages the aut...

Page 89: ...ted as follows 1014371 A Figure 3 55 Autosteer Harness SW1 GSL SW1 A is located in the cab beneath the floor mat at the engine end seat position switch 1000881 A Figure 3 56 Autosteer Harness SW2 GSL SW2 A is located beneath the cab between the fuel tank and evaporator box OPERATOR S STATION ...

Page 90: ...A engages and disengages the header drive To engage the header drive pull up on collar B and push down on switch A To disengage the header drive push the switch down IMPORTANT Always move throttle lever back to IDLE before engaging header drive Do NOT engage header with engine at full rpm 3 18 2 Header Drive Reverse Button 1005292 A B Figure 3 58 Header Drive Switches NOTE The hydraulic reversing ...

Page 91: ...n the GSL A control the most common header functions NOTE A decal B identifying switch functions is located on the cab post above the operator s console 1007606 A B C D E Figure 3 60 GSL Function Groups A Reel Speed B Reel Position C Autosteer Engagement D Display Selector E Header Position OPERATOR S STATION ...

Page 92: ...the cab display module CDM programming For functions related to double windrow attachment DWA position refer to 4 4 10 Using the Double Windrowing Attachment page 213 For functions related to reel fore aft position and height on draper headers refer to 4 6 2 Adjusting the Reel Fore Aft Position page 264 4 6 3 Adjusting the Reel Height page 264 For the center link assist cylinder refer to the secti...

Page 93: ...c to your header for detailed switch operating modes Reel and Disc Speed Switches 1009518 A B Figure 3 64 Ground Speed Lever Press and hold switch A to increase the reel or disc speed Press and hold switch B to decrease the reel or disc speed Release switch at desired speed Auger Header A30 header Not applicable A40 header Auger speed is automatically maintained when reel speed is changed IMPORTAN...

Page 94: ...ft Option Controls deck shifting and float settings for double windrowing options with a draper header 1000626 A B C D Figure 3 66 Header Switches A Deck Shift Float Preset Switch B Float Preset 1 C Float Preset 2 D Float Preset 3 Draper Header with Fixed Decks Auger Header Rotary Header Selects preprogrammed header float settings Refer to Float Options page 199 to learn how to preset the float NO...

Page 95: ...must be programmed for this configuration Refer to Activating the Double Windrow Attachment DWA page 98 Switch A may be used instead of the DWA switches on the ground speed lever GSL The DWA draper speed is controlled with the rotary switch D next to the rocker switch on the operator s console For more information on the DWA attachment and controls refer to 4 4 10 Using the Double Windrowing Attac...

Page 96: ... Engine windrower functions D HAZARD WARNING LIGHTS SWITCH Activates hazard warning lights cancels turn signal E SELECT SWITCH Allows Operator to select display item on lower line Push to SELECT F TURN SIGNAL SWITCHES Activates turn signals on windrower and header Push ON Push OFF G IGNITION SWITCH POSITIONS Accessory Stop Run Start H ENGINE WARNING LIGHTS Engine Pre Heat Water In Fuel CAUTION Sto...

Page 97: ...Changes header float The system remembers setting with deck shift option if activated with float setting switch Push to Increase Push to Decrease E AUGER DRAPER SPEED ADJUST Changes auger draper speed INDEX with INDEX SWITCH ON Changes auger draper SPEED with INDEX SWITCH OFF Push upper switch to increase Push lower switch to decrease F HEADER INDEX SWITCH Links reel and conveyor speed to ground s...

Page 98: ...7 A B C D E A Display Selector for Upper Line B Display C CDM Upper Line D CDM Lower Line E Display Selector for Lower Line Ignition ON Engine Not Running Display Upper Line 2 3 Seconds Description HEADER DISENGAGED Indicates HEADER DRIVE switch is OFF IN PARK Indicates ground speed lever GSL is in N DETENT Engine Running At Initial Start Up Display Upper Line 2 3 seconds Description HEADER TYPE A...

Page 99: ...conds press SELECT to cancel Cab Forward Engine Running Header Disengaged Scroll through display with cab display module CDM switch or ground speed lever GSL switch Display Lower or Upper Line Description ENGINE HRS Total engine operating time UNIT HRS Total windrower operating time HEADER HRS Total header operating time SUB ACRES SUB HECTARES if metric Area cut since last reset To reset display S...

Page 100: ... speed in strokes per minute Sensor disabled SPEED and SENSOR alternate at 1 second intervals HEADER HEIGHT HEADER SENSOR Distance setting 00 0 10 0 between cutterbar and ground Sensor disabled HEIGHTand SENSOR alternate at 1 second intervals HEADER ANGLE HEADER SENSOR Angle setting 00 0 10 0 header relative to ground Sensor disabled ANGLE and SENSOR alternate at 1 second intervals L FLOAT R FLOAT...

Page 101: ...e last reset to reset display SUB ACRES on lower line and hold down PROGRAM switch until display resets 5 to 7 seconds TOTAL ACRES TOTAL HECT if metric Total area cut by machine REEL IND REEL SENSOR Reel peripheral speed along with ground speed in mph or km h Sensor disabled IND and SENSOR alternate at 1 second intervals AUGER SPEED AUGER SENSOR Auger rotational speed 4 7 9 9 Sensor disabled SPEED...

Page 102: ...e HEADER HRS Total header operating time ACRES HOUR HECTARES HOUR if metric Actual cutting rate in acres hectares hour SUB ACRES SUB HECTARES if metric Area cut since last reset To reset display SUB ACRES on lower line and hold down PROGRAM switch until display resets 5 to 7 seconds TOTAL ACRES TOTAL HECT if metric Total area cut by machine REEL MPH REEL KPH if metric REEL SENSOR flashing Reel per...

Page 103: ...speed lever GSL switch Display Lower or Upper Line Description ENGINE HRS Total engine operating time UNIT HRS Total windrower operating time HEADER HRS Total header operating time ACRES HOUR HECTARES HOUR if metric Actual cutting rate in acres hectares hour SUB ACRES SUB HECTARES if metric Area cut since last reset To reset display SUB ACRES on lower line and hold down PROGRAM switch until displa...

Page 104: ...ogrammed set point MINIMUM lower line Reel speed at zero ground speed Cab Forward Engine Running Header Engaged Rotary Header Installed Scroll through display with cab display module CDM switch or ground speed lever GSL switch Display Lower or Upper Line Description ENGINE HRS Total engine operating time UNIT HRS Total windrower operating time HEADER HRS Total header operating time ACRES HOUR HECT...

Page 105: ... with cab display module CDM switch or ground speed lever GSL switch Display Upper Line Description HEADER DISENGAGED Header drive is disengaged FOOT DISK AUGER or DRAPER will appear in place of DISK depending on type of header attached IN PARK GSL in N DETENT position LEFT TURN Indicates left turn when left arrow is pressed on CDM engine forward mode only11 RIGHT TURN Indicates right turn when ri...

Page 106: ...3 71 CDM Engine Warning Lights 1000652 A B C D E A Engine Preheat B Water in Fuel C Caution D Stop E Display ENGINE PRE HEAT Illuminates yellow Wait to start engine WATER IN FUEL Illuminates yellow Service recommended CAUTION Illuminates yellow Prompt attention is required Refer to display code STOP Illuminates red Stop engine immediately Refer to display code DISPLAY Displays malfunction code Ref...

Page 107: ...interlock switch remains closed to apply brake BRAKE SW FAILURE X Short beep with each flash Ignition ON engine not running brake switch and relay closed CAB FORWARD SW ON ENG FORWARD SW ON X Messages flash alternately Both seat switches activated CENTER STEERING Two beeps per second GSL or interlock switches not closed with key ON engine OFF DISENGAGE HEADER RE ENGAGE 1800 RPM X None R80 R85 Engi...

Page 108: ... flash for 5 seconds and then stops for 1 minute flashing continues if oil still cold after 1 minute tone sounds again Hydraulic oil temp 10 C 50 F C or F HYD OIL HOT X Tone with each flash for 5 seconds at 104 C 220 F then tone stops for 1 minute while flashing continues If oil still hot after 1 minute tone sounds again Flashing and steady tone at temperatures of 110 C 230 F and higher Hydraulic ...

Page 109: ...when configuring the cab display module CDM The monitoring system requires configuration for each header The HEADER MUST BE ATTACHED TO THE WINDROWER so the CDM recognizes the header type The transmission must be in Neutral GSL in N DETENT to configure the system with the engine running The ignition switch must be in the RUN position to configure the system when the engine is not running The syste...

Page 110: ...X WCM NOTE M is for M155 and X is for M205 Main Display Displays menu item and selection13 Upper line Menu item Lower line Selection Select Switch Places monitor into Program Mode with PROGRAM switch Press to accept menu item and advance to next item Menu Item Scroll Forward Displays value under menu item Push to scroll forward Hold down for fast scroll14 OPERATOR S STATION 13 The current selectio...

Page 111: ...e configured to meet changing crop conditions activate newly added options indicate a change of header type or increase your comfort level Setting the Header Knife Speed NOTE The header MUST be attached to the windrower to perform this procedure The cab display module CDM automatically adjusts its programming for each header For more information refer to 4 5 Attaching and Detaching Headers page 21...

Page 112: ...E SPEED SPM C X D C B A Figure 3 75 Knife Speed 4 Press left B or right C arrows to select knife speed Press SELECT D 5 Press PROGRAM A to exit programming mode or press SELECT D to proceed to next WINDROWER SETUP action OPERATOR S STATION ...

Page 113: ...nd SELECT C on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES is displayed on the lower line 3 Press right arrow B to select YES Press SELECT C SET KNIFE SPEED is displayed 1009987 KNIFE OVERLOAD SPD 300 SPM C X D C B A Figure 3 77 M205 Knife Overload Speed 4 Press SELECT D until KNIFE OVERLOAD SPD is displayed on the upper line Current overl...

Page 114: ...tion key to RUN or start the engine 2 Press PROGRAM A and SELECT C on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES is displayed on the lower line 3 Press right arrow B to select YES Press SELECT C SET KNIFE SPEED is displayed 1009988 DISC OVERLOAD SPD 300 RPM C X D C B A Figure 3 79 M205 Disc Overload Speed 4 Press SELECT D until DISC OVERL...

Page 115: ...splay module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES is displayed on the lower line 3 Press right arrow B to select YES Press SELECT C SET KNIFE SPEED is displayed 1009991 OVERLOAD PRESSURE 4000 PSI C X D C B A Figure 3 81 M205 Hydraulic Overload Pressure 4 Press SELECT D until OVERLOAD PRESSURE is displayed on the upper line The current overload pressur...

Page 116: ...Buttons 1 Turn ignition key to RUN or start the engine 2 Press PROGRAM A and SELECT C on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES is displayed on the lower line 3 Press right arrow B to select YES Press SELECT C SET KNIFE SPEED is displayed on the upper line 1009992 HEADER INDEX MODE REEL CONVEYOR C X D C B A Figure 3 83 M205 Header Ind...

Page 117: ...gramming Buttons 2 Press PROGRAM A and SELECT C on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES is displayed on the lower line 3 Press right arrow B to select YES Press SELECT C SET KNIFE SPEED is displayed 1009993 RETURN TO CUT MODE HEIGHT TILT C X D C B A Figure 3 85 M205 Return to Cut Mode 4 Press SELECT D until RETURN TO CUT MODE is dis...

Page 118: ...per line 1009998 AUTO RAISE HEIGHT 4 0 C X D C B A Figure 3 87 M205 Auto Raise Height 4 Press SELECT D until AUTO RAISE HEIGHT is displayed on the upper line Last measurement is displayed on the lower line NOTE The auto raise height ranges from 4 0 minimum to 9 5 maximum in 0 5 increments A setting of 10 disables the auto raise function 5 Press left arrow B or right arrow C to change auto raise he...

Page 119: ...T C SET KNIFE SPEED is displayed on the upper line 1009995 DWA INSTALLED NO YES C X B A Figure 3 89 M205 DWA Controls 4 Press SELECT B until DWA INSTALLED is displayed on the upper line NO YES is displayed on the lower line 5 Press right arrow A to select YES Press SELECT B 1009996 SWAP DWA CONTROLS NO YES C X B A Figure 3 90 M205 DWA Controls 6 SWAP DWA CONTROLS is displayed on the upper line NO ...

Page 120: ...O UP DOWN is displayed on the upper line NO YES is displayed on the lower line NOTE If the Operator selects YES the DWA Auto Up function will be activated by the GSL Reel Fore Aft button 8 Press right arrow C to select YES Press SELECT D 9 Press PROGRAM A to exit programming mode or press SELECT D to proceed to next windrower setup action OPERATOR S STATION ...

Page 121: ...fault to the smallest 4 m 14 ft size and will need to be changed to your specific header s size 1 Turn ignition key to RUN or start the engine 1009974 C X WINDROWER SETUP NO YES A B C Figure 3 92 M205 CDM Programming Buttons 2 Press PROGRAM A and SELECT C on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES is displayed on the lower line 3 Press...

Page 122: ...Press PROGRAM A and SELECT C on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES is displayed on the lower line 3 Press right arrow B to select YES Press SELECT C SET KNIFE SPEED is displayed on the upper line 1022629 CXXX MXXX NO YES SWATH COMPR INSTALL B A Figure 3 95 Swath Compressor Controls 4 Press SELECT B until SWATH COMPR INSTALL is dis...

Page 123: ... line when complete SWATH SENSOR CAL is displayed on upper line PRESS SWATH DOWN is displayed on lower line 10 Press switch A on console to lower swath compressor CALIBRATING SWATH is displayed on upper line FORM DOWN and HOLD is displayed on lower line SWATH FORM COMPLETE flashes for 2 seconds on lower line with buzzer when calibration is finished 1009066 CXXX MXXX WINDROWER SETUP NO YES A B C Fi...

Page 124: ...start the engine 2 Press PROGRAM A and SELECT C on CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES is displayed on the lower line 3 Press right arrow B to select YES Press SELECT C SET KNIFE SPEED is displayed on the upper line 1009999 HEADER REEL SPEED RPM MPH C X D C B A Figure 3 99 M205 Reel Speed Display 4 Press SELECT D until HEADER REEL SPEED is displayed ...

Page 125: ...w B to select YES Press SELECT C SET KNIFE SPEED is displayed on the upper line 1010000 SET TIRE SIZE 18 4 X 26 TURF C X D C B A Figure 3 101 M205 Tire Size 4 Press SELECT D until SET TIRE SIZE is displayed on the upper line Currently installed tire size is displayed on the lower line NOTE The following tire sizes are available 18 4 x 26 TURF 18 4 x 26 BAR 23 1 x 26 TURF 600 65 R28 5 Press left B ...

Page 126: ...ed on the upper line NO YES is displayed on the lower line 3 Press right arrow B to select YES Press SELECT C SET KNIFE SPEED is displayed on the upper line 1023538 SET ENGINE ISC RPM NO YES C X B A Figure 3 103 M205 Engine ISC RPM 4 Press SELECT B until SET ENGINE ISC RPM is displayed on the upper line NO YES is displayed on the lower line 5 Press right arrow A to select YES Press SELECT B PRESS ...

Page 127: ...ield or for a particular day The total acres can t be cleared from the windrower s tracking but the sub acres can be cleared between smaller harvesting instances 1018668 C X A Figure 3 105 M205 CDM 1 With the key in the ON position and the operator s station in cab forward mode press SELECT until the cab display module CDM displays sub acres on the bottom line Then press and hold the PROGRAM A but...

Page 128: ...Buttons 1 Turn ignition key to RUN or start the engine 2 Press PROGRAM A and SELECT C on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES is displayed on the lower line 3 Press right arrow B to select YES Press SELECT C SET KNIFE SPEED is displayed on the upper line 1010005 NO YES SET CONTROL LOCKS C X B A Figure 3 107 M205 Control Locks 4 Pres...

Page 129: ... CDM automatically adjusts its programming for each header For more information refer to 4 5 Attaching and Detaching Headers page 217 1009974 C X WINDROWER SETUP NO YES A B C Figure 3 109 M205 CDM Programming Buttons 1 Turn ignition key to RUN or start the engine 2 Press PROGRAM A and SELECT C on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES...

Page 130: ...ut NOTE This procedure is for draper headers only The header MUST be attached to the windrower to perform this procedure The cab display module CDM automatically adjusts its programming for each header For more information refer to 4 5 Attaching and Detaching Headers page 217 1009974 C X WINDROWER SETUP NO YES A B C Figure 3 112 M205 CDM Programming Buttons 1 Turn ignition key to RUN or start the ...

Page 131: ...ECT B 1010012 REEL FORE AFT ENABLED LOCKED C X D C B A Figure 3 114 M205 Reel Fore Aft Control Lock 6 Press SELECT D until REEL FORE AFT is displayed on the upper line ENABLED LOCKED is displayed on the lower line 7 Press left arrow B to enable REEL FORE AFT control switch Press right arrow C to lock REEL FORE AFT control switch 8 Press PROGRAM A to exit programming mode or press SELECT D to proce...

Page 132: ... M205 CDM Programming Buttons 1 Turn ignition key to RUN or start the engine 2 Press PROGRAM A and SELECT C on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES is displayed on the lower line 3 Press right arrow B to select YES Press SELECT C SET KNIFE SPEED is displayed on the upper line 1010005 NO YES SET CONTROL LOCKS C X B A Figure 3 116 M20...

Page 133: ...TE This procedure is for A40D headers only An auger header MUST be attached to the windrower to perform this procedure The cab display module CDM automatically adjusts its programming for each header For more information refer to 4 5 Attaching and Detaching Headers page 217 1009974 C X WINDROWER SETUP NO YES A B C Figure 3 118 M205 CDM Programming Buttons 1 Turn ignition key to RUN or start the en...

Page 134: ...displayed on the upper line ENABLED LOCKED is displayed on the lower line 7 Press left arrow B to enable AUGER SPEED control switch Press right arrow C to lock AUGER SPEED control switch 8 Press PROGRAM A to exit programming mode or press SELECT D to proceed to next WINDROWER SETUP action Activating Knife Speed Control Lockout NOTE The header MUST be attached to the windrower to perform this proce...

Page 135: ...LOCKS C X B A Figure 3 122 M205 Control Locks 4 Press SELECT B until SET CONTROL LOCKS is displayed on the upper line NO YES is displayed on the lower line 5 Press right arrow A to select YES Press SELECT B 1010006 KNIFE SPEED ENABLED LOCKED C X D C B A Figure 3 123 M205 Knife Speed Control Lock 6 Press SELECT D until KNIFE SPEED is displayed on the upper line ENABLED LOCKED is displayed on the lo...

Page 136: ...124 M205 CDM Programming Buttons 1 Turn ignition key to RUN or start the engine 2 Press PROGRAM A and SELECT C on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES is displayed on the lower line 3 Press right arrow B to select YES Press SELECT C SET KNIFE SPEED is displayed on the upper line 1010005 NO YES SET CONTROL LOCKS C X B A Figure 3 125 ...

Page 137: ...CDM automatically adjusts its programming for each header For more information refer to 4 5 Attaching and Detaching Headers page 217 1009974 C X WINDROWER SETUP NO YES A B C Figure 3 127 M205 CDM Programming Buttons 1 Turn ignition key to RUN or start the engine 2 Press PROGRAM A and SELECT C on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES ...

Page 138: ...009974 C X WINDROWER SETUP NO YES A B C Figure 3 130 M205 CDM Programming Buttons 1 Turn ignition key to RUN or start the engine 2 Press PROGRAM A and SELECT C on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES is displayed on the lower line 3 Press right arrow B to select YES Press SELECT C SET KNIFE SPEED is displayed on the upper line 10100...

Page 139: ...xit programming mode or press SELECT D to proceed to next WINDROWER SETUP action 3 19 10 Cab Display Options The display and sound features of the cab display module CDM can be adjusted to suit each particular Operator NOTE The procedures listed in this section are current for cab display module CDM software version C512 and windrower control module WCM X116 The WCM is supplied preloaded with the ...

Page 140: ... A until CAB DISPLAY SETUP is displayed on the upper line NO YES is displayed on the lower line 1009976 DISPLAY LANGUAGE ENGLISH C X D C A B Figure 3 135 M205 Language Display 4 Press right arrow C to select YES Press SELECT D DISPLAY LANGUAGE is displayed on the upper line Default language is displayed on the lower line 5 Press left B or right C arrow to select preferred language NOTE English Rus...

Page 141: ... Display Setup 3 Press SELECT B until CAB DISPLAY SETUP is displayed on the upper line NO YES is displayed on the lower line 4 Press right arrow A to select YES Press SELECT B DISPLAY LANGUAGE is displayed on the upper line 1009977 DISPLAY UNITS IMPERIAL C X D C A B Figure 3 138 M205 Display Units 5 Press SELECT D until DISPLAY UNITS is displayed on the upper line Default setting is displayed on t...

Page 142: ...ure 3 140 M205 Cab Display Setup 3 Press SELECT B until CAB DISPLAY SETUP is displayed on the upper line NO YES is displayed on the lower line 4 Press right arrow A to select YES Press SELECT B DISPLAY LANGUAGE is displayed on the upper line 1009978 BUZZER VOLUME C X D C A B Figure 3 141 M205 Buzzer Volume 5 Press SELECT D until BUZZER VOLUME is displayed on the upper line Previous setting is disp...

Page 143: ...the lower line 1009975 C CAB DISPLAY SETUP NO YES X B A Figure 3 143 M205 Cab Display Setup 3 Press SELECT B until CAB DISPLAY SETUP is displayed on the upper line NO YES is displayed on the lower line 4 Press right arrow A to select YES Press SELECT B DISPLAY LANGUAGE is displayed on the upper line 1009979 BACKLIGHTING C X D C A B Figure 3 144 M205 Backlighting 5 Press SELECT D until BACKLIGHTING...

Page 144: ...6 M205 Cab Display Setup 3 Press SELECT B until CAB DISPLAY SETUP is displayed on the upper line NO YES is displayed on the lower line 4 Press right arrow A to select YES Press SELECT B DISPLAY LANGUAGE is displayed on the upper line 1009980 DISPLAY CONTRAST C X D C A B Figure 3 147 M205 Display Contrast 5 Press SELECT D until DISPLAY CONTRAST is displayed on the upper line Default setting is disp...

Page 145: ...YES A B Figure 3 148 M205 CDM Programming Buttons 1 Start the engine 2 Press PROGRAM A and SELECT B on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line 3 Press SELECT B until CALIBRATE SENSORS is displayed on the upper line NO YES is displayed on the lower line 1009981 CALIBRATING HEIGHT RAISE HEADER HOLD C X C B A Figure 3 149 M205 Header Height Cali...

Page 146: ...s displayed on the upper line PRESS LOWER HEADER is displayed on the lower line 1023540 A Figure 3 151 Header Height Controls on GSL 8 Press and hold HEADER DOWN button A on the GSL NOTE The word HOLD will flash during calibration HT SENSOR COMPLETE will display on the lower line once calibration is complete 9 Release HEADER DOWN button A TO CALIBRATE SELECT is displayed on the upper line HEADER H...

Page 147: ...GRAM A and SELECT B on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line 3 Press SELECT B until CALIBRATE SENSORS is displayed on the upper line NO YES is displayed on the lower line 1009982 HDR TILT SENSOR CAL EXTEND TILT TO START C X C B A Figure 3 153 M205 Header Tilt 4 Press right arrow B to select YES Press SELECT C TO CALIBRATE SELECT is displaye...

Page 148: ... is displayed on the lower line 1023732 A Figure 3 155 Header Tilt Controls on GSL 8 Press and hold HEADER TILT RETRACT button A on GSL CALIBRATING TILT is displayed on the upper line RETRACT TILT HOLD is displayed on the lower line NOTE The word HOLD will flash during calibration HEADER TILT COMPLETE will display on the lower line once calibration is complete 9 Release HEADER TILT RETRACT button ...

Page 149: ...T buttons on the cab display module CDM to perform this procedure 1021948 A Figure 3 156 Float Pin Right Side IMPORTANT Ensure float pins A are installed in the working position 1007188 C X WINDROWER SETUP NO YES A B Figure 3 157 M205 CDM Programming Buttons 1 Start the engine 2 Press PROGRAM A and SELECT B on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upp...

Page 150: ...h during calibration FLOAT DONE will display on the lower line once calibration is complete 7 Release the FLOAT button A CALIBRATING FLOAT is displayed on the upper line FLOAT HOLD is displayed on the lower line 1009986 CALIBRATING FLOAT FLOAT HOLD C X A Figure 3 160 M205 Negative Header Float Display 8 Press and hold FLOAT button A on CDM CALIBRATING FLOAT is displayed on the upper line FLOAT HOL...

Page 151: ...display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line 3 Press SELECT B until CALIBRATE SENSORS is displayed on the upper line NO YES is displayed on the lower line 1025130 SWATH SENSOR CAL SWATH UP TO START C X B A Figure 3 162 Swath Compressor Sensor Calibration 4 Press right arrow A to select YES Press SELECT B TO CALIBRATE SELECT is displayed in upper line ...

Page 152: ...en complete 1025131 SWATH SENSOR CAL PRESS SWATH DOWN C X Figure 3 164 Swath Compressor Sensor Calibration SWATH SENSOR CAL is displayed on the upper line PRESS SWATH DOWN is displayed on the lower line 1022623 A B Figure 3 165 Swath Compressor Controls 7 Press and hold button A to lower the swath compressor CALIBRATING SWATH is displayed on the upper line FORM DOWN and flashing HOLD is displayed ...

Page 153: ...ow A to select YES Press SELECT B 5 VIEW ERROR CODES is displayed on the upper line NO YES is displayed on the lower line 6 Press right arrow A to select YES Press SELECT B VIEW WINDRWR CODES is displayed on the upper line NO YES is displayed on the lower line 1023541 VIEW WINDRWR CODES NO YES C X B B A C Figure 3 168 M205 Windrower Codes 7 Press right arrow A to select YES Press SELECT C The most...

Page 154: ...ing routine NOTE The header MUST be attached to the windrower to perform this procedure The cab display module CDM automatically adjusts its programming for each header For more information refer to 4 5 Attaching and Detaching Headers page 217 Disabled sensors flash the word SENSOR on CDM during regular operation 1009974 C X WINDROWER SETUP NO YES A B C Figure 3 170 M205 CDM Programming Buttons 1 ...

Page 155: ...ader Sensors 7 Press left arrow B to enable a sensor Press right arrow C to disable sensor Press SELECT D to confirm selection and move on to next sensor The following sensors are available HEADER HT SENSOR HEADER TILT SENSOR KNIFE SPEED SENSOR REEL SPEED SENSOR HEADER FLOAT SENSOR OVERLOAD PRESSURE16 HYD OIL TEMP SENSOR When sensors have been modified press SELECT D to display the EXIT SENSOR SET...

Page 156: ...173 M205 CDM Programming Buttons 1 Turn ignition key to RUN or start the engine 2 Press PROGRAM A and SELECT B on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line NO YES is displayed on the lower line 1010019 DIAGNOSTIC MODE NO YES C X A B Figure 3 174 M205 Diagnostic Functions 3 Press SELECT B until DIAGNOSTIC MODE is displayed on the upper line NO Y...

Page 157: ...eader must be attached to the windrower to troubleshoot certain issues If damage has occurred to the header wiring or no header is available you can force the windrower control module WCM to read a header ID The WCM reverts to reading NO HEADER each time the engine ignition is cycled IMPORTANT Forcing a Header ID that is different from the attached header can damage the windrower and header Doing ...

Page 158: ...s displayed on the lower line 6 Press right arrow A to select YES Press SELECT B SELECT HEADER TYPE is displayed on the upper line DISK HEADER is displayed on the lower line 1010023 SELECT HEADER TYPE DISK HEADER C X A B C Figure 3 179 M205 Header Type 7 Press left A or right B arrow to cycle through list of header types 8 When desired header type is displayed press SELECT C EXIT FORCE HEADER is d...

Page 159: ...efer to 4 5 Attaching and Detaching Headers page 217 The engine MUST be running to perform this procedure 1007188 C X WINDROWER SETUP NO YES A B Figure 3 180 M205 CDM Programming Buttons 1 Start the engine 2 Press PROGRAM A and SELECT B on cab display module CDM to enter programming mode Press SELECT B WINDROWER SETUP is displayed on the upper line 1010019 DIAGNOSTIC MODE NO YES C X A B Figure 3 1...

Page 160: ... the upper line DOWN UP is displayed on the lower line 8 Press and hold left arrow B to lower header or press and hold right arrow C to raise header Verify header is functioning properly 9 Press PROGRAM A to exit programming mode or press SELECT D to proceed to next ACTIVATE FUNCTION Testing the Reel Up Down Activate Function Using the Cab Display Module CDM NOTE This procedure is for draper heade...

Page 161: ...r line 1010019 DIAGNOSTIC MODE NO YES C X A B Figure 3 185 M205 Diagnostic Functions 3 Press SELECT B until DIAGNOSTIC MODE is displayed in upper line NO YES is displayed on the lower line 4 Press right arrow A to select YES Press SELECT B 1010024 ACTIVATE FUNCTIONS NO YES C X B A Figure 3 186 M205 Functions 5 Press SELECT B until ACTIVATE FUNCTIONS is displayed on the upper line NO YES is display...

Page 162: ... SELECT D to proceed to next ACTIVATE FUNCTION Testing the Header Tilt Activate Function Using the Cab Display Module CDM NOTE The header MUST be attached to the windrower to perform this procedure The cab display module CDM automatically adjusts its programming for each header For more information refer to 4 5 Attaching and Detaching Headers page 217 The engine MUST be running to perform this pro...

Page 163: ...layed on the upper line NO YES is displayed on the lower line 6 Press right arrow A to select YES Press SELECT B 1010027 ACTIVATE HDR TILT IN OUT C X D C B A Figure 3 191 M205 Header Tilt Angle 7 Press SELECT D until ACTIVATE HDR TILT is displayed on the upper line IN OUT is displayed on the lower line 8 Press and hold left arrow B to decrease header tilt Press and hold right arrow C to increase h...

Page 164: ...217 The engine MUST be running to perform this procedure 1022066 C X WINDROWER SETUP NO YES A B Figure 3 192 M205 CDM Programming Buttons 1 Start the engine 2 Press PROGRAM A and SELECT B on cab display module CDM to enter programming mode Press SELECT B WINDROWER SETUP is displayed on the upper line 1010019 DIAGNOSTIC MODE NO YES C X A B Figure 3 193 M205 Diagnostic Functions 3 Press SELECT B unt...

Page 165: ...rive 8 Press and hold HAZARD C button Press left arrow B to decrease knife speed Press right arrow D to increase knife speed IMPORTANT Verify the knife drive is functioning properly 9 Release the HAZARD C button The knife will stop 10 Press PROGRAM A to exit programming mode or press SELECT E to proceed to next ACTIVATE FUNCTION Testing the Draper Drive Circuit Activate Function Using the Cab Disp...

Page 166: ...igure 3 197 M205 Diagnostic Functions 3 Press SELECT B until DIAGNOSTIC MODE is displayed in upper line NO YES is displayed on the lower line 4 Press right arrow A to select YES Press SELECT B 1010024 ACTIVATE FUNCTIONS NO YES C X B A Figure 3 198 M205 Functions 5 Press SELECT B until ACTIVATE FUNCTIONS is displayed on the upper line NO YES is displayed on the lower line 6 Press right arrow A to s...

Page 167: ... press SELECT E to proceed to next ACTIVATE FUNCTION Testing the Reel Drive Circuit Activate Function Using the Cab Display Module CDM IMPORTANT Do not overspeed a drive Overspeeding can lead to vibration belt failures or other overspeeding related problems NOTE The header MUST be attached to windrower to follow this procedure For more information refer to 4 5 Attaching and Detaching Headers page ...

Page 168: ...elect YES Press SELECT B ACTIVATE HEADER HT is displayed on the upper line 1010037 REEL DRV SPD XXXX D 0 P 0 C X D D B A C E Figure 3 203 M205 Reel Drive CAUTION Check to be sure all bystanders have cleared the area 7 Press SELECT E until REEL DRV SPD XXXX is displayed on the upper line IMPORTANT Do NOToverspeed the reel 8 Press and hold HAZARD C button Press left arrow B to decrease reel speed Pr...

Page 169: ...e MUST be running to perform this procedure 1022066 C X WINDROWER SETUP NO YES A B Figure 3 204 M205 CDM Programming Buttons 1 Start the engine 2 Press PROGRAM A and SELECT B on cab display module CDM to enter programming mode WINDROWER SETUP is displayed on the upper line 1010019 DIAGNOSTIC MODE NO YES C X A B Figure 3 205 M205 Diagnostic Functions 3 Press SELECT B until DIAGNOSTIC MODE is displa...

Page 170: ...hold HAZARD C button Press left arrow B to decrease disc speed Press right arrow D to increase disc speed IMPORTANT Verify the disc drive is functioning properly 9 Release the HAZARD C button The disc drive will stop 10 Press PROGRAM A to exit programming mode or press SELECT to proceed to next ACTIVATE FUNCTION Testing the Double Windrower Attachment DWA Drive Activate Function Using the Cab Disp...

Page 171: ... X A B Figure 3 209 M205 Diagnostic Functions 3 Press SELECT B until DIAGNOSTIC MODE is displayed in upper line NO YES is displayed on the lower line 4 Press right arrow A to select YES Press SELECT B 1010024 ACTIVATE FUNCTIONS NO YES C X B A Figure 3 210 M205 Functions 5 Press SELECT B until ACTIVATE FUNCTIONS is displayed on the upper line NO YES is displayed on the lower line 6 Press right arro...

Page 172: ...ess SELECT E to proceed to next ACTIVATE FUNCTION Testing the Reel Fore Aft Activate Function Using the Cab Display Module CDM NOTE The reel fore aft function requires the completion kit for draper header reel drive MD B5496 For more information refer to 7 3 5 Completion Kit for Draper Header Reel Drive page 446 The header MUST be attached to windrower to perform this procedure For more informatio...

Page 173: ...ES is displayed on the lower line 6 Press right arrow A to select YES Press SELECT B CAUTION Check to be sure all bystanders have cleared the area 1010029 ACTIVATE REEL F A FORE AFT C X D C B A Figure 3 215 M205 Reel Fore Aft 7 Press SELECT D until ACTIVATE REEL F A is displayed on the upper line FORE AFT is displayed on the lower line 8 Verify reel fore aft is functioning properly a Press and hol...

Page 174: ...de WINDROWER SETUP is displayed on the upper line 1010019 DIAGNOSTIC MODE NO YES C X A B Figure 3 217 M205 Diagnostic Functions 3 Press SELECT B until DIAGNOSTIC MODE is displayed in upper line NO YES is displayed on the lower line 4 Press right arrow A to select YES Press SELECT B 1010024 ACTIVATE FUNCTIONS NO YES C X B A Figure 3 218 M205 Functions 5 Press SELECT B until ACTIVATE FUNCTIONS is di...

Page 175: ...cle The CDM will jump to the exit menu if the arrow is released before the end of the timed cycle CAUTION Check to be sure all bystanders have cleared the area 1010034 PURGE CYCLE STARTED PRESS AND HOLD C X A Figure 3 220 M205 Hydraulic Purge Cycle 9 Press and hold right arrow A to activate purge cycle PURGE CYCLE STARTED will display on the upper line 10 When PURGE CYCLE ENDED is displayed releas...

Page 176: ...g a specific problem with engine operation Refer to 8 4 Engine Error Codes page 464 3 19 16 Cab Display Module CDM and Windrower Control Module WCM Fault Codes The CDM displays fault codes when there is a fault with one of the sensors that monitor and control windrower operation to assist the Operator or Technician in locating a specific problem with the windrower Refer to 8 5 Cab Display Module C...

Page 177: ... the windrower for however short a time or distance make sure they have been instructed in its safe and proper use Review the manual and all safety related items with all Operators every year Be alert for other Operators not using recommended procedures or not following safety precautions Correct these mistakes immediately before an accident occurs Do NOT modify the machine Unauthorized modificati...

Page 178: ...ating the windrower 4 2 1 Engine Functions These are the symbols that are used on the console Figure 4 1 Engine Function Symbols 1000659 A B C D E F G H J K L M N A Electrical Power Accessories B Engine Coolant Temperature C Engine Glow Plugs D Engine Malfunction E Engine rpm F Engine Run G Engine Start H Engine Stop J Engine Throttle K Engine Urgent Stop L Fast M Slow N Water in Fuel OPERATION ...

Page 179: ... M N O P Q R S T U V A Turn Signals B Hazard Warning Lights C Forward D Neutral E Reverse F Headlights Low Beam G Headlights High Beam H Work Light J Lighter K Fresh Air L Blower M Windshield Wiper N Seat Height Up P Seat Height Down Q Seat Fore and Aft R Seat Fore Aft Isolator S Seat Back Fore and Aft T Seat Ride Damping U Cab Temperature Control V Air Conditioning W Recirculate OPERATION ...

Page 180: ...yor Auger Speed E Float Left F Float Right G Reel Speed H Disc Speed J Reel Down K Reel Forward L Reel Up M Reel Rearward N Display Select P DWA Down Q DWA Draper Speed R DWA Up S Header Tilt Up T Header Down U Header Up V Header Tilt Down W Increase X Decrease Y Deck Shift Z Float AA Header Engage AB Header Disengage AC Push Down Header Disengage AD Pull Up Header Engage AE Header Reverse OPERATI...

Page 181: ...quipment Protect against noise Wear a suitable hearing protective device such as ear muffs or ear plugs to protect against objectionable or uncomfortable loud noises Follow all safety and operational instructions given in your operator s manuals If you do not have a header manual get one from your Dealer and read it thoroughly Never attempt to start the engine or operate the machine except from th...

Page 182: ... page 313 NOTE During the break in period a higher than usual oil consumption should be considered normal NOTE If windrower must be driven in cold weather below freezing let engine idle for three minutes and then operate at moderate speed until oil has warmed up Watch coolant gauge in cab for temperature rising beyond normal operating range Check that coolant level at reserve tank mounted next to ...

Page 183: ...re 4 6 Climate Control A Blower Switch B Air Conditioning Switch C Outside Air Switch D Temperature Control 1 Turn blower switch A to the first position turn TEMPERATURE control switch D to maximum heating and A C control switch B to OFF 2 Start the engine and operate at low idle until the engine is warm 3 Click A C switch B from OFF to ON for one second then back to OFF for 5 10 seconds Repeat th...

Page 184: ...nd move if normal starting circuitry is bypassed Start engine only from operator s seat with controls in NEUTRAL NEVER start engine while standing on ground Never try to start engine with someone under or near machine Before starting engine be sure there is plenty of ventilation to avoid asphyxiation WARNING If starter engages with steering wheel unlocked ground speed lever out of NEUTRAL or heade...

Page 185: ...r data for five seconds if attached and then returns to previous display IMPORTANT The machine gauges and instruments provide important information about machine operation and condition Familiarize yourself with the gauges and monitor them carefully during start up operation Refer to 3 16 Engine Controls and Gauges page 67 IMPORTANT Do NOT operate starter for longer than 15 seconds at a time If en...

Page 186: ...gine ISC is useful when operating loads are reduced such as in light crop conditions that do not require the maximum engine rpm Reduced engine speed lowers fuel consumption noise levels and exhaust emissions in addition to reducing engine wear The programmed engine speed is activated when the header is engaged Programming instructions are provided in 3 19 6 Cab Display Module CDM Configuration pag...

Page 187: ...ected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason WARNING To avoid personal injury or death from explosion or fire do NOT smoke or allow flame or sparks near fuel tank when refueling NEVER refuel the windrower when the engine is hot or running CAUTION Do NOT allow tank to empty Running out of fuel can cause ai...

Page 188: ...icated by gauge B on the operator s console If the temperature exceeds 104 C 220 F an ongoing intermittent tone will be heard and the cab display module CDM will flash ENGINE TEMP Stop the engine immediately and determine cause The tone will stop and the CDM will return to normal when the temperature drops below 102 C 215 F Engine Oil Pressure The nominal engine oil pressure is 69 kPa 10 psi at lo...

Page 189: ...t of dangers warnings and cautions before operating the windrower for the first time or when training new operators DANGER NEVER move the ground speed lever or steering wheel until you are sure all bystanders have cleared the area Make sure area is clear before making turns as the ends of a header travel in a large arc Check the operation of all controls in a safe clear area before starting work U...

Page 190: ...tely pull ground speed lever GSL to NEUTRAL Be aware that cab structure will NOT withstand a roll over Because of windrower shape characteristics a roll over protected ROPS cab is not required WARNING When travelling on steep slopes Lower header and reduce speed Move GROUND SPEED RANGE switch to L low range If the ground speed is greater than or equal to 40 km h 25 mph the CDM will display a warni...

Page 191: ...rposes Release seat belt Turn off wipers Raise armrest and steering wheel for easier exit and re entry Lock the cab door when leaving the windrower unattended When the door is locked it can still be opened from inside the cab 1000668 A A B B Figure 4 14 Platforms and Doors Swing away platforms and stairs A are provided on both sides of the windrower to accommodate cab forward and engine forward ac...

Page 192: ...DETENT damage to the GSL cable may result when swivelling operator s station 2 Pull up on knob B and hold to release latch C at base of steering column 3 Turn steering wheel counterclockwise to pivot operator s station clockwise 180 until pin engages latch to secure operator s station in new position 4 Ensure seat belt is fastened 5 Start the engine if not running Refer to Starting the Engine page...

Page 193: ...A B Figure 4 18 Operator s Console 1 Set GROUND SPEED RANGE switch A to 1 field speed 2 Move SPEED RANGE switch A to L low range position 3 Move throttle lever B to a mid range position NOTE Steering will be less sensitive in low speed range reduced engine speed CAUTION Check again to be sure all bystanders have cleared the area 4 Move the ground speed lever GSL rearward to desired speed 1000672 F...

Page 194: ...ation 2 Pull up on knob B and hold to release latch C at base of steering column 3 Turn steering wheel clockwise to pivot operator s station counterclockwise 180 until pin engages latch to secure operator s station in new position 4 Start the engine if not running 1000673 A B C D E F Figure 4 22 Operator Console 5 Set GROUND SPEED RANGE switch A to H for road speed 0 37 km h 23 mph Cab display mod...

Page 195: ...o NOT MORE THAN HALF maximum forward speed b Move speed range control B to H high range Steering is more sensitive in this speed range Driving in Reverse in Engine Forward Mode WARNING Back up slowly Steering is opposite to normal when reversing Hold steering wheel at the bottom and turn wheel in direction you want the rear cab forward of the machine to travel 1000671 A B C Figure 4 24 Operator Co...

Page 196: ...eader travel faster and in a large arc 1000674 A Figure 4 26 Operator Console 1 Move the ground speed lever GSL A out of N DETENT towards the seat and hold 2 Slowly turn the steering wheel in the desired direction of turn The windrower will pivot between the drive wheels 3 To increase the turn radius slowly move the GSL away from NEUTRAL Remember that this will increase ground speed as well 4 To s...

Page 197: ... allow turbocharger to slow down while engine oil pressure is available 4 Turn ignition key counterclockwise to OFF position 4 3 7 Adjusting Caster Tread Width The rear casters can be adjusted to a narrow tread width to allow loading and shipping without having to remove them A narrow tread width also suits smaller headers by allowing more space to the uncut crop and provides more maneuverability ...

Page 198: ...2 Remove six bolts B four on backside two on underside and washers from left and right side of walking beam 1000677 Figure 4 29 Caster Wheel Extensions 3 Slide extensions inboard or outboard equal amounts and align holes at desired location NOTE Use the caster wheels to assist in moving the extensions by rotating the caster until the wheel is parallel to the walking beam 1000680 A A Figure 4 30 Ad...

Page 199: ...on the road in cab forward mode but at a reduced speed and under restricted conditions WARNING Collision between windrower and other vehicles may result in injury or death WARNING When driving windrower on public roadways Obey all highway traffic regulations in your area Use pilot vehicles in front and rear of windrower if required by law Use slow moving vehicle emblem and flashing warning lights ...

Page 200: ...ber lamps red tail and head lamps and check that they work properly 3 Clean all reflective surfaces and slow moving vehicle emblems 4 Adjust interior rear view mirror and clean windows 1000682 A B C Figure 4 33 Light Switches 5 Push LIGHTswitch A to ROAD position to activate lamps Always use these lamps on roads to provide warning to other vehicles Refer to 3 7 Exterior Lighting page 49 NOTE If th...

Page 201: ...rd operating speed CDM should display 2320 2350 rpm C 11 Slowly move the ground speed lever GSL E forward to desired speed which will be displayed at location F 12 If towing a header refer to Towing Header with Windrower page 181 Towing Header with Windrower The windrower can be used to tow a MacDon draper header that has the slow speed transport option installed Ensure the optional weight box or ...

Page 202: ...mplements 10 480 23 100 Weight A on both drive wheels Maximum 8500 18 750 Minimum 4570 10 070 Maximum weight B on both caster tires 2750 6050 Converting from Field to Transport Mode DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason DANGER To avoid bodily injury ...

Page 203: ... CAUTION Check to be sure all bystanders have cleared the area 4 Start the engine and raise the header to full height 5 Stop the engine and engage safety props on the lift cylinders 1000709 Figure 4 39 Header in Transport Mode 6 Deploy header slow speed transport system Refer to header operator s manual 1008704 B A Figure 4 40 Lift Arms 7 Remove float pin from engaged position A and insert in stor...

Page 204: ...se the HEADER TILTswitches to release load on the center link if necessary 12 Shut down the engine and remove the key from ignition Disconnect the center link as follows 1000720 A B Figure 4 43 Hydraulic Link 13 If using hydraulic link disconnect the center link as follows a Pull up on latch A and position latch into notch B on top of hook b Release the safety props on the header lift cylinders Fo...

Page 205: ...wly back the windrower away from the header shut the engine OFF and remove the key from the gnition Attaching Header Transport Hitch to Header Attach header transport hitch to header as follows 1000713 A B C D Figure 4 44 Transport Hitch 1 Position end A of the aft section onto front wheel hook B 2 Push down until latch C captures the end A 3 Secure latch C with clevis pin D 1000715 1000715 100071...

Page 206: ...section Lower forward section into aft section 1000716 A B C Figure 4 47 Transport Hitch 6 Fully insert L pin A in upper hole and turn pin to lock it Secure with ring pin B 7 Make electrical connection at the joint C 1000717 A Figure 4 48 Header Transport Wheel 8 Make the electrical connection at the header wheel A OPERATION ...

Page 207: ...9 Drive windrower so that windrower lift arms are positioned into the weight box pockets 10 Raise lift arms slightly install locking pins A into pockets and through windrower header lift linkages Secure with hairpin NOTE Pins A were previously removed from the header lift linkage lower end 1000719 A B Figure 4 51 Weight Box 11 Route the weight box harness A to the electrical connector at the left ...

Page 208: ... press HEADER DOWN switch A on ground speed lever GSL to lower lift arms until the rear of the arms lift away from the linkage 1000722 A B C Figure 4 54 Weight Box 15 Attach slow speed transport hitch to the weight box tongue with drawbar pin Secure using lynch pin A Attach safety chain B 16 Connect hitch harness C to electrical socket at front of weight box OPERATION ...

Page 209: ...peration DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1000719 A B Figure 4 56 Electrical Harness 1 Stop the engine and remove the key from the ignition 2 Disconnect electrical harness at connector B from the windrower and store harness A on weight box OPERA...

Page 210: ...d the area 1000712 A Figure 4 59 Lift Arms 7 Start the engine and lower lift arms until rear of lift arms floats up and away from the lift arm mechanism 8 Stop the engine and remove the key from the ignition 9 Remove temporary lift pins A from weight box and install pins F into holes at rear of lift arms 10 Start the engine and fully raise lift arms Stop the engine and remove the key from the igni...

Page 211: ...ve pins A securing lift linkages to weight box and retain pins for attaching header to windrower Disengage lift cylinder safety props Refer to 4 4 1 Engaging and Disengaging Header Safety Props M Series Self Propelled Windrower page 194 14 Start the engine lower weight box onto blocks and back away 15 Attach the header to the windrower Refer to 4 5 Attaching and Detaching Headers page 217 16 Conve...

Page 212: ...ncy Towing 1 Before towing the vehicle disengage the final drives Refer to Disengaging Final Drives page 192 2 Use attachment point A to tow if windrower gets stuck or when pulling onto a truck or trailer for transport 3 When towing is complete place blocks under front and rear wheels to prevent uncontrolled movement 4 Engage final drives Refer to Disengaging Final Drives page 192 Disengaging Fina...

Page 213: ...t pipe with plastic bags and or waterproof tape 7 If possible store the windrower on blocks to take weight off tires If blocking up the machine is not possible increase tire pressure by 25 for storage Adjust to recommended operating pressure before next use 8 Repaint all worn or chipped painted surfaces to prevent rust 9 Lubricate the windrower thoroughly leaving excess grease on fittings to keep ...

Page 214: ...on the windrower Follow these steps to engage or disengage the header safety props DANGER To avoid bodily injury from fall of raised header always engage safety props when working on or around raised header and before going under header for any reason Engage safety props as follows 1008946 A Figure 4 64 Ground Speed Lever GSL 1 Start engine and press HEADER UP switch A to raise header to maximum h...

Page 215: ...death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1014507 A Figure 4 66 Safety Prop 1 Turn lever A away from header to raise safety prop until lever locks into vertical position Repeat for opposite cylinder 2 Start the engine choose a level area and lower the header to the ground 3 Stop the eng...

Page 216: ...n the header during operation set float with tow bar in place Adjust the float when adding or removing optional attachments that affect the weight of the header Float Operating Guidelines When working with the cutterbar on the ground Set center link to mid range position 5 0 on cab display module CDM Refer to 4 4 5 Adjusting Header Angle page 205 When operating at the flattest header angle minimiz...

Page 217: ...der float as follows DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason CAUTION Check to be sure all bystanders have cleared the area 1 Start the engine 2 Lower header to ground 3 Using HEADER TILTswitches D and F set center link to mid range position 5 0 on CDM ...

Page 218: ...ximately the same at both ends Header Force Required to Lift Header at the Ends with Lift Cylinder Fully Retracted Auger 335 380 N 75 85 lbf Rotary disc 426 471 N 95 105 lbf Draper 335 380 N 75 85 lbf with stabilizer transport wheels raised if equipped Adjusting Float Using Drawbolts Coarse float adjustment is done using the drawbolts located on either side of the windrower If necessary coarse adj...

Page 219: ...check the header float Float Options For draper headers without the deck shift option auger headers and rotary headers the float disc can be preprogrammed for three types of windrowing conditions Example Position 1 Border Position 2 Normal Position 3 Rocky Set float presets as follows 1 Engage header 1005240 A B Figure 4 70 Float Preset Switch 2 Push FLOAT PRESET SWITCH A to Position 1 B OPERATION...

Page 220: ...ive MD B5496 adjust reel fore aft to your normal operating position 4 Using HEADER DOWN switch E lower header fully with lift cylinders fully retracted 5 Set left B and right C float fine adjustments on CDM to approximately 5 0 as follows a Using FLOAT SELECTOR switch B push to increase float or to decrease float on left side of header CDM display A will indicate selected float for left side for e...

Page 221: ...at Options with Deck Shift page 273 4 4 3 Levelling the Header The windrower linkages are factory set to provide the proper level for the header and should not normally require adjustment DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason If the header is not lev...

Page 222: ... Set header approximately 150 mm 6 in off ground and check that member A is against link B Stop engine and remove key from ignition 5 Measure distance to ground at both ends of header and determine the end that is higher 6 If adjustment is necessary start the engine and raise the header fully Turn off the engine and remove the key from the ignition 1008708 A Figure 4 76 Float Pins Engaged 7 Move f...

Page 223: ...9 Lift Linkage 12 Start the engine and raise the header fully 13 Stop the engine and remove the key from the ignition 14 Move float pins to disengaged position 15 Start the engine and set the header approximately 150 mm 6 in off ground and check that member A is against link B Stop the engine and remove the key from the ignition 16 Measure distance to ground at both ends of the header 17 If additi...

Page 224: ...e controls may be installed but will be nonfunctional for certain headers Engaging and Disengaging the Header IMPORTANT Always move throttle lever back to idle before engaging header drive Do NOT engage header with engine at full rpm CAUTION Check to be sure all bystanders have cleared the area 1018464 A B Figure 4 81 Operator Console 1 To Engage Header a Move throttle A to adjust engine speed to ...

Page 225: ...sh down and pull up HEADER DRIVE knob 4 4 5 Adjusting Header Angle Header angle is defined as the angle between the ground and the drapers cutterbar It is adjustable to accommodate crop conditions and or soil type Refer to the appropriate header operator s manual for the range of adjustment and recommended settings for your particular header The header angle can be hydraulically adjusted from the ...

Page 226: ...etween 00 0 and 10 0 To increase steepen header angle operate HEADER TILT DOWN switch C on the GSL handle so the cylinder extends The CDM display will show a reading on the lower line of increasing value between 00 0 and 10 0 NOTE The HEADER TILTswitch can be locked out to prevent inadvertent header angle changes when pressing the HEADER HEIGHT control switches Refer to Activating the Header Tilt ...

Page 227: ...cking device and then lifting the hook off the header pin 1000741 A B C Figure 4 85 Center Link Hook A Handle B Lock Pin C Actuator Rod 2 Lower the handle A into the LOCK position 3 Push up on lock pin B only Handle should catch on casting and pin should NOT lift 1000740 Figure 4 86 Center Link Hook 4 Push up on actuator rod and lock pin should lift with the handle OPERATION ...

Page 228: ...assist you in maintaining the desired cutting height with the RETURN TO CUT feature This feature can be turned OFF or ON with a switch on the cab display module CDM The return to cut RTC feature provides preset cutting height and tilt angle settings for the header If desired the CDM can be programmed so that only the cutting height feature is active The AUTO RAISE HEIGHT feature allows you to rais...

Page 229: ...eader to the desired cutting height with the HEADER UP B or HEADER DOWN C switches on the ground speed lever GSL The cab display module CDM displays between 00 0 and 10 0 at D 4 Adjust the header angle with the HEADER TILT UP E or HEADER TILT DOWN F switches on the GSL The CDM displays between 00 0 and 10 0 This step is not required when height only has been preselected 5 Press the RETURN TO CUTsw...

Page 230: ...et cutting height momentarily press HEADER DOWN switch C and the header will return to preset height 2 If the header is below the preset height press and hold the HEADER UP B switch to raise the header Release switch to stop header Alarm will sound when header rises past the preset height 3 If the header angle changes double click two clicks within 0 5 seconds the HEADER TILT UP E or HEADER TILT D...

Page 231: ...C Select D Right Arrow E Left Arrow F Header Up G Header Down Program the auto raise height feature as follows NOTE RETURN TO CUTswitch A can be OFF or ON 1 Turn ignition ON or run engine 2 Press PROGRAM B and SELECT C on cab display module CDM to enter programming mode 3 Press SELECT C WINDROWER SETUP is displayed on upper line B 4 Press right arrow D then SELECT SET KNIFE SPEED is displayed 5 Pr...

Page 232: ...ISE HEIGHT turned ON the ACRE counter will be disabled when header height greater than preset cutting height 2 If desired press HEADER UP switch while header is being raised to disable auto raise height and maintain current height NOTE With AUTO RAISE HEIGHT turned OFF the ACRE counter will be disabled when header height value is greater than 9 5 OFF is displayed on the cab display module CDM 3 To...

Page 233: ...ing the side delivery system shuts off the draper and allows the crop to be deposited between the windrower wheels as it would be without the side delivery system Refer to MacDon M Series Windrower Double Windrow Attachment Manual for complete operating and maintenance instructions The manual is shipped with the DWA kit 1022639 1022639 Figure 4 93 Double Windrowing 2 The conditioned crop is deposi...

Page 234: ... operator preference The windrower cab display module CDM is programmed during the installation of the double windrow attachment DWA but the controls can be swapped at any time Refer to Activating the Double Windrow Attachment DWA page 98 The draper is activated during deck lowering and deactivated during raising NOTE The same switch is used for raising and lowering a swath compressor if installed...

Page 235: ...itoring system Refer to MacDon M Series Windrower Swath Compressor Attachment Manual for complete operating and maintenance instructions The manual is shipped with the swath compressor kit Using the Swath Compressor The following topic explains how to use the swath compressor and describes the automated raise lower functions CAUTION To avoid bodily injury or death from unexpected startup of machin...

Page 236: ...t with the console buttons becomes the target height When an adjustment is made the display shows the target value The system immediately adjusts to attain the target position After the last adjustment the display shows target value for 5 seconds then the display reverts to the previous screen Swath compressor automated functions header engaged cab forward When ground speed higher than 2 5 km h 1 ...

Page 237: ...nkage CAUTION To prevent damage to the lift system when lowering header lift linkages without a header or weight box attached to the windrower ensure the float engagement pin is installed in storage position B and NOT in engaged position A 1000752 A B Figure 4 102 Header Boot 1 Remove pin B from boot A 1000753 A B C D Figure 4 103 Header Boot 2 Position boot B onto lift linkage A and reinstall pin...

Page 238: ...raper header boots must be installed onto the windrower lift linkage before starting this procedure Refer to 4 5 1 Attaching Header Boots page 217 DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1000754 A B Figure 4 104 Header Leg 1 Remove hairpin A from pins ...

Page 239: ...til the boots A enter the header legs B Continue driving slowly forward until lift linkages contact the support plates in the header legs and the header nudges forward 5 Ensure the lift linkages are properly engaged in the header legs and are contacting the support plates 1008944 A B C D Figure 4 108 Ground Speed Lever 6 Use the following GSL functions to position the center link hook above the he...

Page 240: ... on the GSL until it locks into position hook release B is down 9 Check that center link is locked onto header by pressing the REEL UP switch on the GSL CAUTION Check to be sure all bystanders have cleared the area 1008946 A Figure 4 110 Ground Speed Lever 10 Press HEADER UP switch A to raise the header to maximum height 11 If one end of the header does NOT fully raise rephase the lift cylinders a...

Page 241: ...the header to release and lower safety prop B onto the lift cylinder c Repeat for opposite lift cylinder 1000771 A B C D Figure 4 112 Header Leg 13 Install pin B through the header leg engaging U bracket in lift linkage on both sides and secure with hairpin A 14 Raise header stand D to storage position by pulling spring pin C and lifting stand into uppermost position Release spring pin OPERATION ...

Page 242: ...Figure 4 114 Safety Prop Lever 16 Disengage the safety prop by turning lever A downwards until lever locks into vertical position 17 Repeat for opposite safety prop 1008947 A Figure 4 115 Ground Speed Lever CAUTION Check to be sure all bystanders have cleared the area 18 Start the engine and press HEADER DOWN switch A on the GSL to fully lower the header 19 Stop engine and remove key from ignition...

Page 243: ...drower Refer to the draper header operator s manual Attaching a D Series or D1 SP Series Header Hydraulic Center Link without Self Alignment NOTE Draper header boots must be installed onto the windrower lift linkage before starting this procedure Refer to 4 5 1 Attaching Header Boots page 217 DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and r...

Page 244: ...m exhaust stack 2 Start the engine and activate the HEADER DOWN button A on the ground speed lever GSL to fully retract header lift cylinders 1000757 A B Figure 4 120 Hydraulic Center Link without Self Alignment Kit 3 Remove pin A pin in frame linkage and raise center link B until hook is above the attachment pin on header Replace pin A to hold center link in place IMPORTANT If the center link is ...

Page 245: ...6 Use the following GSL functions to position the center link hook above the header attachment pin HEADER TILT UP A to retract the center link HEADER TILT DOWN B to extend the center link 7 Stop engine and remove key from ignition 1008781 A B Figure 4 123 Hydraulic Center Link 8 Push down on rod end of link cylinder B until hook engages and locks onto header pin IMPORTANT The hook release must be ...

Page 246: ...ress and hold the HEADER UP switch until both cylinders stop moving b Continue to hold the switch for 3 4 seconds Cylinders are now phased NOTE It may be necessary to repeat this procedure if there is air in the system 1000770 A B Figure 4 125 Safety Prop 13 Engage the safety props on both lift cylinders as follows a Stop engine and remove key from ignition b Pull lever A and rotate towards the he...

Page 247: ...pring pin C and lifting stand into uppermost position Release spring pin 1008712 A B Figure 4 127 Header Float Linkage 16 Remove the clevis pin from storage position B in linkage and insert into hole A to engage the float springs Secure with hairpin 1014507 A Figure 4 128 Safety Prop Lever 17 Disengage the safety prop by turning lever A downwards until lever locks into vertical position 18 Repeat ...

Page 248: ...lly lower the header 20 Stop engine and remove key from ignition 1000774 A B Figure 4 130 Header Drive Hoses and Harness 21 Connect header drive hoses A and electrical harness B to header Refer to the draper header operator s manual 1000775 A Figure 4 131 Reel Hydraulics 22 Connect reel hydraulics A at right cab forward side of windrower Refer to the draper header operator s manual OPERATION ...

Page 249: ... 4 132 Ground Speed Lever GSL 1 Start engine and press HEADER UP switch A to raise header to maximum height 2 Rephase cylinders if one end of the header does not raise fully If rephasing is required proceed as follows a Press and hold the HEADER UP switch A until both cylinders stop moving b Continue to hold the switch for 3 4 seconds Cylinders are now phased 3 Stop engine and remove key 1000770 A...

Page 250: ...storage hole B Secure with lynch pin CAUTION To prevent damage to the lift system when lowering header lift linkages without a header or weight box attached to the windrower ensure the float engagement pin is installed in storage position B and NOT in engaged position A 1014507 A Figure 4 136 Safety Prop 8 Turn lever A away from header to raise safety prop until lever locks into vertical position ...

Page 251: ... A Figure 4 138 Reel Hydraulics 12 Disconnect reel hydraulics A from header and store on bracket at windrower left cab forward side Refer to the draper header operator s manual for further information 1008948 A B Figure 4 139 Ground Speed Lever CAUTION Check to be sure all bystanders have cleared the area 13 Start the engine and activate HEADER TILT UP A and HEADER TILT DOWN B cylinder switches on...

Page 252: ... link from the header 1000786 A B Figure 4 141 Header Stand 15 Reinstall pin A into header leg and secure with a hairpin B 4 5 4 Attaching an A Series Header A30D A30S and A40D headers can be attached to an M205 Self Propelled Windrower Refer to the following instructions based on the type of center link installed on your windrower Attaching an A Series Header Hydraulic Center Link with Optional S...

Page 253: ...th sides of the header 1008712 A B Figure 4 143 Header Float Linkage CAUTION To prevent damage to the lift system when lowering header lift linkages without a header or weight box attached to the windrower ensure the float engagement pin is installed in storage position B and NOT in engaged position A 1008925 A Figure 4 144 Ground Speed Lever CAUTION Check to be sure all bystanders have cleared th...

Page 254: ... 146 Header Support 4 Drive the windrower slowly forward until the windrower feet A enter the header supports B Continue driving slowly forward until the feet engage the supports and the header nudges forward 1008944 A B C D Figure 4 147 Ground Speed Lever 5 Use the following GSL functions to position the center link hook above the header attachment pin REEL UP A to raise the center link REEL DOWN...

Page 255: ...il the center link locks into position and the hook release B is down 8 Check that center link is locked onto header by pressing the REEL UP switch on the GSL CAUTION Check to be sure all bystanders have cleared the area 1008946 A Figure 4 149 Ground Speed Lever 9 Press HEADER UP switch A to raise the header to maximum height 10 If one end of the header does NOT fully raise rephase the lift cylind...

Page 256: ...l lever A and rotate towards the header to release and lower safety prop B onto the lift cylinder c Repeat for opposite lift cylinder 1000711 A Figure 4 151 Header Support 12 Install clevis pin A through support and foot and secure with hairpin Repeat for opposite support IMPORTANT Ensure clevis pin A is fully inserted and hairpin is installed behind bracket OPERATION ...

Page 257: ... as shown Reinsert clevis pin A and secure with lynch pin 1008712 A B Figure 4 153 Header Float Linkage 16 Remove the clevis pin from storage position B in linkage and insert into hole A to engage the float springs Secure with hairpin 1014507 A Figure 4 154 Safety Prop Lever 17 Disengage the safety prop by turning lever A downwards until lever locks into vertical position 18 Repeat for opposite sa...

Page 258: ...t header drive hoses A and electrical harness B to header Refer to the draper header operator s manual Attaching an A Series Header Hydraulic Center Link without Self Alignment DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1000778 A B C Figure 4 157 Header B...

Page 259: ...ders have cleared the area IMPORTANT Before starting engine remove protective cover from exhaust stack 2 Start the engine and activate the HEADER DOWN button A on the ground speed lever GSL to fully retract header lift cylinders 1000757 A B Figure 4 160 Hydraulic Center Link without Self Alignment Kit 3 Remove pin A pin in frame linkage and raise center link B until hook is above the attachment pi...

Page 260: ...ter link hook above the header attachment pin HEADER TILT UP A to retract center link HEADER TILT DOWN B to extend center link 6 Stop engine and remove key from ignition 1008781 A B Figure 4 163 Hydraulic Center Link 7 Push down on rod end of link cylinder B until hook engages and locks onto header pin IMPORTANT The hook release must be down to enable the self locking mechanism If the release is o...

Page 261: ...s and hold the HEADER UP switch until both cylinders stop moving b Continue to hold the switch for 3 4 seconds Cylinders are now phased NOTE It may be necessary to repeat this procedure if there is air in the system 1000770 A B Figure 4 165 Safety Prop 12 Engage the safety props on both lift cylinders as follows a Stop engine and remove key from ignition b Pull lever A and rotate towards the heade...

Page 262: ...cket 1000783 A B Figure 4 167 Header Stand 14 Remove lynch pin from clevis pin A in stand B 15 Hold stand B and remove pin A 16 Move stand B to storage position by inverting and relocating onto bracket as shown Reinsert clevis pin A and secure with lynch pin 1008712 A B Figure 4 168 Header Float Linkage 17 Remove the clevis pin from storage position B in linkage and insert into hole A to engage th...

Page 263: ... A Figure 4 170 Ground Speed Lever CAUTION Check to be sure all bystanders have cleared the area 20 Start the engine and press HEADER DOWN switch A on the GSL to fully lower the header 21 Stop engine and remove key from ignition 1000774 A B Figure 4 171 Header Drive Hoses and Harness 22 Connect header drive hoses A and electrical harness B to header Refer to the draper header operator s manual OPE...

Page 264: ...the engine and press HEADER UP switch A on the ground speed lever GSL to raise the header to maximum height 2 If one end of the header does NOT raise fully rephase the cylinders as follows a Press and hold the HEADER UP switch A until both cylinders stop moving b Continue to hold the switch for 3 4 seconds Cylinders are now phased 3 Stop the engine and remove the key DANGER To avoid bodily injury ...

Page 265: ...y Prop 4 Pull lever A and rotate toward header to lower safety prop B onto cylinder Repeat for opposite cylinder 1000780 B A Figure 4 174 Header Boot 5 Remove the hairpin from clevis pin A and remove clevis pin from header boots B on both sides OPERATION ...

Page 266: ... installed in storage position B and NOT in engaged position A 7 Remove the lynch pin from the clevis pin and remove the clevis pin from linkage A to disengage float springs and insert clevis pin into storage hole B Secure with lynch pin Repeat for opposite linkage CAUTION Check to be sure all bystanders have cleared the area 1014507 A Figure 4 177 Safety Props 8 Disengage safety props by turning ...

Page 267: ...m the ignition 12 Lift hook release C and lift hook B off header pin NOTE If optional center link self alignment kit is installed lift release C and then operate the link lift cylinder with REEL UP switch on the GSL to disengage the center link from the header 1000784 A B Figure 4 180 Header Drive Hydraulics 13 Disconnect header drive hydraulics A and electrical harness B Refer to the auger header...

Page 268: ...rated with a 4 m 13 ft R Series Disc Header These drive tires are reversible and should be mounted inset at 3792 mm 149 3 in to provide maximum clearance to uncut crop Mounting these tires outset or mounting all other drive tire options will result in windrower tires slightly wider than the header width This may cause some uncut crop to be trampled by tires in turns and corners during windrower op...

Page 269: ...ystem when lowering header lift linkages without a header or weight box attached to the windrower ensure the float engagement pin is installed in storage position B and NOT in engaged position A 2 Remove the clevis pin from linkage A to disengage float springs and insert clevis pin into storage hole B Secure with lynch pin Repeat for opposite linkage 1008947 A Figure 4 184 Ground Speed Lever CAUTI...

Page 270: ...til the windrower feet A enter the header supports B Continue driving slowly forward until the feet engage the supports and the header nudges forward 1008944 A B C D Figure 4 187 Ground Speed Lever 6 Use the following GSL functions to position the center link hook above the header attachment pin REEL UP A to raise the center link REEL DOWN B to lower the center link HEADER TILT UP C to retract the...

Page 271: ...l the center link locks into position and the hook release B is down 9 Check that center link is locked onto header by pressing the REEL UP switch on the GSL CAUTION Check to be sure all bystanders have cleared the area 1008946 A Figure 4 189 Ground Speed Lever 10 Press HEADER UP switch A to raise the header to maximum height 11 If one end of the header does NOT fully raise rephase the lift cylind...

Page 272: ... and rotate towards the header to release and lower safety prop B onto the lift cylinder c Repeat for opposite lift cylinder 1021447 A B Figure 4 191 Header Support 13 Install clevis pin A through support and windrower lift member and secure with hairpin B Repeat for opposite side IMPORTANT Ensure clevis pin A is fully inserted and hairpin is installed behind bracket OPERATION ...

Page 273: ...Figure 4 193 Safety Prop Lever 15 Disengage the safety prop by turning lever A downwards until lever locks into vertical position 16 Repeat for opposite safety prop 1008947 A Figure 4 194 Ground Speed Lever CAUTION Check to be sure all bystanders have cleared the area 17 Start the engine and press HEADER DOWN switch A on the GSL to fully lower the header 18 Stop engine and remove key from ignition...

Page 274: ...g the operator s seat for any reason 1021748 A B C Figure 4 196 Header Support 1 Remove hairpin B from clevis pin A and then remove clevis pin from header supports C on both sides of the header 1008711 A B Figure 4 197 Header Float Linkage CAUTION To prevent damage to the lift system when lowering header lift linkages without a header or weight box attached to the windrower ensure the float engage...

Page 275: ...nt Kit 4 Remove pin A pin in frame linkage and raise center link B until hook is above the attachment pin on header Replace pin A to hold center link in place IMPORTANT If the center link is too low it may contact the header as the windrower approaches the header for hookup 1000780 B A Figure 4 200 Header Support 5 Drive the windrower slowly forward until the windrower feet A enter the header supp...

Page 276: ...ing mechanism If the release is open up manually push it down after hook engages header pin 9 Check that center link A is locked onto the header by pulling upward on rod end B of cylinder 1008946 A Figure 4 203 Ground Speed Lever CAUTION Check to be sure all bystanders have cleared the area 10 Start the engine 11 Press HEADER UP switch A to raise the header to maximum height 12 If one end of the h...

Page 277: ...nd rotate towards the header to release and lower safety prop B onto the lift cylinder c Repeat for opposite lift cylinder 1021447 A B Figure 4 205 Header Support 14 Install clevis pin A through the support and windrower lift member and secure with hairpin B Repeat for opposite side IMPORTANT Ensure clevis pin A is fully inserted and hairpin is installed behind bracket OPERATION ...

Page 278: ...Figure 4 207 Safety Prop Lever 16 Disengage the safety prop by turning lever A downwards until lever locks into vertical position 17 Repeat for opposite safety prop 1008947 A Figure 4 208 Ground Speed Lever CAUTION Check to be sure all bystanders have cleared the area 18 Start the engine and press HEADER DOWN switch A on the GSL to fully lower the header 19 Stop engine and remove key from ignition...

Page 279: ...om unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1008946 A Figure 4 210 Ground Speed Lever GSL 1 Start engine and press HEADER UP switch A to raise header to maximum height 2 Rephase cylinders if one end of the header does not raise fully If rephasing is required proceed as follows a Press and hold th...

Page 280: ...igure 4 211 Safety Prop 4 Pull lever A and rotate toward header to lower safety prop B onto cylinder Repeat for opposite cylinder 1000812 A B C Figure 4 212 Header Boots 5 Remove hairpin from clevis pin A and remove clevis pin from header boot B on both sides of header OPERATION ...

Page 281: ...ge float springs and insert into storage hole B Secure with hairpin CAUTION Check to be sure all bystanders have cleared the area 1014507 A Figure 4 214 Safety Props 7 Disengage safety props by turning lever A away from header to raise safety prop until lever locks into vertical position Repeat for opposite cylinder 8 Start the engine choose a level area and lower the header to the ground 1008948 ...

Page 282: ...then operate the link lift cylinder from the cab to disengage the center link from the header 1005186 1014769 A Figure 4 217 Header Drive Hydraulics 12 Disconnect header drive hydraulics and electrical harness A For instructions refer to the header operator s manual 13 Back the windrower slowly away from the header 1000812 A B C Figure 4 218 Header Boot 14 Reinstall clevis pin A through boot C and...

Page 283: ...er basic kit and a completion kit as shown If necessary obtain the following kits from your MacDon Dealer and install them in accordance with the instructions supplied with the kits Kit Description Kit Number Base draper auger drive kit MD B5491 Draper header reel drive completion kit MD B5496 Hydraulic couplers kit MD B5497 Hydraulic union kit MD 166844 1005503 Figure 4 220 Draper Header Reel Hyd...

Page 284: ...ss and hold the switch for the desired movement of the reel REEL UP A or REEL DOWN B IMPORTANT Under certain conditions with the reel raised to full height the reel tines may contact the cab roof Exercise care to avoid damage to the machine 4 6 4 Reel Speed Reel speed is controlled with switches on the ground speed lever GSL in the cab On draper headers reel speed can run independently or be set r...

Page 285: ... b Set HEADER INDEX switch B to ON c Press the DISPLAY SELECTOR button E on the GSL to display MIN REEL at A or press the FAST C or SLOW D switch The displayed value rpm or mph or km h18 d Press FAST C or SLOW D until the desired minimum reel speed is achieved 2 Set the reel index as follows IMPORTANT Reel index can only be adjusted while operating at a ground speed faster than minimum reel speed ...

Page 286: ...ound speed plus the index value is LESS THAN the minimum reel speed set point Examples Windrower is operating at 13 km h 8 mph with header index ON and set at 5 5 Display shows 13 5 5 5 REEL IND where 13 5 8 5 5 is the reel speed in mph and 5 5 is the header index setting Windrower speed drops to 12 km h 7 5 mph at the same header index setting Display shows 13 0 5 5 REEL IND where 13 0 7 5 5 5 is...

Page 287: ...perating the windrower NOTE This procedure is similar to changing the draper speed using the draper speed control switch while in motion Refer to Setting Draper Speed Independent of Ground Speed page 270 These changes become the new set points 1 Set HEADER INDEX B to OFF 2 Press REEL FAST C or REEL SLOW D on the ground speed lever GSL until display A shows REEL MPH with desired reel speed The disp...

Page 288: ...ion allows you to run the engine at lower rpm while maintaining the desired ground and draper speed Reducing engine speed saves fuel and reduces noise in the cab Setting draper to ground speed requires setting both the minimum draper speed and the draper index Refer to the following Setting Minimum Draper Speed page 268 Setting Draper Index page 269 Setting Minimum Draper Speed Figure 4 225 Operat...

Page 289: ... desired minimum draper speed Setting Draper Index Figure 4 226 Operator Console 1000793 A B C D E CAUTION Check to be sure all bystanders have cleared the area Set draper index as follows IMPORTANT Draper Index can only be adjusted while operating at a ground speed faster than minimum draper speed plus header index value 1 Engage header 2 Set HEADER INDEX switch B to ON OPERATION 21 Depending on ...

Page 290: ... mph and 1 5 is the header index setting Windrower speed drops to 12 km h 7 5 mph at same header index setting Display shows 9 0 1 5 DRAP INDX where 9 0 7 5 1 5 is the draper speed in mph and 1 5 is the header index setting Windrower is operating at 13 km h 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 ind...

Page 291: ... knife and ground speeds Table 4 2 Knife Speed Table Header Description Knife Speed Type Size Minimum Maximum rpm25 spm26 rpm25 spm26 Draper with double knife 4 6 m 15 ft 750 1500 950 1900 Draper with double knife 6 1 and 7 6 m 20 and 25 ft 700 1400 850 1700 Draper with double knife 9 1 m 30 ft 600 1200 800 1600 Draper with double knife 10 6 m 35 ft 600 1200 700 1400 Draper with double knife 12 2 ...

Page 292: ...NOTE Knife speed cannot be programmed outside the range specified for each header NOTE Knife speed can be adjusted without shutting down the machine however the windrower should be stopped before adjusting CDM settings To adjust the knife speed refer to Setting the Header Knife Speed page 91 4 6 7 Deck Shift Control When connected to a draper header with the deck shift option hydraulic deck shift ...

Page 293: ...wer Setting Float Options with Deck Shift For draper headers equipped with the deck shift option the header float can be set for each deck position Float is maintained when the decks are shifted CAUTION Check to be sure all bystanders have cleared the area Program the float as follows 1 Engage header 1025101 A B C Figure 4 230 Operator Console 2 Using HEADER TILT SWITCHES A and B on the ground spe...

Page 294: ...r Display D will indicate selected float value for left side for example 8 0 L FLOAT R 6 Repeat for right side float with RIGHTswitch C Display D will indicate float value for both sides for example 8 0 L FLOAT R 3 0 1009920 A B C D Figure 4 233 Deck Shift Switch A Deck Shift Switch B Left Side Delivery C Center Delivery D Right Side Delivery 7 Select a second deck position with the DECK SHIFT swi...

Page 295: ...c kit and a completion kit as shown If necessary obtain the following kits from your MacDon Dealer and install them in accordance with the instructions supplied with the kits Kit Description Kit Number Base draper auger drive kit MD B5491 Draper conditioner auger header reverser completion kit MD B5492 Hydraulic coupler kit MD B5497 Hydraulic union kit MD 166844 OPERATION ...

Page 296: ...gage header 2 Set the HEADER INDEX switch B to OFF 3 Set the REEL SPEED to the minimum setting For instructions refer to Reel and Disc Speed Switches page 73 4 Press DISPLAY SELECTOR switch E on the ground speed lever GSL or press FAST C or SLOW D on the cab display module CDM until AUGER SPEED is displayed at A The displayed value auger speed setting NOTE Changes to reel speed will affect the aug...

Page 297: ...direct drive reel with an operating speed range of 50 85 rpm Reel speed is controlled by the cab display module CDM and the ground speed lever GSL in the operator s station The reel drive motor and the auger drive motor are connected in series so changing reel speed also changes auger speed The reel cannot be controlled separately Refer to the following two methods to adjust reel speed To adjust r...

Page 298: ...l to Ground Speed Setting the speed of the reel relative to ground speed using the header index function automatically adjusts the reel speed with changes to ground speed Benefits may include improved crop flow and reduced operator fatigue Setting the reel to ground speed requires setting the minimum reel speed and the reel index Figure 4 237 Operator Console 1000793 A B C D E CAUTION Check to be ...

Page 299: ...ex can only be adjusted while operating at a ground speed faster than minimum reel speed plus header index value Figure 4 238 Operator Console 1000793 A B C D E a Set the HEADER INDEX switch B to ON b Press the DISPLAY SELECTOR button E on the GSL to display REEL IND29 or press the FAST C or SLOW D switch The displayed value reel speed mph or km h or rpm28 The displayed value reel index value OPER...

Page 300: ...eed in mph and 2 0 is the header index setting 4 7 3 Knife Speed The ideal cutting speed should achieve a clean cut Crop types and conditions usually influence the knife and ground speeds When the header is first attached to the windrower the windrower control module WCM receives a code from the header that determines the knife speed range and the minimum speed The desired speed can be programmed ...

Page 301: ...pped with the header are required to hard plumb to the windrower 1005184 Figure 4 240 Kit MD B5456 R85 4 0 m 13 ft R80 4 0 and 4 9 m 13 and 16 ft headers The R85 4 0 m 13 ft header and the R80 4 0 and 4 9 m 13 and 16 ft headers are shipped without the motor and hoses installed The installation of a separate motor and hose bundle is necessary If required obtain kit MD B5456 from your MacDon Dealer ...

Page 302: ... conditions Setting Disc Speed Figure 4 241 Operator Console 1000787 A B C D E A Display B Header Index C Fast D Slow E Display Selector CAUTION Check to be sure all bystanders have cleared the area Follow these steps to set the disc speed 1 Engage header 2 Set HEADER INDEX switch B to OFF 3 Press FAST C or SLOW D on ground speed lever GSL until display A shows DISC RPM with desired disc speed Dis...

Page 303: ...maintenance service and parts information is available from your MacDon Dealer 5 1 Preparation for Servicing WARNING To avoid personal injury before servicing adapter header or opening drive covers Fully lower the header If necessary to service in the raised position always engage lift safety props Disengage drives Stop engine and remove key Wait for all moving parts to stop ...

Page 304: ...dily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Stop the engine and remove the key 1000068 A B C D Figure 5 1 Hood Open Lower Position 2 Locate latch A behind the grill and lift to release the hood 3 Raise hood until strap B which should be looped under hooks C and D stops at...

Page 305: ...ower Position 1 Grasp the strap at location 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 grasp the hood when within reach and lower until hood engages latch A MAINTENANCE AND SERVICING ...

Page 306: ...eason 1 Stop the engine and remove the key 1000069 A B C D Figure 5 3 Hood Open Highest Position 2 Locate latch A behind the grill and lift to release the hood 3 Raise hood until strap B which should be looped under hooks C and D stops at approximately a 40 angle 4 Remove strap B from hook C and allow hood to rise slightly farther 5 Remove the strap from hook D and allow the hood to rise fully to ...

Page 307: ...ull down on strap B and loop under lower hook D 2 Grasp strap 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 3 Pull down on strap B grasp the hood when within reach and lower until hood engages latch A MAINTENANCE AND SERVICING ...

Page 308: ...ydraulics plumbing or battery The maintenance platforms have three positions Closed position Open standard position Open major servicing position 5 3 1 Opening Platforms Standard Position CAUTION Do NOT stand on an unlocked platform It is unstable and may cause you to fall 1006274 A B Figure 5 5 Platforms This procedure describes how to open the cab forward left platform A The same procedure is us...

Page 309: ...tion NOTE Ensure the platform is latched before using 5 3 2 Closing Platforms Standard Position CAUTION Do NOT stand on an unlocked platform It is unstable and may cause you to fall 1006274 A B Figure 5 7 Platforms This procedure describes how to close the cab forward left platform A The same procedure is used for the right platform B MAINTENANCE AND SERVICING ...

Page 310: ...rove access to the hydraulics plumbing or battery the platforms can be swung away from the windrower CAUTION Do NOT stand on an unlocked platform It is unstable and may cause you to fall 1006274 A B Figure 5 9 Platforms This procedure describes how to open the cab forward left platform A The same procedure is used for the right platform B 1 Open the hood Refer to 5 2 1 Opening Hood Lower Position ...

Page 311: ...on 1000067 A B Figure 5 11 Platform 3 Remove the nut and bolt that secure link A to the frame Swing link A out of the way 4 Pull the front cab forward end of platform away from frame while moving it towards the walking beam The aft corner of platform B should project slightly into the engine bay when the opening is optimum MAINTENANCE AND SERVICING ...

Page 312: ...1 Swing link A all the way forward 2 Push the front cab forward end of platform towards the frame while moving the platform forward cab forward 3 Position link A on bracket and install bolt and nut Tighten enough so that link can still swivel on bracket 1000412 A B Figure 5 13 Platform Latch 4 Move platform B forward cab forward until it stops and latch A engages 5 Close the hood Refer to 5 2 2 Cl...

Page 313: ...icating the Windrower DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 To avoid injecting dirt and grit wipe grease fitting with a clean cloth before greasing 2 Inject grease through fitting with grease gun until grease overflows fitting except where noted Re...

Page 314: ...s 1008966 E B A C D E A A Forked Caster Wheel Bearing Two Places Outer Both Wheels B Top Link Two Places Both Sides C Lubrication Decal MD 183411 D Caster Pivot Both Sides E Forked Formed Caster Wheel Bearing Two Places Inner Both Wheels 50 Hrs 250 Hrs MAINTENANCE AND SERVICING ...

Page 315: ...ce the ground speed lever GSL in NEUTRAL and turn the steering wheel until it locks 2 With everyone clear of the machine engage header drive Refer to 3 18 1 Header Drive Switch page 70 3 With header drive running stand up out of the seat In approximately 5 seconds the header should shut off If NOT the Operator Presence System requires adjustment See your MacDon Dealer 4 To restart the header move ...

Page 316: ... your MacDon Dealer A properly functioning system should operate as follows The engine should start ONLY when the GSL is in N DETENT steering wheel is locked in the CENTER position seat base is latched in either engine forward or cab forward direction and header drive switch is in the OFF position The brake should engage and the machine should NOT move after engine start up under the above conditi...

Page 317: ...he tray 1007233 A B Figure 5 17 Control Panel Removed 2 Back off the jam nut A and turn nut B to either tighten or loosen the pivot The nut should be tightened to snug and then backed off 1 2 turn 3 Tighten jam nut A 4 Check movement of GSL 1007216 A B Figure 5 18 Control Panel 5 Reinstall control panel B with five screws A MAINTENANCE AND SERVICING ...

Page 318: ...f the console 1000830 A B Figure 5 20 GSL Adjustment Spring 2 Set spring dimension B to 32 mm 1 1 4 in 3 To increase the pivot resistance turn the nut A clockwise to compress the spring 4 To decrease the resistance turn the nut A counterclockwise to release the spring tension 5 5 4 Steering Adjustments Checking Steering Link Pivots The following checks should be performed every year DANGER To avoi...

Page 319: ...nd speed lever GSL A in N DETENT 2 Shut down the engine and remove the key 1000833 A B Figure 5 22 Steering Rods 3 Check steering rod bolts A for looseness and ball joints B for any perceptible movement 1000834 A B Figure 5 23 Steering Rods Pump End MAINTENANCE AND SERVICING ...

Page 320: ...oose a Back off jam nut A b Tighten inside nut B to 95 108 Nm 70 80 lbf ft c Hold inside nut B and tighten jam nut A to 81 95 Nm 60 70 lbf ft 6 To replace loose steering link ball joints or steering rod ball joints contact your MacDon Dealer 7 After replacing parts or making adjustments perform checks for Neutral Interlock and steering lock Refer to 5 5 2 Safety Systems page 295 MAINTENANCE AND SE...

Page 321: ...If the steering chain does NOT require adjustment skip the following steps 2 If the chain tension requires adjustment swivel the operator s station to position steering column close to the door 1000255 A B C Figure 5 26 Steering Tension Adjuster 3 At the base of the steering column check dimension C at spring It should be 16 mm 5 8 in 4 Adjust dimension as follows a Loosen nut A and turn nut B to ...

Page 322: ...ct cab suspension components by preventing the cab shocks from fully extending The straps do not require regular maintenance but they should be inspected every 100 hours 1014589 A Figure 5 27 Cab Suspension 1 Inspect the material on straps A for fraying or tearing 2 If material is torn or frayed contact your MacDon Dealer for replacement straps MAINTENANCE AND SERVICING ...

Page 323: ...sh Air Filter DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Open the right cab forward platform Refer to 5 3 1 Opening Platforms Standard Position page 288 1000125 A B Figure 5 28 Filter Tray 2 Rotate latch A and slide filter tray B out of the housing 1000...

Page 324: ...lement s inner surface and move up and down pleats 4 Repeat Steps 1 page 304 to 3 page 304 to remove remaining dirt as required 5 Hold a bright light inside the element and check carefully for holes Discard any element that shows the slightest hole 6 Check outer screen for dents Vibration would quickly wear a hole in the filter 7 Check filter gasket for cracks tears or other signs of damage If gas...

Page 325: ...vicing the Return Air Cleaner Filter DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason If replacing the return air filter refer to 8 2 4 Filter Part Numbers page 462 for the part number 1000132 A B Figure 5 33 Return Air Filter 1 Unscrew the two knobs A attachin...

Page 326: ...B Figure 5 35 Return Air Filter 5 Secure filter assembly B to cab wall with knobs A Cleaning Return Air Cleaner Filter Clean the electrostatic filter as follows 1020943 A Figure 5 36 Return Air Filter 1 Mix a solution of warm water and detergent in a suitable container and soak the filter A for a few minutes 2 Agitate to flush out the dirt 3 Rinse with clean water and then dry with compressed air ...

Page 327: ...rator fins Fins will clog up from the side opposite the blowers The evaporator is located inside the heating air conditioning unit under the cab Removing Air Conditioning A C Cover DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Stop the engine and remove th...

Page 328: ...nto the evaporator to prevent fin damage A nozzle extension makes this procedure easier 3 Repeat Step 2 page 308 at the side B opposite the blowers 1009960 A B C C Figure 5 40 Evaporator Core 2015 and Later 4 If you cannot feel the compressed air blowing through the evaporator core proceed as follows a Protect blower motor A from water b Soak evaporator core B with warm water using a low pressure ...

Page 329: ...Cover 1008547 A B Figure 5 41 A C Cover 1 Straighten any bent fins 2 Position cover B onto A C unit and attach with eight screws A 1008578 A Figure 5 42 A C Cover 3 Reattach drain hoses to drain tubes and secure with hose clamps A MAINTENANCE AND SERVICING ...

Page 330: ...d shuts down the compressor When the pressure rises above 172 kPa 25 psi the switch closes and the compressor restarts The low pressure switch is located at the outlet of the evaporator under cab in the A C box The high pressure switch The high pressure switch is closed when there is sufficient refrigerant in the system The system remains pressurized at about 414 483 kPa 60 70 psi with the compres...

Page 331: ...7 Engine Cummins 4021531 are supplied with your machine 5 8 2 Turning the Engine Manually To manually turn the engine with the flywheel an access hole is provided on the left cab forward side for a barring tool that is available from Cummins DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the o...

Page 332: ...Tool 5 Clean the area around the plastic cap on access hole A Remove the cap IMPORTANT Ensure nothing falls into gearbox oil reservoir 6 Insert barring tool B into the flywheel housing until it engages the ring gear 7 Attach a 1 2 in square drive ratchet or breaker bar and turn 8 Remove barring tool B and then clean oil from around access hole A 9 Clean plastic cap and reinstall in access hole A w...

Page 333: ... 2 2 Closing Hood Lower Position page 285 13 Close the platform Refer to 5 3 2 Closing Platforms Standard Position page 289 5 8 3 Engine Oil Checking Engine Oil Level Check engine oil level daily every 10 hours and watch for any signs of leakage CAUTION To avoid bodily injury or death from unexpected startup of machine always stop engine and remove key from ignition before leaving operator s seat ...

Page 334: ... and check the oil level 1000074 Figure 5 47 Engine Oil Level 7 Add oil if level is below low L mark Refer to Adding Engine Oil page 316 IMPORTANT Oil level should be maintained between low L and high H mark on the dipstick 1009928 A Figure 5 48 Engine Oil Dipstick 8 Replace dipstick A and turn it clockwise to lock 9 Close the hood Refer to 5 2 2 Closing Hood Lower Position page 285 MAINTENANCE AN...

Page 335: ...an with a capacity of about 24 liters 6 US gallons under the engine oil drain 1001299 A Figure 5 49 Engine Oil Drain Plug 3 Remove oil drain plug A and allow the oil to drain 4 When all of the oil has drained out of the tank replace drain plug A 5 Check the condition of the used oil If either of the following is evident have your Dealer correct the problem before starting the engine Thin black oil...

Page 336: ...htening can damage the gasket and filter 8 Properly dispose of used filter Adding Engine Oil Refer to inside back cover for recommended lubricants DANGER To avoid bodily injury or death from unexpected startup of machine always stop engine and remove key from ignition before leaving operator s seat for any reason 1 Stop the engine and remove the key Wait about 5 minutes 2 Open the hood Refer to 5 ...

Page 337: ...nt 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 5 12 1 Maintenance Schedule Record page 415 Air Filter Restriction Indicator During engine operation the indicator shows the vacuum in inches of H2O and kPa As dirt accumulates in the fil...

Page 338: ...page 288 1000096 A B Figure 5 54 Engine Air Cleaner 3 Slightly lift catch A at side of end cap B and rotate end cap counterclockwise until it stops 1000097 A Figure 5 55 Engine Air Cleaner 4 Make sure arrow A lines up with UNLOCK symbol on end cap 5 Pull off the end cap 1000098 A Figure 5 56 Engine Air Cleaner Housing 6 Check the aspirator duct opening A for obstructions or damage Clean if necessa...

Page 339: ...filter Ensure canister retaining latches are secure IMPORTANT Do NOT remove the secondary filter element unless it needs replacing Do NOT attempt to clean the secondary element A The secondary element is to be replaced only 9 If required replace the secondary filter Refer to Removing and Installing Secondary Air Filter page 322 10 Clean the inside of the canister housing and end cap carefully Dirt...

Page 340: ...rt for the housing Identify and rectify the cause of any leaks before replacing the filter element Installing Primary Air Filter NOTE If replacing air filter refer to 8 2 4 Filter Part Numbers page 462 1000099 A Figure 5 59 Primary Filter Element 1 Insert new primary filter element A into canister over secondary element and push into place ensuring that element is firmly seated in canister 1000097...

Page 341: ...r to 5 3 1 Opening Platforms Standard Position page 288 Cleaning Engine Air Filter Primary Element IMPORTANT The secondary inner element should NEVER be cleaned only replaced IMPORTANT Air filter element cleaning is NOT recommended due to the possible degradation of the element material If cleaning is performed there are several risks involved and the following procedure should be followed If any ...

Page 342: ...y Air Filter 1000100 A Figure 5 63 Secondary Filter Element NOTE Refer to 8 2 4 Filter Part Numbers page 462 for replacement filter part number Replace the secondary air filter A every year or after every third primary filter change even if it appears clean If the secondary air filter is dirty inspect the primary filter and the filter canister to determine the reason for contamination Examine the ...

Page 343: ...ent There are no scheduled servicing requirements other than to ensure the intake is not blocked 5 8 5 Fuel System Replacing Fuel Tank Vent Filter The fuel tank is vented by a hose that is connected to the filler tube The hose is connected to a filter that should be changed every year For fuel tank vent filter replacement part number refer to 8 2 4 Filter Part Numbers page 462 DANGER To avoid bodi...

Page 344: ...king arrow should point up 7 Attach lower hose to filter and secure both hoses with tension clamps B 8 Close hood Refer to 5 2 4 Closing Hood Highest Position page 287 9 Close the maintenance platform Refer to 5 3 2 Closing Platforms Standard Position page 289 Maintaining Fuel Filters 1025128 A B Figure 5 67 Fuel System Filters The windrower fuel system is equipped with primary A and secondary B s...

Page 345: ... seat for any reason 1 Stop the engine and remove the key 2 Open the hood Refer to 5 2 3 Opening Hood Highest Position page 286 1000112 A Figure 5 68 Fuel Shut off Valve 3 On the bottom of the fuel tank locate fuel supply valve A and move it to the closed position 1025129 A Figure 5 69 Primary Fuel Filter Location 4 Locate primary fuel filter A on the right cab forward side of the windrower MAINTE...

Page 346: ... B Figure 5 71 Primary Fuel Filter 2 Screw the new filter A onto the filter mount until the gasket contacts the filter head 3 Tighten the filter an additional 3 4 turn by hand Use a 25 4 mm 1 in wrench and torque it to 38 Nm 28 lbf ft 4 Tighten the filter an additional 1 2 to 3 4 turn by hand IMPORTANT Do NOT use a filter wrench to install the filter Overtightening can damage the gasket and filter...

Page 347: ... refer to 8 2 4 Filter Part Numbers page 462 1022762 A Figure 5 73 Secondary Fuel Filter 1 Screw the new secondary filter A onto the filter mount until the gasket contacts the filter head 2 Tighten the filter an additional 1 2 to 3 4 turn by hand IMPORTANT Do NOT use a filter wrench to install the filter Overtightening can damage the gasket and filter 1000112 A Figure 5 74 Fuel Shut off Valve 3 Op...

Page 348: ...ed startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Stop the engine and remove the key 2 Open the hood Refer to 5 2 1 Opening Hood Lower Position page 284 1000112 A Figure 5 75 Fuel Shut off Valve 3 Close fuel supply valve A located on the bottom of the fuel tank 1000115 A B Figure 5 76 Fuel System 4 Place a 20 l...

Page 349: ...in and a sensor that triggers a warning on the cab display module CDM if water is detected in the fuel Drain the water and sediment from the separator daily or at any time the CDM water in fuel WIF light illuminates To remove water from the fuel system refer to Removing Water from Fuel System page 329 Removing Water from Fuel System Drain the water and sediment from the separator daily or at any t...

Page 350: ...the fuel filters are changed in accordance with instructions IMPORTANT Bleeding the fuel system is NOT recommended or required Manual priming will be required if Fuel filter is replaced Injection pump is replaced High pressure fuel lines are replaced Engine is run until fuel tank is empty Priming Fuel System To prime the fuel system follow these steps DANGER To avoid bodily injury or death from un...

Page 351: ...f antifreeze strength is not adequate do NOT drain cooling system to protect against freezing The system may not drain completely and damage from freezing could still result Refer to 8 2 Recommended Fuel Fluids and Lubricants page 460 for detailed information Inspecting Radiator Cap The radiator cap must fit tightly and the cap gasket must be in good condition to maintain the 97 124 kPa 14 18 psi ...

Page 352: ...e key from the ignition before leaving the operator s seat for any reason CAUTION To avoid personal injury from hot coolant do NOT turn radiator cap until engine cools 1 Stop the engine and remove the key 2 Open the hood Refer to 5 2 3 Opening Hood Highest Position page 286 3 Open the platform Refer to 5 3 1 Opening Platforms Standard Position page 288 1000120 A Figure 5 82 Engine Cooling System 4...

Page 353: ...dard Position page 289 6 Close the hood Refer to 5 2 4 Closing Hood Highest Position page 287 Changing Coolant Coolant should be drained and the system flushed and filled with new coolant every 2000 hours or 2 years Refer to the following procedures Draining and Cleaning the Coolant Tank page 333 Adding Coolant page 336 Draining and Cleaning the Coolant Tank DANGER To avoid bodily injury or death ...

Page 354: ...coolant running onto frame 1000121 A Figure 5 85 Radiator Drain Valve 5 Remove the radiator cap and open radiator drain valve A located at the bottom of the engine side of the radiator lower tank NOTE Frame has been removed from illustration for clarity 1000122 A Figure 5 86 Heater Shut Off Valve 6 Close the heater shut off valve A and disconnect hose on heater side of valve 7 Open valve to drain ...

Page 355: ...he engine and drain water out before rust or sediment settles Repeat coolant removal procedure 14 Close drain valves and fill system with a solution of clean water and a heavy duty radiator cleaner Follow instructions provided with cleaner 15 After using the cleaner solution flush system with clean water again Inspect radiator hoses and fittings for leaks 16 Close drain valves and fill system Refe...

Page 356: ...he engine and remove the key 2 Open the hood Refer to 5 2 3 Opening Hood Highest Position page 286 3 Open the platform Refer to 5 3 1 Opening Platforms Standard Position page 288 1009941 A B Figure 5 90 Coolant Recovery Tank 4 Remove cap A from coolant recovery tank B 5 Add coolant at a rate not exceeding 3 gallons per minute until the recovery tank is one half full CAUTION Before starting the mac...

Page 357: ...creen page 337 Charge Air Cooling page 338 Cleaning Screens and Coolers page 338 Cleaning Cooler Box Components page 339 Adjusting Screen Cleaner Rotor to Screen Clearance page 341 Closing Cooler Box Screen page 342 Opening Cooler Box Screen 1 Open the hood Refer to 5 2 3 Opening Hood Highest Position page 286 1000170 A B Figure 5 91 Engine Cooling System 2 Push latch A and open screen assembly ac...

Page 358: ... the engine s cooling fan sweep and vacuum debris away from the cooling box screen If the screen is not being cleaned the rotors or ducts may be plugged Follow these steps to clear plugged rotors NOTE The following procedure is performed on one side procedure also applies to the other side 1 Open the hood Refer to 5 2 3 Opening Hood Highest Position page 286 1000172 A B C Figure 5 93 Screen Cleane...

Page 359: ...n Clearance page 341 10 Close the cooler box screen Refer to Closing Cooler Box Screen page 342 11 Close the hood Refer to 5 2 4 Closing Hood Highest Position page 287 Cleaning Cooler Box Components The radiator and oil cooler should be cleaned daily with compressed air More frequent cleaning may be necessary in severe conditions The charge air cooler and air conditioning A C condenser may also be...

Page 360: ... Lift latch A and open right access door B 1000275 A Figure 5 97 A C Condenser Assembly 3 Slide out the oil cooler air conditioning A C condenser assembly A 1000176 A B Figure 5 98 Left Cooler Access Door 4 Lift latch A and open left access door B MAINTENANCE AND SERVICING ...

Page 361: ...lide oil cooler air conditioning condenser B back into cooling box D 10 Close side access door and lock with lever 11 Close access door on top of the cooling box and secure with wing nut 12 Close cooler box screen Refer to Closing Cooler Box Screen page 342 Adjusting Screen Cleaner Rotor to Screen Clearance The clearance between trailing edge of screen cleaner rotor and screen should be 1 8 mm 0 0...

Page 362: ...6 Loosen the two motor mount bolts D 7 Move motor duct assembly E to obtain 1 8 mm 0 039 0 314 in gap to screen at full rotation of the rotor 8 Tighten nuts D on motor mount 9 Close the hood Refer to 5 2 2 Closing Hood Lower Position page 285 Closing Cooler Box Screen 1000170 A B Figure 5 102 Engine Cooling System 1 Unhook the support rod and store it in the screen door Close screen access door B ...

Page 363: ...he lubricant level every 50 hours as follows 1018382 A Figure 5 103 Gearbox Lubricant Check Plug 1 Park the windrower on level ground shut down engine and remove key 2 Remove check plug A The lubricant should be visible through the hole or slightly running out 1000862 A Figure 5 104 Gearbox Breather Cap 3 Add lubricant as follows a Remove breather cap A and add lubricant until it runs out the chec...

Page 364: ... key 2 Place a 4 liter 1 US gallon drain pan under the gearbox 1018414 A B Figure 5 105 Gearbox Lubricant Drain Plug 3 Remove drain plug B and allow oil to completely finish draining 4 Install drain plug B and remove check plug A 1000862 A Figure 5 106 Gearbox Breather Cap 5 Add lubricant as follows a Remove breather cap A and add lubricant until it runs out the check port If refilling add approxi...

Page 365: ...ased fuel economy and increased turbo wear If dents are relatively large increased bearing and cylinder wear will occur due to increased exhaust temperature 4 Make sure the exhaust system is secured to eliminate vibration The brackets B should fit securely to muffler C and to the engine IMPORTANT Do NOTchange muffler type piping sizes or exhaust configuration See your Dealer for proper replacement...

Page 366: ...an not shown and onto pulleys in order 3 2 1 10 Insert the drive end of a 1 2 in drive ratchet wrench into belt tensioner A 11 Rotate tensioner clockwise until belt B can be slipped onto pulley C Release tensioner and remove wrench 12 Check that belt is properly seated in all pulley grooves 1000078 A B Figure 5 110 A C Compressor 13 Install new compressor belt A 14 Pry compressor away from engine ...

Page 367: ...2 2 Closing Hood Lower Position page 285 Replacing Air Conditioner A C Compressor Belt DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Shut down the engine and remove the key 2 Open the hood Refer to 5 2 1 Opening Hood Lower Position page 284 1000078 A B Fig...

Page 368: ... Speed Control ISC page 166 for additional information about engine speed Throttle Adjustment The engine speed is controlled by a throttle lever 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 lever is contacti...

Page 369: ...tor field terminal or field Never connect or disconnect alternator or regulator wires with battery connected or alternator operating Always disconnect cables from the battery when using a charger to charge battery in windrower Ensure all cables are securely connected before operating engine To avoid damage to circuit boards by static electricity disconnect negative battery terminal when replacing ...

Page 370: ...prevent loss of battery charge when the windrower will not be used for periods longer than one week Charging the Batteries 1000849 Figure 5 115 Charging Battery CAUTION Ventilate the area where batteries are being charged Do NOT charge a frozen battery Warm to 16 C 60 F before charging Do NOT connect or disconnect live circuits To prevent sparks turn off charger and connect positive cable first PR...

Page 371: ...mmended rates and times Turn off charger prior to hook up to avoid dangerous sparks Wear proper eye protection Reduce charge rate if the terminal voltage is higher than 16 0 volts while charging The maximum charge rate in amperes should NOT exceed 1 3 of the battery s reserve capacity minute rating Continue charging if there is no change in voltage or current for a period of two hour and reduce th...

Page 372: ...e last connection and first disconnection at the point furthest away from the batteries Wear protective eye wear when using a booster battery Be sure everyone is clear of machine when starting engine Start engine from operator s station only 1 Open the hood Refer to 5 2 1 Opening Hood Lower Position page 284 1007877 A B Figure 5 117 Battery Boost Posts 2 Remove red rubber cover from boost post A o...

Page 373: ... 1000016 Figure 5 119 Battery Safety WARNING Battery electrolyte causes severe burns Avoid contact with skin eyes or clothing Wear protective eyewear and heavy gloves If electrolyte is spilled or splashed on clothing or on the body neutralize it immediately with a solution of baking soda and water then rinse with clean water Electrolyte splashed into the eyes is extremely dangerous Should this occ...

Page 374: ...ng Platforms Standard Position page 289 Removing Batteries DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 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 1 Sto...

Page 375: ...ries 1023971 A B C D E E F Figure 5 122 Batteries 4 Remove bolt A that secures the platform arm to the platform Swing arm B out of the way 5 Remove the black plastic cover from the negative cable clamps D Loosen clamps and remove cable from batteries 6 Remove the red plastic cover from positive cable clamps C Loosen the clamps and remove cable from batteries 7 Remove bolts E securing strap F to fr...

Page 376: ...the specifications shown in the following table Table 5 2 Battery Specification Rating Group CCA min Volt Maximum Dimension Heavy duty off road vibration resistant BCI 29H or 31A 750 12 334 x 188 x 232 mm 13 25 x 7 37 x 9 44 in 1006037 A Figure 5 124 Battery Main Disconnect Switch 1 Ensure the battery main disconnect switch A is turned to the POWER OFF position the battery main disconnect switch i...

Page 377: ...tion before leaving the operator s seat for any reason 1 Stop engine and remove key from ignition 2 Open the right cab forward maintenance platform Refer to 5 3 1 Opening Platforms Standard Position page 288 1006037 A Figure 5 126 Battery Main Disconnect Switch 3 Ensure the battery main disconnect switch A is turned to the POWER OFF position the battery main disconnect switch is located on the rig...

Page 378: ...ighten clamps Reposition plastic covers onto clamps 8 Turn the battery switch to the POWER ON position 9 Close the platform Refer to 5 3 2 Closing Platforms Standard Position page 289 5 9 3 Headlights Engine Forward Replacing Headlight Bulb Replacement bulb MD 110267 H4 12V 60 55W 1000845 A Figure 5 128 Headlight 1 Remove two screws A and remove headlight assembly from hood 1000846 A Figure 5 129 ...

Page 379: ...lb B from body 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 1000848 A B C Figure 5 131 Headlight Assembly 5 Align lugs B on new bulb with slots C in body and push into place 6 Secure bulb with wire retainer A MAINTENANCE AND SERVICING ...

Page 380: ...lights page 360 Aligning Headlights DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason NOTE Header should be attached and raised to maintain proper windrower stance 1 Position windrower in engine forward mode on level ground so that headlights are positioned 7 5 ...

Page 381: ... Turn on ROAD lights A and switch to low beam B 1022703 A Figure 5 136 Headlights 4 Align the headlights to the following specifications by turning adjusting screws A Adjustments are for low beam Light beams laterally centered on the direction of travel line from the headlights that is NOT skewed left or right MAINTENANCE AND SERVICING ...

Page 382: ...ght 5 9 4 Field Lights Cab Forward Adjusting Field Lights The field lights are best adjusted with the machine in the field or equivalent to suit Operator preference DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1000891 A A Figure 5 138 Windrower Cab Forward ...

Page 383: ...light Bulb page 358 5 9 5 Floodlights Forward Adjusting Forward Floodlights The forward floodlights are NOTadjustable Replacing Bulb in Cab Forward Flood Light Replacement bulb MD 109113 H3 12V 55W DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason Replace bulbs ...

Page 384: ...s 3 Remove two screws B and remove light bezel C 4 Remove light from receptacle 1000837 A B C Figure 5 142 Floodlight Assembly 5 Pinch wire retainer A and lift away from hooks 6 Remove bulb B from body and pull wire from connector C IMPORTANT Do NOT touch the glass of the halogen bulb as the oils or other chemicals from your skin will cause the bulb to fail prematurely MAINTENANCE AND SERVICING ...

Page 385: ...sity Discharge HID Auxiliary Lighting Optional MD B5596 Two optional HID lights provide additional lighting during field operation They operate only in cab forward mode Adjusting High Intensity Discharge HID Auxiliary Lights if Installed If installed HID auxiliary lights are best adjusted with the machine in the field or equivalent to suit Operator preference DANGER To avoid bodily injury or death...

Page 386: ... avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason To remove and replace the lamp only follow these steps 1000891 A A Figure 5 146 Cab Forward Lights 1 Shut down engine and remove key Turn lights OFF NOTE Hold onto the handholds A on the cab front corners and stand on the...

Page 387: ...g washer and nut 5 Adjust lamp B to desired position and tighten bolt A To remove and replace the HID lamp assembly follow these steps 1006323 A B Figure 5 148 HID Auxiliary Light Harness 6 Disconnect lamp connector A from electrical harness B 1006324 C A B Figure 5 149 HID Light Assembly 7 Remove grommet A from light support B 8 Remove nut C and spring washer from inside light support B 9 Remove ...

Page 388: ...dware C provided with light assembly 11 Adjust light assembly to desired position and tighten nut C 12 Route lamp harness through grommet A and slot in light support B 13 Reinstall grommet A in light support B 1006323 A B Figure 5 151 HID Auxiliary Light Harness 14 Connect lamp plug A to main harness connector B MAINTENANCE AND SERVICING ...

Page 389: ... bolts A and B 3 Position light to desired position 4 Tighten bolts A and B Replacing Bulb in Rear Flood Light Replacement bulb MD 109113 H3 12V 55W DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1000831 A B Figure 5 153 Rear Flood Light 1 Shut down engine an...

Page 390: ...from body and pull wire from connector D 6 Match slots on new bulb B with lugs C in optical unit and insert bulb into unit 7 Secure bulb with wire retainer A 8 Push wire into connector D 1000831 A B Figure 5 155 Rear Flood Light 9 Position light into light receptacle ensuring top is up 10 Secure with bezel B and screws A MAINTENANCE AND SERVICING ...

Page 391: ... down engine and remove key Turn lights OFF NOTE Hold onto handholds A 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 1000890 A Figure 5 157 Red and Amber Lights 2 Remove two screws A from lens and remove lens 3 Push and twist light bulb to remove from socket 4 Install new bulb in socket ensuring that b...

Page 392: ...ctor from light 5 Connect wiring harness to new light B and install light with screws A 5 9 10 Replacing the Bulbs in Beacon Lights If installed Beacon warning lights are available as an optional Dealer installed attachment MD B5582 DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s...

Page 393: ... 5 160 Warning Beacon 2 Turn lens A counterclockwise to unlock lens from base and remove lens 1000895 A Figure 5 161 Beacon Lamp Assembly 3 Pinch retainer A and remove it from lamp socket 4 Pull lamp out of socket MAINTENANCE AND SERVICING ...

Page 394: ... Do NOT touch the glass A of the halogen bulb as the oils or other chemicals from your skin will cause the bulb to fail prematurely 1000808 A Figure 5 163 Beacon Lamp Assembly 6 Connect harness to new lamp place lamp in socket and line up the flat side on lamp with recess in socket MAINTENANCE AND SERVICING ...

Page 395: ...ssembly 7 Place retainer A over lamp and pinch tabs to secure retainer to socket 1000806 Figure 5 165 Beacon Lamp Assembly 8 Line up the three lugs one is longer in the base with slots in lens and seat the lens against the rubber seal MAINTENANCE AND SERVICING ...

Page 396: ...llow these steps DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1000803 A Figure 5 167 Operator Console 1 Shut down engine and remove key Turn lights OFF 2 Remove the appropriate gauge access hole decal A behind the operator s console MAINTENANCE AND SERVICIN...

Page 397: ...kwise until it locks 7 Push gauge into console 8 Locate bracket C onto back of gauge and secure with nut B Tighten nut 9 Replace gauge access hole decal 5 9 12 Replacing the Cabin Dome Light To replace a cabin dome light in the headliner switch panel follow these steps 1000804 A Figure 5 169 Cabin Dome Light 1 Remove two screws A from the dome light assembly and remove the assembly 2 Disconnect th...

Page 398: ...o place in cab roof until tabs hold fixture in place 5 9 14 Turn Signal Indicators If the turn signal indicators on the operator console do not function contact your MacDon Dealer 5 9 15 Circuit Breakers and Fuses The circuit breakers and fuses are located inside a fuse box mounted on the right cab forward side of the frame under the platform Accessing Circuit Breakers and Fuses DANGER To avoid bo...

Page 399: ...nition before leaving the operator s seat for any reason 1 Stop the engine and remove the key 2 Open the right cab forward side platform Refer to 5 3 1 Opening Platforms Standard Position page 288 3 Remove fuse box cover Refer to Accessing Circuit Breakers and Fuses page 378 1022596 Figure 5 173 Fuses and Circuit Breakers 4 Refer to the decal on inside of cover for identification of fuses and circ...

Page 400: ...nd relays as follows 1 Stop engine and remove key 2 Move right cab forward side platform rearward cab forward 3 Remove fuse box cover Refer to Accessing Circuit Breakers and Fuses page 378 1022597 A B Figure 5 174 Relays and Breakers 4 To replace circuit breaker A pull breaker out of receptacle and install new circuit breaker 5 To replace relay B pull relay out of receptacle and install new relay ...

Page 401: ...214603 381 Revision A Fuse Box Decal Figure 5 175 Fuse Decal 1022431 MAINTENANCE AND SERVICING ...

Page 402: ...rator s seat for any reason 1 Stop engine and remove key 2 Move right cab forward side platform rearward 1000827 A B Figure 5 176 125A Main Fuses 3 To check condition of fuse pull tab A and open cover B 1000800 A B C Figure 5 177 125A Main Fuse 4 Visually examine fuse B for indications of melting 5 To remove fuse B remove two nuts C and pull fuse free from holder existing wiring may need to be pul...

Page 403: ...214603 383 Revision A 1000827 A B Figure 5 178 125A Main Fuses 8 Close cover B and secure with tab A 9 Return platform to operating position Ensure lock engages MAINTENANCE AND SERVICING ...

Page 404: ...ctor familiar with this type of injury or gangrene may result IMPORTANT Foreign materials such as dirt dust and water are the major cause of trouble in the hydraulic system If hydraulic system components must be disconnected for service protect the ends of hoses tubing and ports of components from contamination with clean lint free towels or clean plastic bags Before installing any replacement hos...

Page 405: ...remove the key 3 Open the hood Refer to 5 2 1 Opening Hood Lower Position page 284 1000436 A Figure 5 181 Hydraulic Oil Sight Glass NOTE A sight glass A is provided under the hood on the right side of the tank It indicates oil level and signs of contamination No oil in the sight glass indicates oil level is below the add mark on the dipstick 1000435 A Figure 5 182 Engine Hood 4 Stand on left cab f...

Page 406: ...ide the cooling box behind the radiator It should be cleaned daily with compressed air Refer to Cleaning Cooler Box Components page 339 5 10 3 Changing the Hydraulic Oil DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason Hydraulic oil should be changed every 1500...

Page 407: ...servoir Refer to 5 10 1 Checking and Filling Hydraulic Oil page 385 5 10 4 Changing Hydraulic Oil Filters Charge Oil Filter The charge oil filter cleans the oil in the hydraulic charge circuit The charge circuit replenishes oil losses that occur normally at the motor and pump case drains and associated circuits Refer to the following procedures to change the charge oil filter Removing Charge Oil F...

Page 408: ... engine and remove the key 2 Clean around head of the filter A 3 Place a container beneath the filter to collect any oil that may leak out 4 Unscrew filter A with a filter wrench 5 Dispose of used oil and filter in accordance with local legislation MAINTENANCE AND SERVICING ...

Page 409: ...er drive systems and should be changed after the first 50 hours of operation and then at 500 hour intervals The return oil filter is a part of the hydraulics package required to run a draper or auger header and is NOT present in a windrower unless this package is installed To change the return oil filter refer to the following procedures Removing Return Oil Filter page 389 Installing Return Oil Fi...

Page 410: ...neath filter A to collect any oil that may leak out 6 Unscrew filter A with a filter wrench 7 Dispose of used oil and filter in accordance with local legislation 1007179 A B C D Figure 5 188 Return Oil Filter NOTE Filter head removed to show component clarity 8 Remove gasket C from groove B in filter head A Filter D shown for context MAINTENANCE AND SERVICING ...

Page 411: ...he filter gasket C 3 Install new gasket C into the groove B in the filter head A 4 Screw the new filter D onto the filter head until the gasket contacts the filter 1006247 A Figure 5 190 Return Oil Filter 5 Tighten filter A an additional 3 4 turn by hand IMPORTANT Do NOT use a filter wrench to install oil filter Overtightening can damage gasket and filter 6 Close maintenance platform Refer to 5 3 ...

Page 412: ...hine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason 1 Stop engine and remove key 2 Open the hood Refer to 5 2 3 Opening Hood Highest Position page 286 1000437 A Figure 5 191 Hydraulic System 3 Locate lift filter A below the hydraulic oil reservoir 4 Place a container underneath the filter to catch any oil that may leak NOTE If replacin...

Page 413: ...hin film of clean oil to filter gasket C 3 Install new gasket into groove B in filter head A 4 Screw new filter D onto the filter head until the gasket contacts the filter 1000437 A Figure 5 194 Lift Filter Installed on Hydraulic Reservoir 5 Tighten filter A an additional 3 4 turn by hand IMPORTANT Do NOT use a filter wrench to install oil filter Overtightening can damage gasket and filter MAINTEN...

Page 414: ...er tips and connectors clean Dust dirt water and foreign material are the major causes of hydraulic system damage DO NOT attempt to service hydraulic system in the field Precision fits require WHITE ROOM CARE during overhaul Relief Valve and Overload Settings Pressure relief valves are preset Relief points windrower differential relief setting vary depending on the attached header model size and o...

Page 415: ...i Suggested Overload Warning Setting kPa psi R80 and R85 Disc Pressure 37 921 5500 37 232 5400 D60 D65 and A40D Reel Draper Pressure 19 995 2900 19 995 2900 Knife Conditioner Pressure 27 579 4000 27 579 4000 Flow Control Blocks 1005510 Figure 5 197 Draper Header Hydraulics Two hydraulic valve blocks with multiple cartridges are used for the various windrower functions and are controlled by the win...

Page 416: ...knob B on needle valve and refer to the following options Turn outer knob A clockwise to decrease the drop rate Turn outer knob A counterclockwise to increase the drop rate 4 Tighten inner knob B 5 Check the drop rate and readjust as required 6 Close the platform Refer to 5 3 2 Closing Platforms Standard Position page 289 Adjusting Reel Drop Rate The reel should lower gradually when the lower reel...

Page 417: ... gearbox from the engine Each pump requires charge flow in order to Make up for internal leakage Maintain positive pressure in the main circuit Provide flow for cooling Replace any leakage losses from external valving or auxiliary systems The charge pressure is monitored The cab display module CDM sounds a tone and displays a flashing warning if charge pressure drops below 1725 kPa 250 psi Refer t...

Page 418: ... fully Refer to 5 2 3 Opening Hood Highest Position page 286 2 Attach a 0 4000 kPa 600 psi pressure gauge to a hose that is long enough to allow pressure gauge to be read from the operator s seat 1006247 A Figure 5 201 Charge Pump Test Port 3 Locate test port A on the charge filter head Clean the test port fitting and then attach hose to the fitting 4 Start engine and leave at idle Pressure should...

Page 419: ... the correct position on the rim or if overinflated 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 direction endangering anyone in the area DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the oper...

Page 420: ...ts and studs are dry with no lubricant or Never Seez compound Torque each to 510 Nm 375 lbf ft using the tightening sequence shown at right 3 Repeat tightening sequence two additional times at specified torque 4 Repeat torque procedure every hour until two consecutive checks produce no movement of the nuts Lubricating Wheel Drive Refer to these procedures to lubricate the wheel drive Checking Whee...

Page 421: ...or s seat for any reason CAUTION Park on a flat level surface with the header on the ground and the ground speed lever in N DETENT position with the steering wheel locked IMPORTANT Do NOT mix lubricants of different brands or characteristics 1007544 A B C Figure 5 205 Drive Wheel Hub 1 Rotate the wheel drive so plugs A and B are horizontal with the center of the hub C 2 Stop windrower and remove k...

Page 422: ...Drive Wheel Hub 1 Park windrower on level ground and position windrower so that one of the drain plugs A or B is at the lowest point on the drive wheel hub 2 Shut down the windrower and remove key from ignition 3 Place a container that can contain at least 2 liters 2 quarts under the lower drain plug B 4 Remove both plugs A and B and drain lubricant into container CAUTION Dispose of oil in a manne...

Page 423: ...nexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s seat for any reason CAUTION Header MUST be removed and NO weight box installed Use a hydraulic jack with minimum lifting capacity of 2268 kg 5000 lb to provide adequate support for the machine 1 Remove the header 2 Park windrower on level ground and block all wheels 1020876 A ...

Page 424: ...a small metal plate on top of the jack stand 5 Lower the windrower onto the jack stand Removing Drive Wheel CAUTION Use a suitable lifting device capable of supporting a minimum of 907 kg 2000 lb to lift the wheel assembly away from the windrower 1008818 A B Figure 5 210 Drive Wheel 1 Raise windrower drive wheel A off the ground Refer to Raising Drive Wheel page 403 2 Remove wheel nuts B 3 Use a s...

Page 425: ...on sidewall points in cab forward rotation 2 Lift wheel onto hub using a suitable lifting device 3 Remove the lifting device 1021082 A Figure 5 212 Drive Wheel Nuts 4 Line up the holes in the rim with the studs on the wheel drive hub and install wheel nuts A IMPORTANT To avoid damage to wheel rims and studs tighten nuts by hand Do NOT use an impact gun do NOT use lubricant or Never Seez compound a...

Page 426: ...htly off the jack stand 2 Remove the jack stand from under cylinder lift mount B and lower the drive wheel to the ground 3 Remove the jack 5 11 2 Caster Wheels Inflating Caster Tire 1000019 Figure 5 214 Safely Filling a Tire with Air DANGER Do NOT exceed maximum inflation pressure as per label on tire Use a safety cage if available Do NOT stand over tire Use a clip on chuck and extension hose NEVE...

Page 427: ...ssure and adjust pressure as needed Underinflation of tires can cause sidewall cracks NOTE If caster wheels shimmy a possible cause is overinflation Table 5 5 Caster Tire Options Formed Caster Forked Caster 7 5 16SL single rib 10 16 front steer tire 16 5L 16 1 rib implement flotation 10 16 front steer tire 69 kPa 10 psi 69 kPa 10 psi Tightening Caster Wheel Nuts At first use or when a wheel is rem...

Page 428: ...el page 410 Installing Forked Caster Wheel page 411 Removing Formed Caster Wheel page 412 Installing Formed Caster Wheel page 412 Raising Caster Wheel Formed and Forked This procedure is the same for forked and formed caster wheels DANGER To avoid bodily injury or death from unexpected startup of the machine always stop the engine and remove the key from the ignition before leaving the operator s ...

Page 429: ... B Figure 5 218 Caster Wheels and Walking Beam Engine Forward View 3 Raise the end of walking beam A until the caster wheel assembly B is slightly off the ground Use a suitable lifting device capable of lifting 2268 kg 5000 lb minimum 4 Place a jack stand beneath the walking beam and lower the beam until resting on the stand MAINTENANCE AND SERVICING ...

Page 430: ...y using a suitable lifting device capable of lifting minimum 2268 kg 5000 lb 2 Remove the jack stand and lower the end of the walking beam until the caster wheel assembly B is on the ground Removing Forked Caster Wheel CAUTION Wheel assemblies are heavy Support wheel assembly before removing axle bolts 1 Raise caster wheel Refer to Raising Caster Wheel Formed and Forked page 408 1006260 A B C D E ...

Page 431: ...ked Caster Wheel 1 Position wheel assembly C on axle assembly B and install wheel nuts A 2 Torque wheel nuts A Refer to Tightening Caster Wheel Nuts page 407 1006260 A B C D E Figure 5 223 Forked Caster Wheel 3 Position wheel assembly D in forked caster E 4 Position cover plates C and install eight bolts A four on each side of caster to secure axle B to caster E Torque bolts to 97 107 Nm 75 79 lbf...

Page 432: ...lts A that secure wheel B to the hub 3 Remove wheel B Installing Formed Caster Wheel CAUTION Wheel assemblies are heavy Support wheel assembly before removing axle bolts 1000548 A B 1 2 3 4 5 6 Figure 5 225 Formed Caster Wheel 1 Position wheel assembly B on hub and install six wheel bolts A 2 Refer to the tightening sequence at right and torque bolts A to 163 Nm 120 lbf ft 3 Lower caster wheel Ref...

Page 433: ...e stability of the machine varies with different attachments windrower options terrain and the 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 Table 5 6 Fluid Capacity and Ballast We...

Page 434: ... x 16 1 R Series All 0 7 5 x 16 10 x 16 16 5 x 16 1 D Series and D1 SP Series 7 6 m 25 ft and smaller 0 7 5 x 16 10 x 16 16 5 x 16 1 9 1 m 30 ft single or double reel without conditioner 10 6 m 35 ft single reel 0 0 38 10 91 200 7 5 x 16 10 x 16 16 5 x 16 1 9 1 m 30 ft double reel steel fingers and conditioner 10 6 m 35 ft double reel 5 or 6 bat 69 18 170 380 115 30 288 630 Level ground 10 x 16 Le...

Page 435: ...ne more often if operated under adverse conditions severe dust extra heavy loads etc CAUTION Carefully follow safety messages given in 1 Safety page 1 5 12 1 Maintenance Schedule Record Windrower Serial Number ___________________ Combine this record with the record in the header operator s manual Make copies of this page to continue the record Action ü ü Check S S Lubricate Change Clean Hour meter...

Page 436: ...lant Level page 333 ü Fuel tank35 Refer to Filling the Fuel Tank page 167 ü Fuel filter water trap35 Refer to Removing Water from Fuel System page 329 ü Hydraulic hoses and lines35 Refer to Hoses and Lines page 394 Hydraulic oil cooler35 Refer to 5 10 2 Hydraulic Oil Cooler page 386 ü Hydraulic oil level35 Refer to 5 10 1 Checking and Filling Hydraulic Oil page 385 Radiator35 Refer to Maintaining ...

Page 437: ...0 hours33 Cab fresh air intake filter Refer to Inspecting and Cleaning Fresh Air Filter Element page 304 S Caster pivots Refer to 5 4 2 Lubrication Points page 294 S Forked caster spindle bearings Refer to 5 4 2 Lubrication Points page 294 ü Gearbox oil level Refer to Checking Lubricant Level and Adding Lubricant page 343 S Top lift link pivots Refer to 5 4 2 Lubrication Points page 294 S Walking ...

Page 438: ...e Oil page 315 Engine air cleaner primary filter element Refer to Removing Primary Air Filter page 318 and Installing Primary Air Filter page 320 S Formed caster wheel hub bearings Refer to 5 4 2 Lubrication Points page 294 ü Drive wheel lubricant Refer to Checking Wheel Drive Lubricant Level page 400 Every 500 hours or once a year41 42 Fuel filters Refer to Maintaining Fuel Filters page 324 Gearb...

Page 439: ... 1000 hours41 p Drive wheel lubricant Refer to Changing Wheel Drive Lubricant page 402 ü Engine valve tappet clearance 1500 hours or every two years41 p Hydraulic oil and lift filter 5000 hours or every two years41 ü Engine valve tappet clearance MAINTENANCE AND SERVICING ...

Page 440: ......

Page 441: ...start Old fuel in tank Drain tank Refill with fresh fuel 5 8 5 Fuel System page 323 Engine hard to start or will not start Water dirt or air in fuel system Drain flush fill and prime system 5 8 5 Fuel System page 323 Engine hard to start or will not start Improper type of fuel Use proper fuel for operating conditions 8 2 2 Fuel Specifications page 460 Engine hard to start or will not start Crankca...

Page 442: ...l page 316 Engine knocks Low or high coolant temperature Contact Dealer Contact Dealer Engine knocks Improper fuel Use proper fuel 8 2 2 Fuel Specifications page 460 Low oil pressure Low oil level Add oil Adding Engine Oil page 316 Low oil pressure Improper type of oil Drain and fill crankcase with proper oil 8 2 3 Lubricants Fluids and System Capacities page 461 Low oil pressure Worn components C...

Page 443: ...k of power Clogged fuel filter Replace primary fuel filter and if necessary replace secondary fuel filter Maintaining Fuel Filters page 324 Lack of power High back pressure Clean out or replace muffler 5 8 8 Exhaust System page 345 Lack of power Improper type of fuel Use proper fuel 8 2 2 Fuel Specifications page 460 Lack of power High or low engine temperature Remove and check thermostat Contact ...

Page 444: ...or screen rotors not turning Check connections to rotor electric motor Maintaining Engine Cooling Box page 337 Engine overheats Dirty radiator core Clean radiator 5 8 6 Engine Cooling System page 331 Engine overheats Cooling system dirty Flush cooling system 5 8 6 Engine Cooling System page 331 Engine overheats Defective thermostat Remove and check thermostat Contact Dealer Engine overheats Defect...

Page 445: ...eering wheel to CENTER position Driving Reverse in Cab Forward Mode page 173 Starter cranks slowly or will not operate Controls not in NEUTRAL Disengage header Engaging and Disengaging the Header page 204 Starter cranks slowly or will not operate Relay not functioning Check relay and wire connections 5 9 Electrical System page 349 Starter cranks slowly or will not operate Main fuse defective blown...

Page 446: ...e Air filters require frequent cleaning Aspirator plugged Clean out aspirator 5 8 4 Air Intake System page 317 Air filters require frequent cleaning Pre cleaner rotor not turning freely Repair replace Maintaining Engine Cooling Box page 337 TROUBLESHOOTING ...

Page 447: ...dim High resistance in circuit or poor ground on lights Check the wiring circuit for a break in a wire or a poor ground Lights do not light Burned out or defective light bulb Replace light bulb Replacing Headlight Bulb page 358 Lights do not light Burned out or defective light bulb Replace light bulb Replacing Bulb in Cab Forward Flood Light page 363 Lights do not light Burned out or defective lig...

Page 448: ...cab Broken or disconnected wire Contact Dealer Contact Dealer No current to cab Circuit breaker tripped Breaker automatically resets No current to cab Battery disconnect switch is OFF Turn battery disconnect switch ON Battery Main Disconnect Switch page 350 TROUBLESHOOTING ...

Page 449: ... Reel and or conveyor not turning Flow controls adjusted too low Toggle speed controls on CDM to increase flow D Series and D1 SP Series 4 6 5 Draper Speed page 268 and 4 6 4 Reel Speed page 264 A Series 4 7 1 Auger Speed page 276 Reel and or conveyor not turning Appropriate solenoid on flow control block not being energized Contact Dealer Contact Dealer Reel and or conveyor turns but lacks power ...

Page 450: ...engaging Appropriate solenoid not being energized by activating switch Contact Dealer Contact Dealer Header drive lacks power Relief valve setting too low Contact Dealer Contact Dealer Header drive lacks power Hydraulic couplers unions not properly connected Ensure hoses are connected correctly and hose couplers unions are tight Refer to the header operator s manual Header drive lacks power Header...

Page 451: ... grade or pulling out of a ditch Internal pump or motor damage Contact Dealer Contact Dealer Wheels lack pulling ability on a grade or pulling out of a ditch Insufficient torque at drive wheels Move ground speed range control to field position and reduce ground speed Driving Forward in Engine Forward Mode page 174 Wheels lack pulling ability on a grade or pulling out of a ditch Loose or worn contr...

Page 452: ...erse Pump arms have broken shaft or loose hardware Repair or tighten Contact Dealer Both wheels will not pull in forward or reverse Brakes binding or not releasing fully Check pressure on brake release valve min 1379 kPa 200 psi Contact Dealer Both wheels will not pull in forward or reverse Low oil level Check oil reservoir level 5 10 1 Checking and Filling Hydraulic Oil page 385 Both wheels will ...

Page 453: ...ents page 298 One wheel does not pull in forward or reverse High pressure relief valve stuck open damaged seat Check valve and clean or replace Contact Dealer One wheel does not pull in forward or reverse Brakes binding or not releasing fully Check pressure on brake release valve min 1379 kPa 200 psi Contact Dealer One wheel does not pull in forward or reverse Damaged hydraulic lines preventing pr...

Page 454: ...tem Air in system Check lines for leakage Excessive noise from drive system Hydraulic line clamps loose Tighten clamps Hydraulic oil filter leaks at seal Not properly tightened Tighten filter element Servicing the Lift Filter page 392 Hydraulic oil filter leaks at seal Damaged seal or threads Replace filter or filter head Servicing the Lift Filter page 392 TROUBLESHOOTING ...

Page 455: ...oves on flat ground with controls in neutral GSL servo misadjusted Contact Dealer Contact Dealer Machine moves on flat ground with controls in neutral GSL cable misadjusted Contact Dealer Contact Dealer Steering wheel will not lock with GSL in n detent Transmission interlock misadjusted Contact Dealer Contact Dealer Steering wheel will not unlock Transmission interlock cylinder not working Contact...

Page 456: ...wer fan operating but no air coming into cab Evaporator clogged Clean evaporator Cleaning Air Conditioning A C Evaporator Core page 308 Blower fan operating but no air coming into cab Air flow passage blocked Remove blockage Heater not heating Heater shut off valve at engine closed Open valve 3 10 1 Heater Shut Off page 58 Heater not heating Defective thermostat in engine water outlet manifold Rep...

Page 457: ...pressor Belt page 347 Air conditioning not cooling Dirty filters Clean fresh air and recirculation filters Cleaning Engine Air Filter Primary Element page 321 and Cleaning Return Air Cleaner Filter page 306 Air conditioning not cooling Broken or disconnected electrical wire Check all terminals for loose connections check wiring for hidden breaks Air conditioning not cooling Broken or disconnected ...

Page 458: ...s clogged with dirt or insects Clean condenser 5 7 3 Air Conditioning Condenser page 307 Air conditioning not producing sufficient cooling 43 Evaporator fins clogged Clean evaporator fins under cab floor Cleaning Air Conditioning A C Evaporator Core page 308 Air conditioning not producing sufficient cooling 43 Refrigerant low Contact Dealer Contact Dealer Air conditioning not producing sufficient ...

Page 459: ... slipping Contact Dealer Contact Dealer Air conditioning system too noisy Defective winding or improper connection in compressor clutch coil or relay Contact Dealer Contact Dealer Air conditioning system too noisy Excessive charge in system Contact Dealer Contact Dealer Air conditioning system too noisy Low charge in system Contact Dealer Contact Dealer Air conditioning system too noisy Excessive ...

Page 460: ...ing system too noisy Blower fan noisy due to excessive wear Remove blower motor for service or replacement as necessary Contact Dealer Windows fog up High humidity Run A C to dehumidify air and heater to control temperature 3 10 3 Climate Controls page 59 TROUBLESHOOTING ...

Page 461: ...on not adjusted for operator s weight Adjust seat suspension 3 3 Operator s Seat Adjustments page 42 Rough ride High air pressure in tires Deflate to proper pressure Inflating Drive Wheel Tire page 399 and Inflating Caster Tire page 406 Rough ride Cab suspension too stiff Adjust suspension Contact Dealer TROUBLESHOOTING ...

Page 462: ......

Page 463: ...has an automated steering autosteer engage switch and the Trimble display mounting kit MD 183348 is supplied in the cab The Trimble AutoPilot system requires the MacDon automated steering hydraulic interface kit MD B5589 Installation instruction MD 169539 is included in the bundle Other GPS providers may supply parts in their vehicle specific installation packages or make installation kits availab...

Page 464: ...cons are standard equipment for exported windrowers and are optional for North America Fits 2009 and newer machines MD B5582 Instruction MD 169538 is included in the bundle 7 1 7 Windshield Shades This kit includes retractable sun shades for front and rear windows Attachment hardware is also included in the kit MD B4866 Instruction MD 169218 is included in the bundle OPTIONS AND ATTACHMENTS ...

Page 465: ...The Engine Fan Air Baffle kit prevents the windrow from being disturbed by engine cooling fan air blast MD B5440 Instruction MD 169443 is included in the bundle 7 2 3 Reversible Fan Allows the cooling fan to reverse direction on a timed interval to clear crop debris accumulated on the engine air intake screen and or coolers radiator charge air cooler oil cooler and air conditioner condenser MD B56...

Page 466: ...3 3 Completion Kit for Auger and Draper Header Drives Used to allow operation of a draper or auger header Requires installation of Draper Header Reel Drive Kit 7 3 5 Completion Kit for Draper Header Reel Drive page 446 or Auger Header Drive Kit 7 3 4 Completion Kit for Auger Header Drive and Conditioner Reverser page 446 MD B5491 Instruction MD 169478 is included in the bundle 7 3 4 Completion Kit...

Page 467: ... B4664 Instruction MD 169033 is included in the bundle 7 3 9 Quick Coupler Kit Allows for quick removal of header hydraulics from windrower MD B5497 Instruction MD 169481 is included in the bundle 7 3 10 Self Aligning Center Link This kit allows the center link cylinder to be hydraulically positioned and connected to the header without leaving the operator s station MD B4802 Instruction MD 169004 ...

Page 468: ...80 Weight box harness only Includes hitch pin and wiring for use with slow speed header transport option Instruction MD 169278 is included in the bundle 7 4 2 Weight Box A weight box installed onto the windrower header lift system is required to transport a header behind the windrower MD B5238 Weight box without harness A towing harness is required to use the weight box Refer to 7 4 1 Towing Harne...

Page 469: ...e applied to regular nuts by f 0 65 Self tapping screws Standard torque is to be used NOT to be used on critical or structurally important joints SAE Bolt Torque Specifications Torque values shown in following tables are valid for non greased or non oiled threads and heads therefore do NOT grease or oil bolts or cap screws unless otherwise specified in this manual A 1004958 B C D Figure 8 1 Bolt G...

Page 470: ...12 105 116 77 86 5 8 11 144 160 107 118 3 4 10 259 286 192 212 7 8 9 413 456 306 338 1 8 619 684 459 507 A 1004958 B C D Figure 8 3 Bolt Grades A Nominal Size B SAE 8 C SAE 5 D SAE 2 Table 8 3 SAE Grade 8 Bolt and Grade G Distorted Thread Nut Nominal Size A Torque Nm Torque lbf ft lbf in Min Max Min Max 1 4 20 16 8 18 6 150 165 5 16 18 24 26 18 19 3 8 16 42 46 31 34 7 16 14 67 74 50 55 1 2 13 102 ...

Page 471: ...7 5 8 11 299 330 221 345 3 4 10 531 587 393 435 7 8 9 855 945 633 700 1 8 1165 1288 863 954 Metric Bolt Specifications 1001370 1001370 A Figure 8 5 Bolt Grades Table 8 5 Metric Class 8 8 Bolts and Class 9 Free Spinning Nut Nominal Size A Torque Nm Torque lbf ft lbf in Min Max Min Max 3 0 5 1 4 1 6 13 14 3 5 0 6 2 2 2 5 20 22 4 0 7 3 3 3 7 29 32 5 0 8 6 7 7 4 59 66 6 1 0 11 4 12 6 101 112 8 1 25 28...

Page 472: ...5 65 72 48 53 14 2 0 104 115 77 85 16 2 0 161 178 119 132 20 2 5 314 347 233 257 24 3 0 543 600 402 444 1001370 1001370 A Figure 8 7 Bolt Grades Table 8 7 Metric Class 10 9 Bolts and Class 10 Free Spinning Nut Nominal Size A Torque Nm Torque lbf ft lbf in Min Max Min Max 3 0 5 1 8 2 18 19 3 5 0 6 2 8 3 1 27 30 4 0 7 4 2 4 6 41 45 5 0 8 8 4 9 3 82 91 6 1 0 14 3 15 8 140 154 8 1 25 38 42 28 31 10 1 ...

Page 473: ... 8 95 105 8 1 25 26 29 19 21 10 1 5 51 57 38 42 12 1 75 90 99 66 73 14 2 0 143 158 106 117 16 2 0 222 246 165 182 20 2 5 434 480 322 356 24 3 0 750 829 556 614 Metric Bolt Specifications Bolting into Cast Aluminum 1001370 1001370 A Figure 8 9 Bolt Grades Table 8 9 Metric Bolt Bolting into Cast Aluminum Nominal Size A Bolt Torque 8 8 Cast Aluminum 10 9 Cast Aluminum Nm lbf ft Nm lbf ft M3 1 M4 4 2 ...

Page 474: ...n nut E with other wrench to torque shown 5 Assess final condition of connection Table 8 10 Flare Type Hydraulic Tube Fittings SAE Dash Size Thread Size in Torque Value44 Flats from Finger Tight FFFT Nm lbf ft Tube Swivel Nut or Hose 2 5 16 24 4 5 3 4 3 3 8 24 7 8 5 6 4 7 16 20 18 19 13 14 2 1 2 2 5 1 2 20 19 21 14 15 2 2 6 9 16 18 30 33 22 24 2 1 1 2 8 3 4 16 57 63 42 46 2 1 1 2 10 7 8 14 81 89 6...

Page 475: ...ar as possible 3 Check that O ring A is NOTon threads and adjust if necessary 4 Apply hydraulic system oil to O ring A 1003432 D A E B C Figure 8 12 Hydraulic Fitting 5 Install fitting B into port until back up washer D and O ring A contact part face E 6 Position angle fittings by unscrewing no more than one turn 7 Turn lock nut C down to washer D and tighten to torque shown Use two wrenches one o...

Page 476: ... 13 106 115 4 7 16 20 19 21 14 15 5 1 2 20 21 33 15 24 6 9 16 18 26 29 19 21 8 3 4 16 46 50 34 37 10 7 8 14 75 82 55 60 12 1 1 16 12 120 132 88 97 14 1 3 8 12 153 168 113 124 16 1 5 16 12 176 193 130 142 20 1 5 8 12 221 243 163 179 24 1 7 8 12 270 298 199 220 32 2 1 2 12 332 365 245 269 REFERENCE 45 Torque values shown are based on lubricated connections as in reassembly ...

Page 477: ...ble 8 12 page 457 6 Check final condition of fitting Table 8 12 O Ring Boss ORB Hydraulic Fittings Non Adjustable SAE Dash Size Thread Size in Torque Value46 Nm lbf ft lbf in 2 5 16 24 6 7 53 62 3 3 8 24 12 13 106 115 4 7 16 20 19 21 14 15 5 1 2 20 21 33 15 24 6 9 16 18 26 29 19 21 8 3 4 16 46 50 34 37 10 7 8 14 75 82 55 60 12 1 1 16 12 120 132 88 97 14 1 3 8 12 153 168 113 124 16 1 5 16 12 176 19...

Page 478: ...ut 5 Torque fittings according to values in Table 8 13 page 458 NOTE If applicable hold hex on fitting body E to prevent rotation of fitting body and hose when tightening fitting nut D 6 Use three wrenches when assembling unions or joining two hoses together 7 Check final condition of fitting Table 8 13 O Ring Face Seal ORFS Hydraulic Fittings SAE Dash Size Thread Size in Tube O D in Torque Value4...

Page 479: ...r typically 45º or 90º is aligned to receive incoming tube or hose assembly Always finish alignment of fitting in tightening direction Never back off loosen pipe threaded connectors to achieve alignment 5 Clean all residue and any excess thread conditioner with appropriate cleaner 6 Assess final condition of fitting Pay special attention to possibility of cracks to port opening 7 Mark final positi...

Page 480: ...uel gelling or wax plugging of the fuel filters Table 8 15 Fuel Specification Fuel Specification Sulphur by weight Water and Sediment by volume Cetane No Lubricity Grade no 2 ASTM D975 0 5 maximum 0 05 maximum 40 C 104 F minimum 520 Microns Grade no 1 and 2 mix50 n a 1 maximum 0 5 maximum preferred 0 1 maximum 45 55 C 113 131 F cold weather high altitude 460 Microns In extreme situations when avai...

Page 481: ...2360 preferred 2 1 liters 2 2 US quarts Gear lubricant Wheel drive52 SAE 75W 90 API service class GL 5 Fully synthetic gear lubricant SAE J2360 preferred 1 4 liters 1 5 US quarts Antifreeze Engine cooling system ASTM D 6210 and Fleetguard ES Compleat See notes at the end of this table 31 liters 8 2 US gallons 53 Engine oil Engine oil pan SAE 15W 40 compliant with SAE specs for API class SJ and CH ...

Page 482: ...ncentrate in a 40 60 mixture of concentrate with quality water Water quality is important to the performance of the cooling system Distilled deionized or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate IMPORTANT Do NOT use cooling system sealing additives or antifreeze that contains sealing additives 8 2 4 Filter Part Numbers ...

Page 483: ...essure megapascal MPa x 145 038 pounds per square inch psi Pressure bar Non SI bar x 14 5038 pounds per square inch psi Torque Newton meter Nm x 0 7376 pound feet or foot pounds lbf ft Torque Newton meter Nm x 8 8507 pound inches or inch pounds lbf in Temperature degrees Celsius ºC ºC x 1 8 32 degrees Fahrenheit ºF Velocity meters per minute m min x 3 2808 feet per minute ft min Velocity meters pe...

Page 484: ...uit voltage below normal or shorted to low source 2114 52 0 Red Coolant temperature Coolant temperature 2 data valid but above normal operational range most severe level 2111 52 3 Amber Coolant temperature Coolant temperature 2 sensor circuit voltage above normal or shorted to high source 2112 52 4 Amber Coolant temperature Coolant temperature 2 sensor circuit voltage below normal or shorted to lo...

Page 485: ...ic intermittent or incorrect 546 94 3 Amber Fuel delivery pressure Fuel delivery pressure sensor circuit voltage above normal or shorted to high source 547 94 4 Amber Fuel delivery pressure Fuel delivery pressure sensor circuit voltage below normal or shorted to low source 2261 94 15 Amber Blinking Fuel delivery pressure Fuel pump delivery pressure data valid but above normal operational range lea...

Page 486: ...range moderately severe level 2973 102 2 Amber Boost pressure Intake manifold pressure sensor circuit data erratic intermittent or incorrect 122 102 3 Amber Boost pressure Intake manifold pressure sensor circuit voltage above normal or shorted to high source 123 102 4 Amber Boost pressure Intake manifold pressure sensor circuit voltage below normal or shorted to low source 124 102 16 Amber Boost p...

Page 487: ... or shorted to high source 232 109 4 Amber Coolant pressure Coolant pressure sensor circuit voltage below normal or shorted to low source 233 109 18 Amber Coolant pressure Coolant pressure data valid but below normal operational range moderately severe level 151 110 0 Red Engine coolant temperature Coolant temperature high data valid but above normal operational range most severe level 334 110 2 A...

Page 488: ...sure data valid but above normal operational range most severe level 224 9 157 1 Amber Injector metering rail 1 pressure Injector metering rail 1 pressure data valid but below normal operational range most severe level 554 157 2 Amber Injector metering rail 1 pressure Fuel pressure sensor error data erratic intermittent or incorrect 451 157 3 Amber Injector metering rail 1 pressure Injector meteri...

Page 489: ...e sensor circuit voltage above normal or shorted to high source 256 171 4 Amber Ambient air temperature Ambient air temperature sensor circuit voltage below normal or shorted to low source 263 174 3 Amber Fuel temperature Engine fuel temperature sensor 1 circuit voltage above normal or shorted to high source 265 174 4 Amber Fuel temperature Engine fuel temperature sensor 1 circuit voltage below no...

Page 490: ...e normal or shorted to high source 2376 412 4 Amber Exhaust gas recirculation temperature Exhaust gas recirculation temperature sensor circuit voltage below normal or shorted to low source 293 441 3 Amber OEM temperature Auxiliary temperature sensor input 1 circuit voltage above normal or shorted to high source 294 441 4 Amber OEM temperature Auxiliary temperature sensor input 1 circuit voltage be...

Page 491: ...ontrol module critical internal failure bad intelligent device or component 343 629 12 Amber Controller 1 Engine control module warning internal hardware failure bad intelligent device or component 341 630 2 Amber Calibration memory Engine control module data lost data erratic intermittent or incorrect 342 630 13 Red Calibration memory Electronic calibration code incompatibility out of calibration...

Page 492: ...nder 03 Injector cylinder 3 mechanical system not responding properly or out of adjustment 332 654 5 Amber Injector cylinder 04 Injector solenoid cylinder 4 circuit current below normal or open circuit 1143 654 7 Amber Injector cylinder 04 Injector cylinder 4 mechanical system not responding properly or out of adjustment 323 655 5 Amber Injector cylinder 05 Injector solenoid cylinder 5 circuit cur...

Page 493: ...ta erratic intermittent or incorrect 731 723 7 Amber Engine speed sensor 2 Engine speed position 2 mechanical misalignment between camshaft and crankshaft sensors mechanical system not responding properly or out of adjustment 2555 729 3 Amber Inlet air heater driver 1 Intake air heater 1 circuit voltage above normal or shorted to high source 2556 729 4 Amber Inlet air heater driver 1 Intake air he...

Page 494: ...engine fuel Fuel priming pump control signal circuit voltage below normal or shorted to low source 2368 1112 3 Amber Engine brake output 3 Engine brake actuator driver 3 circuit voltage above normal or shorted to high source 2365 1112 4 Amber Engine brake output 3 Engine brake actuator driver output 3 circuit voltage below normal or shorted to low source 697 1136 3 Amber Sensor circuit voltage ECM...

Page 495: ...77 2 Amber Switch circuit Multiple unit synchronization switch circuit data erratic intermittent or incorrect 649 1378 31 Amber Blinking Engine oil change interval Change lubricating oil and filter condition exists 297 1388 3 Amber Auxiliary pressure Auxiliary pressure sensor input 2 circuit voltage above normal or shorted to high source 298 1388 4 Amber Auxiliary pressure Auxiliary pressure senso...

Page 496: ...c control module Electronic control module data lost condition exists 2115 2981 3 Amber Coolant pressure Coolant pressure 2 circuit voltage above normal or shorted to high source 2116 2981 4 Amber Coolant pressure Coolant pressure 2 circuit voltage below normal or shorted to low source 2117 2981 18 Amber Coolant pressure Coolant pressure 2 data valid but below normal operational range moderately s...

Page 497: ...mber System diagnostic code 1 Sensor supply voltage 4 circuit voltage below normal or shorted to low source 193 520199 3 Amber Cruise control Cruise control resistive signal circuit voltage above normal or shorted to high source 194 520199 4 Amber Cruise control Cruise control resistive signal circuit voltage below normal or shorted to low source REFERENCE 68 The descriptions of Cummins J1939 SPN ...

Page 498: ...r was engaged E6 TEMP GAUGE SHORT Wiring connection problem E7 SPEED STICK SHORT Wiring connection problem E8 HEADER ENABLE SHORT Wiring connection problem E9 WCM ENABLE SHORT Wiring connection problem E10 CDM INTERNAL ERROR A generic internal CDM error summarizing a number of internal problems E11 CDM POWER UP Indicates that the voltage on CDM connector P38 pin 26 is too low or the ground connect...

Page 499: ...9 LOW RANGE P61 Low range solenoid P61 fault detected E40 E140 HIGH RANGE P60 High range solenoid P60 fault detected E41 E141 REEL AFT Reel aft solenoid P55 P59 fault detected E42 E142 REEL FORE Reel fore solenoid P55 P59 fault detected E43 E143 REEL UP DOWN P58 Reel up down solenoid P58 P52 P62 fault detected E44 E144 FLOAT RHS P64 RHS float solenoid P64 fault detected E45 E145 FLOAT LHS P63 LHS ...

Page 500: ...that the communication between the two micros inside the WCM module is not working properly could be resolved by reprogramming the WCM E102 CAN ERROR E102 is detected by the WCM module so the issue is related to the CANBUS signals on the WCM end it may happen when the CDM sees the engine ECU but not the WCM not hooked up or experiencing power or CANBUS problems may also happen if the CDM connector...

Page 501: ...ing systems 443 B batteries adding electrolyte 353 battery safety 8 boosting 352 charging 350 connecting 357 installing 356 main battery disconnect switch 350 maintaining 349 removing 354 belts 345 A C compressor belt replacing 347 tensioning 347 alternator fan belt tensioning 345 engine belts alternator fan belt replacing 345 bolts definition 27 C cab display module CDM CDM WCM fault codes 156 co...

Page 502: ...system configuring the windrower See CanWin service tool consoles 39 conversion chart 463 cutting height 208 D D Series header knife speed 271 D Series headers attaching 218 attaching header boots 217 attaching to M205 218 deck shift 272 deck shift control 272 setting float options 273 definition 27 draper index setting draper index 269 draper speed setting draper speed 268 setting draper to groun...

Page 503: ...CM definition 27 electrical system 169 battery 349 electrical systems 349 accessing circuit breakers and fuses 378 batteries adding electrolyte 353 battery main disconnect switch 350 boosting the batteries 352 charging the batteries 350 connecting 357 installing 356 maintaining the battery 349 removing 354 checking and replacing fuses 379 circuit breakers and fuses 378 fuse box decal 381 inspectin...

Page 504: ...ilters 324 installing primary fuel filter 326 installing secondary fuel filter 327 removing primary fuel filter 325 removing secondary fuel filter 326 HVAC filters fresh air filter inspecting cleaning filter element 304 installing 304 removing 303 return air cleaner filter cleaning 306 servicing 305 hydraulic filters changing oil filters 387 charge oil filter 387 installing 389 removing 387 lift f...

Page 505: ...drive 204 header drop rate 212 levelling the header 201 operating with a header A Series header 275 D Series header 263 D1 SP Series header 263 header float 196 R Series header 281 reversing the header 205 header sensors calibrating header sensors 125 header float sensor 129 header height sensor 125 header tilt sensor 127 switching installed sensors on or off 134 headers A Series headers attaching...

Page 506: ...filters charge oil filter 387 installing 389 removing 387 return oil filter 389 installing 391 removing 389 hydraulic hoses and lines 394 hydraulic oil cooler 386 hydraulic safety 6 lift filter 392 installing 393 removing 392 reel drop rate adjusting 396 relief valves 394 traction drive hydraulics 397 charge pump pressure 398 transmission oil pressure 397 warnings 384 I ISC definition 27 J JIC def...

Page 507: ...s 462 fuel system 323 fuel fluids and lubricants 460 HVAC system 303 fresh air filter cleaning filter element 304 installing 304 hydraulic oil tank checking and filling hydraulic oil 385 lighting aligning headlights 360 lubricating the windrower 293 maintenance schedule 415 operator presence system 295 operator s station 295 checking engine interlock 296 preparing for servicing 283 priming procedu...

Page 508: ... engine and transmission 41 header drive 41 rear view mirror 57 safety systems 295 seat belts 47 295 steering adjustments 298 steering column 48 training seat 46 windrower controls 68 windshield wiper 56 options and attachments 443 AM FM radio 443 automated steering systems 443 booster spring kit internal 446 completion kit for auger and draper header drives 446 for auger header drive and conditio...

Page 509: ...mbols 1 safety sign decals 12 installing decals 12 interpreting decals 17 sign location 13 signal words 2 tire safety 7 welding precautions 9 screen cleaners adjusting clearance 341 screws definition 27 SDD definition 27 seat belts 47 maintaining seat belts 295 self propelled windrower definition 27 serial numbers location iv shutting down the engine 166 SK definition 27 SKD definition 27 soft joi...

Page 510: ...field mode 189 troubleshooting cab air 436 electrical 427 engine 421 header drive 430 header problems 139 hydraulics 429 operator s station 441 steering and ground speed control 435 traction drive 431 windrower problems 133 U UCA definition 27 ULSD definition 27 V ventilating See HVAC system W washers definition 27 WCM definition 27 weight boxes 448 attaching to windrower 185 welding 9 wheels and ...

Page 511: ...windshield wipers 56 INDEX ...

Page 512: ......

Page 513: ...e class GL 5 Fully synthetic gear lubricant SAE J2360 preferred 2 1 liters 2 2 US quarts Gear lubricant Wheel drive71 SAE 75W 90 API service class GL 5 Fully synthetic gear lubricant SAE J2360 preferred 1 4 liters 1 5 US quarts Antifreeze Engine cooling system ASTM D 6210 and Fleetguard ES Compleat refer to 8 2 3 Lubricants Fluids and System Capacities page 461 Engine oil Engine oil pan SAE 15W 40...

Page 514: ...stralia 3061 t 61 3 8301 1911 f 61 3 8301 1912 MacDon Brasil Agribusiness Ltda Rua Grã Nicco 113 sala 202 B 02 Mossunguê Curitiba Paraná CEP 81200 200 Brasil t 55 41 2101 1713 f 55 41 2101 1699 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Centre t 7 495 775 6971 f 7 495 967 7600 CUSTOMERS MacDon com DEALERS Portal MacDon com Trademarks...

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