MacDon M 2009 Series Assembly Instructions Manual
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MacDon M 2009 Series Assembly Instructions Manual

MacDon M 2009 Series Assembly Instructions Manual

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M Series Self-Propelled Windrower
UNLOADING AND ASSEMBLY
INSTRUCTIONS
for
CONTAINER SHIPMENTS
Published: July, 2012
Form 169242
Revision F

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Summary of Contents for MacDon M 2009 Series

  • Page 1 M Series Self-Propelled Windrower UNLOADING AND ASSEMBLY INSTRUCTIONS CONTAINER SHIPMENTS Published: July, 2012 Form 169242 Revision F...
  • Page 2 MACDON M SERIES SELF-PROPELLED WINDROWER Form 169242 Revision E...

  • Page 3: Introduction

    INTRODUCTION This instructional manual describes the unloading, set- u p and pre-delivery requirements for the MacDo n M Series Self-Propelled Windrowers that have been shipped in containers. Use the Table of Contents to guide you to specific areas. Retain this instruction for future reference. CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE, OR USE THE MACHINE.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS   INTRODUCTION ................................ 3   GENERAL SAFETY ..............................6   RECOMMENDED TORQUES ........................... 8     GENERAL ............................8     SAE BOLTS............................8     METRIC BOLTS ..........................8     FLARE TYPE HYDRAULIC FITTINGS ....................9  ...
  • Page 5 TABLE OF CONTENTS     STEP 21. START ENGINE............................. 53     STEP 22. CHECK TRACTION DRIVE ........................54     STEP 23. REMOVE WINDROWER FROM STAND ....................55     FACTORY STAND ..........................55     FIELD-CONSTRUCTED STAND ...................... 55  ...

  • Page 6: General Safety

    GENERAL SAFETY CAUTION following general farm safety precautions that should be part of your operating procedure for all types of machinery.  Provide a first-aid kit for use in case of  Protect yourself. emergencies.  When assembling, operating and servicing ...
  • Page 7  Do not modify the machine. Unauthorized modifications may impair the function and/or safety and affect machine life.  Stop engine, and remove key from ignition before leaving Operator's seat for any reason. A child or even a pet could engage an idling machine.

  • Page 8: Recommended Torques

    RECOMMENDED TORQUES C. METRIC BOLTS STD COARSE BOLT TORQUE* A. GENERAL BOLT 10.9 DIA. "A" The tables shown below give correct torque values for various bolts and capscrews. ft·lbf N·m ft·lbf N·m Tighten all bolts to the to rques specified in ...

  • Page 9: Flare Type Hydraulic Fittings

    E. O-RING BOSS (ORB) HYDRAULIC D. FLARE TYPE HYDRAULIC FITTINGS FITTINGS FITTING LOCKNUT FLARE WASHER O-RING GROOVE BODY FLARESEAT SEAT a. Check flare and flare seat for defects that might cause leakage. b. Align tube with fitting before tightening. c. Lubricate connection, and hand-tighten swivel nut a.

  • Page 10: O-Ring Face Seal (Orfs) Hydraulic Fittings

    F. O-RING FACE SEAL (ORFS) a. Check components to en sure that the sealin g HYDRAULIC FITTINGS surfaces and fitting threads are free of burrs, nicks, and scratches, or any foreign material. b. Apply lubricant (typically Petroleum Jelly) to O-ring and threads. If O -ring is not already installed, install O-ring.

  • Page 11: Conversion Chart

    CONVERSION CHART INCH-POUND UNITS SI UNITS (METRIC) QUANTITY FACTOR UNIT NAME ABBR. UNIT NAME ABBR. acres acres x 0.4047 = hectares Area US gallons per minute (gpm) x 3.7854 = liters per minute L/min Flow pounds force x 4.4482 = Newtons Force inch...

  • Page 12: Step 1. Unload Container

    UNLOADING AND ASSEMBLY STEP 1. UNLOAD CONTAINER CAUTION To avoid injury to bystanders from being struck by machinery, do not allow persons to stand in unloading area. a. Move trailer into positio n, and blo ck trailer wheels. b. Lower trailer storage stands. c.

  • Page 13: Step 2. Move To Assembly Area

    Using inadequate equipment may result in chain breakage, vehicle tipping or machine damage. LIFTING VEHICLE b. Attach lifting frame asse mbly (MacDon Part 20,000 lb Minimum Lifting #163871) to the four designated lift po ints on (9072 kg) Capacity windrower shipping frame.

  • Page 14: Forklift Method

    UNLOADING AND ASSEMBLY B. FORKLIFT METHOD CAUTION To avoid injury to bystanders from being struck by machinery, do not allow persons to stand in unloading area. CAUTION Equipment used for unloading must meet or c. Lower assembly onto 5 –6 inch (127 152 mm) –...

  • Page 15: Step 3. Remove Wheel And Step Assembly

    UNLOADING AND ASSEMBLY STEP 3. REMOVE WHEEL AND STEP ASSEMBLY e. Remove the four (two per side) carriage bolts at the rear of the wheel/step assembly. a. Remove shipping wire and bolt se curing hose support to shippin g frame, and rem ove hose support.
  • Page 16 UNLOADING AND ASSEMBLY g. Attach a chain to wheel/step assembly, and pull away from shipping assembly with lifting device. h. Lift center-link so that it clea rs wheel/step assembly frame. Re-install leg bolts, washers, and nuts to secure the lifting plate onto the mainframe. Form 169542 Revision F...

  • Page 17: Step 4. Remove Drive Wheels

    UNLOADING AND ASSEMBLY STEP 4. REMOVE DRIVE WHEELS IMPORTANT Remove the drive wheels as a pair from above the hood. d. Carefully lift wheels off frame. IMPORTANT Ensure that tire is g uided away fro m cab roof when lifting wheels to prevent damage to the cab.

  • Page 18: Step 5. Remove Platforms

    UNLOADING AND ASSEMBLY NOTE STEP 5. REMOVE PLATFORMS The M105 windrower is equipped with a. Remove the two support tubes on either side of only one platform. hood. d. Carefully lift platform off frame. e. Back away from windrower, and set assembly on a level surface.

  • Page 19: Step 6. Remove Hand Rails And Exhaust Stack

    UNLOADING AND ASSEMBLY Repeat for o ther hand rail on oppo site side. Retain hardware. STEP 6. REMOVE HAND RAILS g. Set parts aside for later installation. AND EXHAUST STACK a. Cut plastic cable ties, an d move hose bundle clear of platform.

  • Page 20: Step 7. Remove Leg Assemblies

    UNLOADING AND ASSEMBLY STEP 7. REMOVE LEG ASSEMBLIES a. Ensure that lift bar i s attached to leg assembly as shown, and that clevis pin is installed with head on near side. b. Attach chain to lifting bar on leg assembly, and d.

  • Page 21: Step 8. Remove Wheel And Platform Support

    UNLOADING AND ASSEMBLY STEP 8. REMOVE WHEEL AND STEP 9. ASSEMBLE PLATFORM SUPPORT WINDROWER SUPPORT STAND Special stands for assembling the windrower are available from the facto ry. If this sta nd is not available, an equivalent support system can be used.

  • Page 22: Step 10. Lift Windrower Onto Stand

    UNLOADING AND ASSEMBLY STEP 10. LIFT WINDROWER ONTO STAND CAUTION To avoid injury to bystanders from being struck by machinery, do not allow persons to stand in unloading area. CAUTION Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment may result in chain breakage, vehicle tipping or machine damage.

  • Page 23: Forklift Method

    UNLOADING AND ASSEMBLY B. FORKLIFT METHOD LIFTING VEHICLE 20,000 lb Minimum Lifting Capacity * (9072 kg) * At 48 inches (1220 mm) from back end of forks. a. Approach windrower from aft end, and slide forks fully into shipping support channels. b.

  • Page 24: Step 11. Install Legs

    UNLOADING AND ASSEMBLY STEP 11. INSTALL LEGS a. Remove front leg bolts an d pins, and set aside for re-installation. Remove carriage bolt, and remove lifting plate. d. Feed hydraulic hose bundle into frame, and through hole at center of frame. b.
  • Page 25 UNLOADING AND ASSEMBLY h. Slightly lift the header lift arms with lifting device, and remove lifting bars from leg s. Re-locate spring locking pins to front of lift arms. Form 169542 Revision F...

  • Page 26: Step 12. Install Front Wheels

    UNLOADING AND ASSEMBLY STEP 12. INSTALL FRONT 4. Release pressure so that locks suppor t weight of windrower. WHEELS a. If factory stand is being used, proceed as follows. Otherwise, proceed to step b: b. Remove shipping supports on drive wheel hubs, and remove wheel lug nuts.
  • Page 27 UNLOADING AND ASSEMBLY Install wheel nuts, a nd tighten to 220 ft·lbf (300 N·m) using the tigh tening sequence as shown above. NOTE To avoid damage to wheel disks, do not over-tighten wheel nuts. g. Repeat sequence three times. Form 169542 Revision F...

  • Page 28: Step 13. Install Caster Wheels

    UNLOADING AND ASSEMBLY STEP 13. INSTALL CASTER WHEELS a. Remove the two g uide plates from ends of d. Remove tie bar between the two caster wheels. walking beam. e. Remove the two braces from caster wheels and frame. Retain bolts for attaching caster to walki ng beam.
  • Page 29 UNLOADING AND ASSEMBLY k. Tighten bolts as follows: 1. Snug up the two bolts underneath beam. 2. Tighten the four back bolts to 330 ft·lbf (447 N·m). 3. Tighten bolts underneath beam to 330 ft·lbf (447 N·m). Repeat above steps g. to k. for LH caster. m.

  • Page 30: Step 14. Install Hydraulics

    UNLOADING AND ASSEMBLY Remove caps and connect these two ho ses STEP 14. INSTALL HYDRAULICS together. Position hoses in frame. g. Retrieve the four remaini ng capped off hoses coming out of frame. A. M205 a. Retrieve all capped off hoses from inside frame. h.
  • Page 31 UNLOADING AND ASSEMBLY o. Connect drive hoses to pump as follows: SHORT - NO TIE SHORT - YELLOW m. Remove clamp from ro und plastic hose block. 1. Remove caps, and attach hoses with short Case drain hose is pre-installed in block. elbows to re spective side of pump (ei ther yellow or no tie).
  • Page 32 UNLOADING AND ASSEMBLY Remove one cap on tee fitting, and quickly attach hose to minimize oil spillage. s. Remove second cap from tee, and quickly connect other hose. Tighten fittings. u. Push hoses into frame. v. Secure hoses with plastic ties as required. Form 169542 Revision F...
  • Page 33 UNLOADING AND ASSEMBLY b. Connect hoses as follows, using colored plastic B. M155 cable ties as a guide. a. The hydraulic hoses under the cab may require proper placement under the existing clip. If necessary, proceed as follows: 111327 GREEN 1.
  • Page 34 UNLOADING AND ASSEMBLY ORANGE BLUE YELLOW 7. Locate two hoses (red ties) inside frame. 13. Remove the caps from three fittings (blue, orange, and yellow ties) o n the valve b lock 8. Route RH hose behind bundle. from inboard side of frame. 9.
  • Page 35 UNLOADING AND ASSEMBLY c. Remove clamp from round plastic hose block. e. Connect drive hoses to pump as follows: SHORT - NO TIE SHORT - YELLOW 1. Remove caps, and attach hoses with short elbows to re spective side of pump (ei ther yellow or no tie).
  • Page 36 UNLOADING AND ASSEMBLY g. Remove caps from the hoses only. Disengage hook, and rotate to up position. h. Remove one cap on tee fitting, and quickly attach Position hose bundle over hose support, and hose to minimize oil spillage. locate under hook. Rotate hook, and re-engage Remove second cap from tee, a nd quickly in bracket.
  • Page 37 UNLOADING AND ASSEMBLY C. M105 a. Connect hoses as follows, using colored plastic cable ties as a guide. 111324 GREEN 7. Locate two hoses (red ties) inside frame. 8. Route RH hose behind bundle. 9. Remove caps, make connection, and tighten fitting.
  • Page 38 UNLOADING AND ASSEMBLY YELLOW 13. Remove the cap from fitting with yellow tie on 2. Remove caps, and attach hoses (red and the valve block from inboard side of frame. white ties) to matching fittings on b ottom of pump. Tighten fittings. 14.
  • Page 39 UNLOADING AND ASSEMBLY h. Bundle traction drive hoses, and secure with two plastic cable ties at 7-3/4 in ch (200 mm) intervals from frame opening. Bundle smaller hoses, and se cure with two 2. Disengage hook, and rotate to up po sition. plastic cable ties at 6 inch (150 mm ) intervals Position hose bundle over hose support, and from frame opening.

  • Page 40: Step 15. Install Platforms

    UNLOADING AND ASSEMBLY STEP 15. INSTALL PLATFORMS NOTE The following procedure is applicable to M155 and M205 machines with LH and RH platforms. The M105 has a LH platform only. LH installation is shown. RH installation is opposite. d. Position platform against windrower frame. a.
  • Page 41 UNLOADING AND ASSEMBLY Check that rubber bumper is contacting the g. Attach railings to platform with 1/2 inch x 0.75 frame, and that front of platform is contacting the locking bolts provided. Tighten bolts to 75 ft·lbf. guide. (102 N·m). Adjust platform horizontally with the 1/2 in.

  • Page 42: Step 16. Install Steps

    UNLOADING AND ASSEMBLY STEP 16. INSTALL STEPS The following procedure is applicable to M155 and M205 machines with LH and RH platforms. The M105 has a LH platform only. RH installation is shown. LH instal lation is opposite. a. Remove the two existing upper bolts. b.

  • Page 43: Step 17. Install Exhaust Stack

    UNLOADING AND ASSEMBLY NOTE STEP 17. INSTALL EXHAUST If shroud (E) interferes with the stack, STACK loosen the wing-nut (F) on the shroud and move the shroud so that stack can A. M205 be installed. a. Open engine compartment hood. b.
  • Page 44 UNLOADING AND ASSEMBLY NOTE B. M155, M105 If shroud (E) interferes with the stack, loosen the wing-nut (F) on the shroud, a. Open engine compartment hood. and move the shroud so that stack can b. Retrieve exhaust stack that wa s previously be installed.

  • Page 45: Step 18. Position Light And Mirror Assemblies

    UNLOADING AND ASSEMBLY STEP 18. POSITION LIGHT AND MIRROR ASSEMBLIES a. Remove nut and bolt (A) from shipping position. b. Swing mirror/light assembly (B) fo rward up to stop. c. Re-install bolt (A) and nut in other hole. d. Repeat for opposite mirror assembly. Form 169542 Revision F...

  • Page 46: Step 19. Install Batteries

    UNLOADING AND ASSEMBLY IMPORTANT STEP 19. INSTALL BATTERIES BATTERY IS NEGATIVE GROUNDED. Always connect starter cable to th e A. M205, M155 positive (+) terminal of battery an d battery ground cable to negative (-) Batteries should meet the following specification: terminal of battery.
  • Page 47 UNLOADING AND ASSEMBLY d. Position new batteries on holder (A). B. M105 e. Install strap (B) with bolts (C). Batteries should meet the following specification: IMPORTANT BATTERY IS NEGATIVE GROUNDED. MAXIMUM RATING GROUP VOLT Always connect starter cable to th e DIMENSION positive (+) terminal of battery, and Heavy...

  • Page 48: Step 20. Prime Hydraulic System

    UNLOADING AND ASSEMBLY STEP 20. PRIME HYDRAULIC CAUTION SYSTEM Check to be sure all bystanders have cleared the area. A. M205 d. Crank engine with starter for 15 seconds to prime a. Open maintenance platform on LH side. the system. e.
  • Page 49 UNLOADING AND ASSEMBLY B. M155 a. Remove hydraulic oil reservoir filler cap/dipstick. b. Open engine compartment hood fully. d. Locate plug on TOP of HEADER d rive pump housing from above, and l oosen plug to blee d pump housing. Re-tighten plug once oil starts to run out.
  • Page 50 UNLOADING AND ASSEMBLY g. Open maintenance platform on LH side. Open maintenance platform on RH side (M205, M155). k. Open circuit breaker/fuse box, and remove ECM ignition fuse (5A). h. Disconnect brake engage solenoid connector (P-V3) at valve block on LH side of windrower. CAUTION Check to be sure all bystanders have cleared the area.
  • Page 51 UNLOADING AND ASSEMBLY C. M105 a. Remove hydraulic oil reservoir filler cap/dipstick. b. Open engine compartment hood fully. d. Locate plug on TOP of T RACTION drive pump housing from above, and l oosen plug to blee d pump housing. Re-tighten plug once oil starts to run out.
  • Page 52 UNLOADING AND ASSEMBLY m. Close engine compartment hood. h. Disconnect electrical connection at fuel pump on right side of engine. n. Check hydraulic oil level in re servoir. necessary, add SAE15W-40 oil. Open circuit breaker/fuse box, and remove ECM ignition fuse (5A). CAUTION Check to be sure all bystanders have cleared the area.

  • Page 53: Step 21. Start Engine

    Locked. Ensure lock is engaged. (M155 and M205 only). e. Push HEADER DRIVE switch (C) to OFF. Neutral Interlock Contact MacDon Dealer. Misadjusted. Normal Start (All Engines): engine temperature Fill empty fuel tank. above 60°F (16°C). No Fuel To Engine.

  • Page 54: Step 22. Check Traction Drive

    UNLOADING AND ASSEMBLY g. Cold Start: engine temperature below 40°F STEP 22. CHECK TRACTION (5°C). DRIVE NOTE Engines are not equipped with cold CAUTION start assist system. 1. Follow step e. Normal Start procedure on Check to be sure all bystanders have cleared last page.

  • Page 55: Step 23. Remove Windrower From Stand

    UNLOADING AND ASSEMBLY STEP 23. REMOVE WINDROWER B. FIELD-CONSTRUCTED STAND FROM STAND a. Position a jack under the jack point of each drive wheel leg, and another under the rear hitch. b. Raise jacks to take weight off stan ds, and A.

  • Page 56: Step 24. Install Am/Fm Radio

    UNLOADING AND ASSEMBLY STEP 24. INSTALL AM/FM RADIO Provision has been made for installation of AM/ FM d. Remove the cut-out by cutting the tabs (E) in the radio. The mounting is designed to fit a DIN E panel. Remove sharp edges on panel. style radio with a depth ‘X’...
  • Page 57 UNLOADING AND ASSEMBLY h. Attach two additional wires in the wiring harness to the radio: 1. Circuit 503: Red with 1/4 in. female blade terminal. This is a live wire provided for powering a radio clock/memory, if these exist on your radio. 2.

  • Page 58: Step 25. Install Beacons

    UNLOADING AND ASSEMBLY STEP 25. INSTALL BEACONS a. Retrieve the two beacons from shipment. e. Fit beacon onto base making sure beacon is oriented as shown, with the point on lens facing forward (Cab-Forward). b. Remove hardware and rubber base from one of the beacons as shown.

  • Page 59: Step 26. Install Slow Moving Vehicle (Smv) Sign

    UNLOADING AND ASSEMBLY STEP 26. INSTALL SLOW MOVING VEHICLE (SMV) SIGN ENGINE - FORWARD a. Install SMV sign (shipped in cab) on Windrower in accordance with instructions supplied with the sign. CAB - FORWARD ALTERNATE LOCATION (CAB-FORWARD) b. The SMV signs must be visible when travelling on the road.

  • Page 60: Step 27. Attach Header

    UNLOADING AND ASSEMBLY If necessary, obtain the following kits from your STEP 27. ATTACH HEADER MacDon Dealer, and install them in accordance with the instructions supplied with the kits. A. M205 Kit Description Kit Number Base Kit B5491 Completion B5496...
  • Page 61 UNLOADING AND ASSEMBLY HEADER UP HEADER HEADER TILT UP TILT DOWN HEADER DOWN c. Start the en gine, and activate HEADER DOWN button on th e GSL to fu lly retract header lift cylinders. 2. Locate boot (D) on lift linkage (E), and re-install pin (C).
  • Page 62 UNLOADING AND ASSEMBLY Remove pin from storage position (K) in linkage, g. Lower the center-link onto the header with REEL and insert in hole (L) to engage float springs. DOWN switch until it locks into position (handle is Secure with hairpin. down).

  • Page 63: Header Attachment - A Series

    (C), and If necessary, obtain the fo llowing kits from you r not installed at hole location (D). MacDon Dealer, and install them in accordance with the instructions supplied with the kits. (continued next page)
  • Page 64 UNLOADING AND ASSEMBLY CAUTION Check to be sure all bystanders have cleared the area. REEL DOWN REEL UP HEADER UP HEADER UP HEADER HEADER TILT UP TILT DOWN HEADER HEADER TILT UP TILT DOWN d. Adjust the position of the center-link cylinder with the REEL UP and REEL DOWN switches, and HEADER TILT switches on the GSL to position HEADER DOWN...
  • Page 65 UNLOADING AND ASSEMBLY m. Disengage lift cylinder stops. n. Start engine, and activate HEADER DOWN switch on GSL to lo wer header fully. Stop engine, and remove key. h. Install pin (A) through each boot and foot, and secure with hairpin. IMPORTANT Ensure pin (A) is fully inserted, and hairpin is installed behind bracket.

  • Page 66: Header Attachment - R Series

    IMPORTANT To prevent damage to the lift system when a. If required, o btain kit n umber B5456 from your lowering header lift linka ges without a MacDon Dealer, and install it in accordance with header weight attached the instructions supplied with the kit.
  • Page 67 UNLOADING AND ASSEMBLY CAUTION Check to be sure all bystanders have REEL UP REEL DOWN cleared the area. HEADER UP HEADER UP HEADER HEADER TILT UP TILT DOWN HEADER HEADER TILT UP HEADER DOWN TILT DOWN e. Adjust the position of the center-link cylinder with HEADER DOWN the REEL UP and REEL DOWN switches, and HEADER TILT switches on the GSL to position...
  • Page 68 UNLOADING AND ASSEMBLY Install pin (A) through each boot and foot, and secure with hairpin. IMPORTANT Ensure pin (A) is fully inserted, and hairpin is installed behind bracket. Remove pin (F) from storage position in linkage, and insert in hole (G) to engage float sprin gs. Secure with hairpin.
  • Page 69 RH side. If necessary, obtain the fo llowing kits from you r DRAPER HEADER HYDRAULICS FOR M155 MacDon Dealer, and install them in accordance with instructions supplied with the kits. M155 windrowers must be fitted with a dra per...
  • Page 70 UNLOADING AND ASSEMBLY IMPORTANT To prevent d amage to th e lift system when lowering header lift linkages b. Locate boot (D) on lift linkage (E), and re-install without a header or weig ht box pin (C). Pin may be installed from either side of attached to windrower, ensure that float boot.
  • Page 71 UNLOADING AND ASSEMBLY g. If necessary, adjust position of the h ydraulic center-link (G) so that the hook (H) is above the attachment pin on the header by o ne of the following methods: e. Remove hairpin on pin s (F), and rem ove pins from header legs.
  • Page 72 UNLOADING AND ASSEMBLY Connect center-link: HYDRAULIC LINK WITH OPTIONAL SELF-ALIGNMENT KIT (M155) REEL DOWN REEL UP HEADER UP HEADER TILT UP HEADER 3. Check that cente r-link (G) is lo cked onto TILT DOWN header by pressing the REEL UP switch on HEADER DOWN the GSL.
  • Page 73 UNLOADING AND ASSEMBLY k. If engine is not running, start engine, and press MECHANICAL LINK (M155, M105 OPTIONAL) HEADER UP switch to raise header to maximum height. WARNING NOTE Stop windrower engine, and remove key If one end of the header does not raise before making adjustments to machine.
  • Page 74 UNLOADING AND ASSEMBLY WARNING Stop windrower engine, and remove key before making adjustments to machine. A child or even a pet could engage the drive. m. Install pin (F) through header leg, (engaging U- bracket in lift linkage) on both sides, and secure with hairpin.

  • Page 75: Header Attachment: A Series

    Remove hairpin from pin (A), and remove pin If necessary, obtain the following kit from your from left and right header boots (B) on header. MacDon Dealer, and install it in accordance with instructions supplied with the kits. KIT DESCRIPTION...
  • Page 76 UNLOADING AND ASSEMBLY CAUTION Check to be sure all bystanders have cleared the area. REEL DOWN REEL UP 1. If the optional center-link self-alignment kit is HEADER UP installed, activate the REEL UP switch on the HEADER TILT UP GSL to raise the center-link (E). HEADER TILT DOWN HEADER DOWN...
  • Page 77 UNLOADING AND ASSEMBLY e. Connect center-link: HYDRAULIC LINK WITH OPTIONAL SELF-ALIGNMENT KIT REEL DOWN REEL UP 2. Lower the center-link onto the hea der with HEADER UP REEL DOWN switch until it locks into position HEADER TILT UP (hook release (J) is down). HEADER 3.
  • Page 78 UNLOADING AND ASSEMBLY MECHANICAL LINK (M155, M105 OPTIONAL) WARNING 1. Stop engine, and remove key from ignition. Stop windrower engine, and remove key before making adjustments to machine. A child or even a pet could engage the drive. DANGER To avoid bodily injury from fall of raised header, always engage header lift cylinder stops when working on or around raised header, and before going under header for any...
  • Page 79 UNLOADING AND ASSEMBLY h. Install pin (N) through each boot and foot, and secure with hairpin. m. Remove pin (Q) from storage position in linkage, and insert in hole (R) to engage float springs. IMPORTANT Secure with lynch pin. Ensure pin (N) is fully inserted, and hairpin is installed behind bracket.
  • Page 80 UNLOADING AND ASSEMBLY WARNING Stop windrower engine, and remove key before making adjustments to machine. A child or even a pet could engage the drive. q. Stop engine, and remove key. Connect header drive hydraulics (S) and electrical harness (T) to header. Refer to Auger Header Operator’s Manual.

  • Page 81: Header Attachment: R Series (M155 Only)

    (B) on header. KIT B5510 To operate these headers, the M155 windrower requires the installation of hydraulic valve Kit B4657. See your MacDon Dealer. IMPORTANT To prevent d amage to th e lift system when lowering header lift linkages...
  • Page 82 UNLOADING AND ASSEMBLY CAUTION Check to be sure all bystanders have cleared the area. REEL DOWN REEL UP 1. If the optional center-link self-alignment kit is HEADER UP installed, activate the REEL UP switch on the GSL to raise the center-link (E). HEADER TILT UP HEADER TILT DOWN...
  • Page 83 UNLOADING AND ASSEMBLY Connect center-link: HYDRAULIC LINK WITHOUT SELF-ALIGNMENT KIT (M155 OPTIONAL) HYDRAULIC LINK WITH OPTIONAL SELF- ALIGNMENT KIT REEL DOWN REEL UP HEADER UP HEADER TILT UP HEADER TILT DOWN HEADER DOWN 1. Activate HEADER TILT cylinder switches on GSL to extend or retract center-link cylinder (E) so that the hook lines-up with the header attachment pin.
  • Page 84 UNLOADING AND ASSEMBLY MECHANICAL LINK (M155 OPTIONAL) CAUTION WARNING Check to be sure all bystanders have cleared the area. Stop windrower engine, and remove key before making adjustments to machine. A child or even a pet could engage the drive. 1.
  • Page 85 UNLOADING AND ASSEMBLY DANGER To avoid bodily injury from fall of raised header, always engage header lift cylinder stops when working on or around raised header, and before going under header for any reason. h. Cylinder stops are lo cated on both hea der lift cylinders on the windrower.

  • Page 86: Step 28. Lubricate Machine

    UNLOADING AND ASSEMBLY STEP 28. LUBRICATE MACHINE CAUTION Check to be sure all bystanders have cleared Recommended Lubricant the area. SPEC DESCRIPTION High Temperature Extreme Pressure (EP2) HEADER UP As Required Performance With 1% Max SAE Multi- Unless Otherwise Molybdenum Disulphide Purpose Specified (NLGI Grade 2)
  • Page 87 UNLOADING AND ASSEMBLY Lubrication Points (Cont’d) High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2). Lithium Base. TOP LINK - TWO FITTINGS (BOTH SIDES) WALKING BEAM PIVOT) FORMED CASTER WHEEL BEARING 1 PLACE (BOTH WHEELS) CASTER PIVOT (BOTH SIDES) FORKED CASTER SPINDLE BEARINGS...

  • Page 88: Step 29. Program Cab Display Module (Cdm)

    UNLOADING AND ASSEMBLY STEP 29. PROGRAM CAB Proceed to program the CDM as follows: DISPLAY MODULE (CDM) IMPORTANT Header must be attach ed to the The monitoring system requires programming for windrower so that the CDM can detect each header, and the header must be attached to the type of h eader (Header ID), an d the windrower.

  • Page 89: M205, M155 Detailed Programming Instructions

    UNLOADING AND ASSEMBLY A. M205, M155 DETAILED PROGRAMMING INSTRUCTIONS (Ignition ON / Engine Running or Not / Header Disengaged). (Press PROGRAM and SELECT on CDM to enter programming mode). (If necessary, refer to the M Series Windrower Operator’s Manual for programming to specific crop types and conditions). (continued next page) Form 169242 Revision F...
  • Page 90 UNLOADING AND ASSEMBLY (continued next page) Form 169242 Revision F...
  • Page 91 UNLOADING AND ASSEMBLY IMPORTANT: ENGINE MUST BE RUNNING TO CALIBRATE SENSORS (continued next page) Form 169242 Revision F...
  • Page 92 UNLOADING AND ASSEMBLY (continued next page) Form 169242 Revision F...
  • Page 93 UNLOADING AND ASSEMBLY (continued next page) Form 169242 Revision F...
  • Page 94 UNLOADING AND ASSEMBLY Form 169242 Revision F...

  • Page 95: M105 Detailed Programming Instructions

    UNLOADING AND ASSEMBLY B. M105 DETAILED PROGRAMMING INSTRUCTIONS (Ignition ON / Engine Running or Not / Header Disengaged). (Press PROGRAM and SELECT on CDM to enter programming mode). (If necessary, refer to the M Series Windrower Operator’s Manual for programming to specific crop types and conditions). Programming Menu Flow Chart If "NO"...
  • Page 96 UNLOADING AND ASSEMBLY C x x x || D R A P E R S P E E D This menu allows the operator to selectably "lock out" M x x x || E N A B L E D / L O C K E D the control functions for the various header functions.
  • Page 97 UNLOADING AND ASSEMBLY IMPORTANT: ENGINE MUST BE RUNNING TO CALIBRATE SENSORS C x x x || C D M B U Z Z E R V O L U M E ▂ ▂ ▃ ▅ ▆ ▇ M x x x || The "arrow"...
  • Page 98 UNLOADING AND ASSEMBLY If "NO" then jump to: C x x x D I A G N O S T I C M O D E ? M x x x N O / Y E S T R A C T O R S E T U P ? If "NO"...
  • Page 99 UNLOADING AND ASSEMBLY C x x x || S E N S O R I N P U T M x x x || H D R H E I G H T S E N S O R If a sensor has been disabled "SENSOR" will be flashing in the area where the input reading would C x x x || S E N S O R I N P U T...

  • Page 100: Step 30. Perform Hydraulic Purge

    UNLOADING AND ASSEMBLY STEP 30. PERFORM HYDRAULIC PURGE The purge cycle allows for low flow and pressure staging of th e pumps when running up a new windrower with all the lines and filters empty. This has been performed at the factory , but is recommended that it b e repeated when th e windrower has been disassembled for shipping and then reassembled.
  • Page 101 UNLOADING AND ASSEMBLY k. Message PURGE CYCLE ENDED appears when cycle is complete. Release the ARROW button. Press PROGRAM button to return to operating screens. Form 169242 Revision F...

  • Page 102: Step 31. Perform Pre-Delivery Checks

    PRE-DELIVERY CHECKS STEP 31. PERFORM PRE- B. TIRE PRESSURES AND BALLAST DELIVERY CHECKS REQUIREMENTS TIRE PRESSURES WARNING Measure tire pressure with a gauge: Stop windrower engine and remove key before  Bar: 32 psi (221 kPa) making adjustments to machine. A child or ...
  • Page 103 PRE-DELIVERY CHECKS RECOMMENDED BALLAST HEADER DESCRIPTION LEVEL GROUND HILLS APPLICABLE RECOMMENDED PER TIRE BOTH TIRES PER TIRE BOTH TIRES WINDROWER TIRE SIZE TYPE SIZE U.S. Gal. U.S. Gal. lb (kg) * lb (kg) * (Liters) (Liters) A Series All Options 25 FT and Down 7.5 X 16 10 X 16...

  • Page 104: Engine Air Intake

    PRE-DELIVERY CHECKS C. ENGINE AIR INTAKE 0.157 +/-.02 in. (4 +/- 0.5 mm) M205 M205 d. Check constant torque clamps (B) on charge air cooling duct connection at turbocharger inlet (M205). Constant torque type clamps (B) should be tightened to achieve gap as shown. M155, M105 a.

  • Page 105: Hydraulic Oil Level

    PRE-DELIVERY CHECKS D. HYDRAULIC OIL LEVEL E. FUEL SEPARATOR M105 a. For M105: Turn filler cap counterclockwise to loosen bung, and remove dipstick. a. Place a container under the filter drain. b. Turn drain v alve by ha nd 1-1/2 to 2 turns counterclockwise, until draining occurs.

  • Page 106: Gear Box Lubricant Level

    PRE-DELIVERY CHECKS G. GEAR BOX LUBRICANT LEVEL a. Remove plug (A). The lubricant should be visible through the hole, or slightly running out. b. Replace plug, and tighten. H. A/C COMPRESSOR BELT a. Tension on A/C compressor belt should be such that a force of 8 to 12 lbf (35–55 N) deflects the belt 3/16 inch (5 mm) at mid-span.

  • Page 107: Perform Safety System Checks

    PRE-DELIVERY CHECKS 2. Pry the steering interlock away from pintle arms by inserting a wedge or pry bar between I. PERFORM SAFETY SYSTEM CHECKS one of the interlock channels and pintle arm. Ensure battery main disconnect switch is switched 3. Insert a woo d block approximately 3/4 inch to POWER ON position.

  • Page 108: Operational Checks

    PRE-DELIVERY CHECKS J. OPERATIONAL CHECKS M205, M155 M205, M155: A battery main disconnect switch is M155, M205 SHOWN - M105 SIMILAR located on the RH (cab-forward) frame rail, behind the maintenance platform, and can be accessed b. Ensure the steering wheel is cente red. Move by moving the platform.

  • Page 109: Gauges And Cdm Display

    PRE-DELIVERY CHECKS GAUGES AND CDM DISPLAY a. Check engine temperature gauge and fuel gauge are working (M205, M155 ONLY). DISPLAY Engine / Windrower Functions b. Check CDM display i s working by pushing SELECT on CDM, or SELECT button on GSL. ELECTRICAL Push the SE LECT button on GSL, o r SELECT switch on CDM to display VOLTS.

  • Page 110: Operator's Presence System Checks

    PRE-DELIVERY CHECKS 4. If the engine does not shut down, the seat position switches require adjustment. Refer to OPERATOR’S PRESENCE SYSTEM Technical Service Manual. CHECKS d. With the windrower moving at less than 5 mph (8 km/h): 1. Stand up out of the seat. 2.

  • Page 111: Exterior Lights

    PRE-DELIVERY CHECKS c. Switch ROAD lights ON, and check that all lights are functioning as shown below: VII. EXTERIOR LIGHTS M155, M205 a. Ensure Operator’s seat is in cab-forward mode . b. Switch FIELD lights ON, and check that all lights are functioning as shown below: HIGH / LOW - ROAD FIELD LIGHTS...
  • Page 112 PRE-DELIVERY CHECKS g. Rotate Operator’s seat to engine-forward mode. h. Switch ROAD lights ON, and check that all lights are functioning as shown below: BEACON LIGHTS - AMBER TURN SIGNALS / HAZARDS - AMBER k. Switch beacons ON, and check that they are working properly.
  • Page 113 PRE-DELIVERY CHECKS c. Switch ROAD lights ON, and check that all lights M105 shown are functioning as shown below: a. Switch FIELD lights ON, and check that all lights shown are functioning as shown below: HIGH / LOW LIGHTS FIELD LIGHTS TURN SIGNALS / HAZARDS - AMBER FRONT FRONT...

  • Page 114: Interior Lights

    PRE-DELIVERY CHECKS VIII. INTERIOR LIGHTS M155, M205 SHOWN - M105 SIMILAR BEACON LIGHTS - AMBER a. Switch lights ON and OFF with switches on each light. Overh ead ambient light only wo rks with ROAD/FIELD light switch ON. Switch beacons ON, and check that they are working properly.

  • Page 115: A/C And Heater

    PRE-DELIVERY CHECKS A/C AND HEATER IMPORTANT To distribute the oil throughout the A/C system, perform the followin g steps whenever the machine i s first sta rted after storage for more than one week: BLOWER SWITCH Controls Blower Speed OFF / LOW / MEDIUM / HIGH TEMPERATURE CONTROL Controls Cab Temperature INCREASE: Clockwise...

  • Page 116: Manuals

    PRE-DELIVERY CHECKS K. MANUALS L. CAB INTERIOR a. Remove plastic coverings from Cab Display Module and seats, after pre-delivery check is complete. M105 M155, M205 The following manuals can be stored in the manual storage case behind the Operator’s seat: OPERATOR’S PARTS QUICK...
  • Page 117 MacDon Inc. 10708 N. Pomona Avenue Kansas City, Missouri United States, 64153-1924 t. (816) 891-7313 f. (816) 891-7323 MacDon Australia Pty. Ltd. A.C.N. 079 393 721 P.O. Box 243 Suite 3, 143 Main Street Greensborough, Victoria Australia 3088 t. 03 9432 9982 f.

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M seriesM205M155

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