Page 1 M205 Self-Propelled Windrower OPERATOR’S MANUAL Revision C Part #169469 $25...
Page 2 This Manual contains instructions for “SAFETY”, “OPERATION”, and “MAINTENANCE/SERVICE” for your new MacDon Model M205 Self-Propelled Windrower. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Page 3: Introduction
1 INTRODUCTION This manual contains information on the MacDon Model M205 Self-Propelled Windrower that is designed to cut and lay in windrows, a wide variety of grain, hay and specialty crops. Windrowing allows starting the harvest earlier, protects the crop from wind damage, and gives you more flexibility in scheduling combine time.
Page 4: Model And Serial Number
2 MODEL AND SERIAL NUMBER Record the Model Number, Serial Number, and Model Year of the Header, Slow Speed Transport/Stabilizer Wheel Option (if installed), and the Combine Adapter on the lines below: WINDROWER SERIAL NO.__________________YEAR_____ Serial Number Plate is located on the left cab-forward side of the main frame near the walking beam.
Page 5: Table Of Contents
TABLE OF CONTENTS Section/Title Page INTRODUCTION ............................ 1 MODEL AND SERIAL NUMBER ......................2 SAFETY ..............................7 SAFETY ALERT SYMBOL ......................7 SIGNAL WORDS ........................... 7 SAFETY SIGNS ..........................7 3.3.1 Safety Sign Installation ..........................7 3.3.2 Safety Sign Locations ..........................7 GENERAL SAFETY ........................
Page 6 TABLE OF CONTENTS OWNER/OPERATOR RESPONSIBILITIES ................54 SYMBOL DEFINITIONS ......................54 6.2.1 Engine Functions ........................... 54 6.2.2 Windrower Operating Symbols ....................... 54 6.2.3 Header Functions ........................... 55 WINDROWER OPERATION ....................... 56 6.3.1 Operational Safety ..........................56 6.3.2 Break-In Period ............................56 6.3.3 Pre-Season Check ..........................
Page 7 TABLE OF CONTENTS 7.7.5 Park Brake ............................133 7.7.6 HVAC System ............................135 ENGINE ............................. 138 7.8.1 General Engine Inspection ........................138 7.8.2 Manually Turning Engine ........................139 7.8.3 Oil Level ..............................140 7.8.4 Changing Oil and Oil Filter ........................141 7.8.5 Air Intake System ..........................
Page 8 TABLE OF CONTENTS INTERNAL BOOSTER SPRING KIT ..................208 LIGHT HEADER FLOTATION KIT .................... 208 WINDSHIELD SHADES ......................208 9.10 AM-FM RADIO ........................... 208 9.11 PRESSURE SENSOR KIT ......................208 9.12 WEIGHT BOX ..........................208 9.13 TOWING HARNESS ........................208 9.14 SWATH ROLLER ........................
Page 9: Safety
SAFETY 3 SAFETY WARNING 3.1 SAFETY ALERT SYMBOL Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It is also used to alert against unsafe practices. CAUTION Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.
Page 10 SAFETY Safety Sign Locations (continued) BELOW DOOR HANDLE #32744 IN CAB #32744 FRONT OF PLATFORM #134070 BEHIND DOOR ON SILL – LH SIDE ONLY #160396 LIFT LINKAGES #163561 BEHIND DOOR ON SILL #109843 Form 169469/169470/169471 Revision C...
Page 11 SAFETY Safety Sign Locations (continued) IN CAB #109868 IN CAB #160422 IN CAB #109844 BEL0W DOOR HANDLE #32744 FRONT OF PLATFORM #110989 BEHIND DOOR ON SILL #109843 Form 169469/169470/169471 Revision C...
Page 12 SAFETY Safety Sign Locations (continued) ON FAN SHROUD #134068 ON COOLER TOP DOOR / EXHAUST COVER #139668 ON FRAME #42130 ON FRAME #110986 Form 169469/169470/169471 Revision C...
Page 13 SAFETY Safety Sign Locations (continued) ON DRINK COOLER #160429 ON FRAME #110986 INSIDE FRAME #32743 ON LIFT LINKAGE #163562 Form 169469/169470/169471 Revision C...
Page 14: General Safety
SAFETY 3.4 GENERAL SAFETY CAUTION following general farm safety precautions that should be part of your operating procedure types machinery. Provide a first-aid kit for use in case of • emergencies. Protect yourself. Keep a fire extinguisher on the machine. •...
Page 15 SAFETY 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 16: Product Description
DEFINITIONS 4 PRODUCT DESCRIPTION 4.1 DEFINITIONS The following terms/abbreviations may be used in this manual: TERM DEFINITION American Petroleum Institute Articulating Power Tongue ASTM American Society Of Testing and Materials Windrower operation with the operator and cab facing in the direction of Cab-Forward travel.
Page 17: Specifications
PRODUCT DESCRIPTION 4.2 SPECIFICATIONS ENGINE Type Cummins QSB-6.7L 6 Cylinder Turbo Diesel. B20 Bio-Diesel Approved. Displacement 409 cu.in. (6.7 L) Rated 220 hp (164 kW) @ 2200 rpm Power Peak 230 hp (172 kW) @ 2000 rpm Bore 4.21 in. (107 mm) Stroke 4.88 in.
Page 18 PRODUCT DESCRIPTION HEADER LIFT/TILT Hydraulic Double Acting Cylinders. Tilt – Hydraulic Positioning, Optional Type Mechanical Link Displacement 1.02 cu.in. (16.7 cc) Flow 12 U.S. gpm (45 L/min) Gear Pump System Pressure (Relief/Max) 2500 psi (172 bar) HEADER FLOTATION Manual, External, Draw-Bolt With Springs (1 per side). One Inner Booster Primary Adjustment Spring On Left Side.
Page 19: Windrower Dimensions
PRODUCT DESCRIPTION 4.3 WINDROWER DIMENSIONS See Illustration on Next Page WHEEL TREAD HUBS CASTERS TIRES SHIPPING WHEEL BASE Inch/mm POSITION Inch/mm Inch/mm Inch/mm Inch/mm Inch/mm CAB FWD ENG FWD DRIVE TIRES Inner/Outer 123.1/3127 139.1/3532 142.2/3612 18.4 x 26 Bar & Turf Outer/Outer 130.2/3307 146.1/3712...
Page 20 PRODUCT DESCRIPTION WINDROWER DIMENSIONS (cont’d) 133 in. (3378 mm) 45.7 in. (1160 TREAD WHEEL BASE HUBS TIRES CAB FORWARD TREAD WHEEL BASE CASTERS ENGINE-FORWARD Form 169469/169470/169471 Revision C...
Page 21: Component Identification
PRODUCT DESCRIPTION 4.4 COMPONENT IDENTIFICATION TAIL LIGHT – ENG-FWD FIELD/ROAD LIGHTS HAND RAILS TAIL LIGHT – ENG-FWD TURN SIGNAL/HAZARD LIGHTS MIRROR WINDSHIELD WIPER DOOR OPERATOR’S STATION HEADER FLOAT SPRINGS HEADER LIFT LEG CENTER-LINK MAINTENANCE PLATFORM WINDSHIELD WIPER FIELD/ROAD LIGHTS HORN TURN SIGNAL/HAZARD LIGHTS ENGINE COMPARTMENT HOOD MIRROR...
Page 22: Operator's Station
OPERATOR’S STATION 5 OPERATOR’S STATION The operator’s station is designed for operating the windrower in a cab-forward mode (working mode), or in an engine-forward mode (transport mode). The operator station, which includes the seat, console, and steering column, pivots 180° so that the operator maintains access to the windrower controls and gauges regardless of the direction of travel.
Page 23: Operator Presence
OPERATOR’S STATION 5.2 OPERATOR PRESENCE 5.2.2 ENGINE AND TRANSMISSION • The engine will not be allowed to start when The Operator Presence System is a safety feature that is designed to deactivate or alarm the header drive switch is engaged. selected systems when the operator is not •...
Page 24: Training Seat
OPERATOR’S STATION 5.4 TRAINING SEAT SEAT BELT RELEASE a. To fasten seat belt, pull belt completely across A wall mounted fold-up training seat complete your body. Push the metal eye into the buckle with seat belt is provided for use as described until it locks.
Page 25: Lights
OPERATOR’S STATION 5.7.1 CAB-FORWARD LIGHTING: FIELD 5.7 LIGHTS LIGHTS Controls field and transport lights. Field Road BEACON Controls Beacons On Cab. Standard for Export. Optional for N.A. On – Off HI/LO LIGHTS Controls Hi/Lo Beam For Road Lights. HIGH / LOW Hi - Lo FIELD LIGHTS The field and transport light switches are located...
Page 26: Engine-Forward Lighting: Road
Optional red tail lighting and marking kit must be installed so that road travel in the cab-forward mode complies with road travel regulations. See your MacDon dealer. TURN SIGNALS / HAZARDS - AMBER TAIL / BRAKE LIGHTS - RED HIGH / LOW...
Page 27: Beacon Lighting: Export (N.a. Optional)
OPERATOR’S STATION 5.7.4 BEACON LIGHTING: EXPORT (N.A. OPTIONAL) The beacon lights are functional when the ignition and the beacon switches are on. The beacons must be used when driving on the road. BEACON LIGHTS - AMBER Form 169469/169470/169471 Revision C...
Page 28: Windshield Wipers
OPERATOR’S STATION 5.8 WINDSHIELD WIPERS 5.10 CAB TEMPERATURE The cab environment is controlled by a climate- control system that provides clean air- FRONT WIPER SWITCH conditioned or heated air for the operator. The Controls Front Windshield Wiper ON/OFF heater/evaporator/blower assembly is located under the cab floorboard and is accessible from beneath the windrower.
Page 29: Controls
OPERATOR’S STATION 5.10.4 A/C COMPRESSOR PROTECTION The compressor is protected from excessively BLOWER SWITCH low and high pressures by two switches that Controls Blower Speed shut down the compressor to prevent damage to OFF/LO/MEDIUM/HI the system. OUTSIDE AIR SWITCH The LOW pressure switch opens when the •...
Page 30: Operator Amenities
OPERATOR’S STATION 5.12 OPERATOR AMENITIES SWITCHED BATTERY CIGARETTE UTILITY TRAY LIGHTER UNDER ARMREST GROUND AUXILIARY ASHTRAY/ POWER CUPHOLDER UTILITY AUXILIARY TRAY POWER COOLER MANUAL STORAGE CASE Form 169469/169470/169471 Revision C...
Page 31: Radios
OPERATOR’S STATION 5.13 RADIOS 5.13.1 AM/FM RADIO 11 GA. OR 3.0 mm CQHRS A radio is available as optional equipment from your dealer and a space (A) is provided in the IMPORTANT cab headliner to accommodate the installation. Antenna base can only be installed on the Two pre-wired speakers (B) have been factory LH and RH rear cab roof bolts.
Page 32: Engine Controls/Gauges
OPERATOR’S STATION 5.15 ENGINE CONTROLS/GAUGES All engine controls and gauges are conveniently located on the operator’s console. Refer to the following illustration for the location and a description of each. IGNITION SWITCH ACC – Fully Counter-Clockwise OFF – All Electrical Systems Off RUN –...
Page 33: Windrower Controls
OPERATOR’S STATION 5.16 WINDROWER CONTROLS GROUND SPEED LEVER (GSL) Controls Speed and Direction of Movement F – Forward N – Neutral TURN SIGNALS N-DETENT – Engages Neutral Interlock and Applies Activates Turn Signals on Windrower and Header Park Brake When Steering Locked In Center Momentary Switches on Monitor R - Reverse HAZARD WARNING LIGHTS...
Page 34: Header Controls
OPERATOR’S STATION 5.17.2 HEADER DRIVE REVERSE BUTTON 5.17 HEADER CONTROLS All header controls are conveniently located on HEADER REVERSE the operator’s console and on the GSL handle. ENGAGE – Push/Hold/Engage Header DISENGAGE – Release Button NOTE Some controls are optional equipment and may not be present in your unit.
Page 35: Gsl Header Switches
OPERATOR’S STATION 5.17.3 GSL HEADER SWITCHES 5.17.3.1 Display Selector Switch DISPLAY SELECTOR Selects and displays the settings in the CDM (B) top line read-out for each of the header controls. • Press switch to scroll through settings. 5.17.3.2 Reel Position Switches REEL FORWARD DWA DOWN REEL UP...
Page 36: Console Header Switches
OPERATOR’S STATION 5.17.4 CONSOLE HEADER SWITCHES 5.17.3.3 Header Position Switches The operator’s console contains switches for the following header functions. HEADER UP 5.17.4.1 Deck Shift/Float Preset Switch HEADER TILT DOWN HEADER HEADER DOWN TILT UP Press and hold switch at location shown to move header.
Page 37: Cab Display Module (Cdm)
OPERATOR’S STATION 5.18 CAB DISPLAY MODULE (CDM) 5.18.1 ENGINE AND WINDROWER FUNCTIONS GROUND SPEED DISPLAY HAZARD WARNING LIGHTS SWITCH mph or kph Engine/Windrower Functions Activates Hazard Warning Lights Cancels Turn Signal ENGINE RPM SELECT SWITCH Allows Operator To Select Display Item On Lower Line.
Page 38: Operating Screens
OPERATOR’S STATION The information displayed in various operating 5.18.3 OPERATING SCREENS modes is described in the following sections: The M205 windrower Cab Display Module (CDM) and the Windrower Control Module (WCM) provide information on several functions for the engine, header, and windrower. DISPLAY UPPER LINE LOWER LINE...
Page 39 OPERATOR’S STATION CAB-FORWARD - ENGINE RUNNING - HEADER DISENGAGED (Scroll Through Display with CDM Switch or GSL Switch) DISPLAY (Lower or Upper Line) DESCRIPTION #####.# ENGINE HRS Total Engine Operating Time. #####.# HEADER HRS Total Header Operating Time. ###.# SUB ACRES Area Cut Since Last Reset.
Page 40 OPERATOR’S STATION CAB-FORWARD - ENGINE RUNNING - HEADER ENGAGED AUGER HEADER (Scroll Through Display with CDM Switch or GSL Switch) DISPLAY (Lower or Upper Line) DESCRIPTION #####.# ENGINE HRS Total Engine Operating Time. #####.# HEADER HRS Total Header Operating Time. ##.# ACRES/HOUR Actual Cutting Rate In Acres (Hectares)/Hour.
Page 41 OPERATOR’S STATION CAB-FORWARD - ENGINE RUNNING - HEADER ENGAGED DRAPER HEADER - INDEX SWITCH OFF (Scroll Through Display with CDM Switch or GSL Switch) DISPLAY (Lower or Upper Line) DESCRIPTION #####.# ENGINE HRS Total Engine Operating Time. #####.# HEADER HRS Total Header Operating Time.
Page 42 OPERATOR’S STATION CAB-FORWARD - ENGINE RUNNING - HEADER ENGAGED DRAPER HEADER - INDEX SWITCH ON (Scroll Through Display with CDM Switch or GSL Switch) DISPLAY (Lower or Upper Line) DESCRIPTION #####.# ENGINE HRS Total Engine Operating Time. #####.# HEADER HRS Total Header Operating Time.
Page 43 OPERATOR’S STATION CAB-FORWARD - ENGINE RUNNING - HEADER ENGAGED ROTARY HEADER (Scroll Through Display with CDM Switch or GSL Switch) DISPLAY (Lower or Upper Line) DESCRIPTION #####.# ENGINE HRS Total Engine Operating Time. #####.# HEADER HRS Total Header Operating Time. ##.# ACRES/HOUR Actual Cutting Rate In Acres (Hectares)/Hour.
Page 44 OPERATOR’S STATION MISCELLANEOUS OPERATIONAL INFORMATION DISPLAY (Upper Line) DESCRIPTION < LEFT TURN ■ Indicates Left Turn When Is Pressed On CDM. See Note 1. ■ RIGHT TURN > Indicates Left Turn When Is Pressed On CDM. See Note 2. ■ HAZARD ■...
Page 45: Cab Display Module (Cdm) Warnings/Alarms
OPERATOR’S STATION 5.18.4 CAB DISPLAY MODULE (CDM) WARNINGS/ALARMS The CDM displays warnings and sounds alarms to notify the operator of abnormal windrower status at startup when the ignition is turned on and at engine operating speeds above 500 rpm. 5.18.4.1 Engine Warning Lights CAUTION ENGINE PREHEAT Illuminates Yellow...
Page 46 OPERATOR’S STATION 5.18.4.2 Display Warnings DISPLAY WARNINGS Informs Operator of Abnormal Windrower Conditions See Table Below DISPLAY WARNINGS AND ALARMS DISPLAY ALARM TONE DESCRIPTION Engine Running, Brake Solenoid Not BRAKE OFF Activated. GSL Out Of N-Detent But Interlock BRAKE ON ...
Page 47 OPERATOR’S STATION DISPLAY WARNINGS AND ALARMS (Continued) DISPLAY ALARM TONE DESCRIPTION Tone Sounds With Each Flash For 5 Seconds and Then Stops For 1 ### °C or F HYD OIL COLD Minute. Flashing Continues. If Oil Hydraulic Oil Temp <10C or 50F. ...
Page 48: Cab Display Module (Cdm) Programming
OPERATOR’S STATION Proceed as follows to program the CDM: 5.18.5 CAB DISPLAY MODULE (CDM) IMPORTANT PROGRAMMING Header must be attached to the windrower The monitoring system requires programming so that the CDM can detect the type of for each header and the header must be header (Header ID) and adjust the attached to the windrower so that the CDM programming mode accordingly.
Page 49 OPERATOR’S STATION DETAILED PROGRAMMING INSTRUCTIONS IMPORTANT: ENGINE MUST BE RUNNING TO CALIBRATE SENSORS. NOTE: The software version code Mxxx in the following charts will show as Xxxx on the CDM for the M205 windrower. Programming Menu Flow Chart C x x x T R A C T O R S E T U P ? If "NO"...
Page 50 OPERATOR’S STATION C x x x || E X I T E N G I N E I S C ? If "NO" then jump to: M x x x || N O / Y E S P R E S S H A Z A R D S E T C x x x || S E T...
Page 51 OPERATOR’S STATION (continued next page) Form 169469/169470/169471 Revision C...
Page 52 OPERATOR’S STATION C x x x C A B D I S P L A Y S E T U P ? If "NO" then jump to: M x x x N O / Y E S C A L I B R A T E S E N S O R S ? C x x x || D I S P L A Y L A N G U A G E ?
Page 53 OPERATOR’S STATION C x x x || T O C A L I B R A T E S E L E C T Select any of the sensors by using the turn signal switches to M x x x || H E A D E R H E I G H T cycle through the choices.
Page 54 OPERATOR’S STATION NOTE: The oil temp. readout applies to the C x x x || S E N S O R I N P U T M205 model with the Sensata oil temp. sensor. M x x x || W H E E L S P E E D 1 2 3 C x x x || S E N S O R...
Page 55: Setting Guidelines
OPERATOR’S STATION 5.18.6 SETTING GUIDELINES 5.18.6.1 Pressure Settings SUGGESTED OVERLOAD WINDROWER PRESSURE WARNING SETTING DIFFERENTIAL RELIEF SETTING HEADER MODEL APPLICATION/SYSTEM psi (kPa) psi (kPa) R80/R85 Disc Pressure 5000 (34474) 5800 (39990) Reel/Draper Pressure 3000 (20684) 3500 (24132) D-SERIES A-SERIES Knife/Conditioner Pressure 4000 (27579) 4500 (31026) 5.18.6.2 R Series Rotary Header Disc Speeds...
Page 56: Operation
WINDROWER OPERATION 6.2.1 ENGINE FUNCTIONS 6 OPERATION Electrical Power- Engine Stop 6.1 OWNER/OPERATOR Accessories RESPONSIBILITIES Engine Coolant Engine Temperature Throttle CAUTION Engine Glow Engine It is your responsibility to read and • Plugs Urgent Stop understand this manual completely before operating the windrower. Contact Engine Fast your dealer if an instruction is not clear...
Page 57: Header Functions
WINDROWER OPERATION Windrower Operating Symbols (cont’d) DWA Draper Speed Air Conditioning Fresh Air Recirculate Blower 6.2.3 HEADER FUNCTIONS Header Tilt Program Header Header Index Down Return To Cut Header Up Conveyor/Auger Header Tilt Speed Down Float Left Increase Float Right Decrease Reel Speed Deck Shift...
Page 58: Windrower Operation
WINDROWER OPERATION Check excessive vibration • 6.3 WINDROWER OPERATION unusual noises. If there is any indication of trouble, shut down and inspect the 6.3.1 OPERATIONAL SAFETY machine. Follow proper shutdown procedure. Refer to Section 6.3.5.4 Follow these safety precautions: Shutdown Procedure. •...
Page 59: Pre-Season Check
WINDROWER OPERATION 6.3.3 PRE-SEASON CHECK 6.3.4 DAILY CHECK a. Perform the following safety checks at the a. Check the machine for leaks or any parts that beginning of each operating season: are missing, broken, or not working correctly. NOTE: CAUTION Use proper procedure when searching for pressurized fluid leaks.
Page 60: Engine Operation
WINDROWER OPERATION 6.3.5 ENGINE OPERATION 6.3.5.1 Starting DANGER Avoid possible injury or death from a • runaway machine. • This machine has safety devices which allow the engine to start only when the ground speed lever is in N-DETENT, the steering wheel is locked in the neutral position, and the header drive switch is position.
Page 61 WINDROWER OPERATION g. Normal Start - engine temperature above 60°F WARNING (16°C): If starter engages with steering wheel unlocked, ground speed lever out of neutral, or header clutch engaged, DO NOT START ENGINE. See your dealer. h. Cold Start - engine temperature below 40°F (5°C) 1.
Page 62 WINDROWER OPERATION 6.3.5.5 Fueling 6.3.5.3 Engine Intermediate Speed Control (ISC) WARNING engine operating speed programmed to enable the windrower to operate To avoid personal injury or death from • at reduced engine rpm, i.e. 1800, 1900, 2000 explosion or fire, do not smoke or allow rpm, OFF (full throttle) without significantly flame or sparks near fuel tank when affecting the ground or header speeds.
Page 63 WINDROWER OPERATION NOTE 6.3.5.8 Electrical Fill fuel tank daily, preferably at the end of IGNITION ENGINE READING INDICATED the day's operation to help prevent CONDITION condensation in the tank. Tank Capacity 13.8-15.0 Normal is 97 U.S. Gallons (378 L). > 16.0 Regulator Out of IMPORTANT Adjustment.
Page 64: Driving The Windrower
WINDROWER OPERATION 6.3.6 DRIVING THE WINDROWER CAUTION WARNING With the engine running, moving the ground speed lever out of N-DETENT unlocks Before starting engine, securely fasten your steering. Any movement of steering wheel seat belt and ensure trainer’s seat belt is will then cause the machine to move, even if fastened if occupied.
Page 65 WINDROWER OPERATION Avoid inclines, ditches and fences. • Do not rapidly accelerate or decelerate • when turning • Reduce speed before turning, crossing slopes, or travelling over rough ground. Do not allow anyone to stand behind the • machine while operating. Foreign objects may be forcibly ejected.
Page 66 WINDROWER OPERATION 6.3.6.2 Cab-forward Operation WARNING Do not drive windrower on road in Cab- forward configuration, unless it is equipped with the proper lighting and markings for Cab-forward road travel. d. There are two cab-forward speed ranges. Set ground speed range switch (D) to either H (0-16 mph (25.7 km/h)), or L (0-11 mph (17.7 km/h)).
Page 67 WINDROWER OPERATION 6.3.6.3 Engine-forward Operation 6.3.6.2.1 Reverse In Cab-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.
Page 68 WINDROWER OPERATION 6.3.6.3.1 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. c. Set ground speed range switch (D) to H for road speed (0-23 mph (37 km/h)).
Page 69 WINDROWER OPERATION 6.3.6.4 Spin Turn 6.3.6.5 Stopping Hydrostatic steering gives operator WARNING significantly more manoeuvrability than mechanical steering. To make a spin turn, refer Do not move ground speed lever rapidly to illustration and proceed as follows: back to neutral. Operator may be thrown forward by sudden stop.
Page 70: Adjustable Caster Tread Width
WINDROWER OPERATION c. Slide extensions inboard or outboard equal 6.3.7 ADJUSTABLE 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 around poles, irrigation inlets, or other obstacles.
Page 71 WINDROWER OPERATION d. Position bracket (A), and install bolts (B). The two shorter bolts are installed at the back inboard locations. e. Install bottom bolts (C). Tighten bolts as follows: 1. Snug bottom bolts (C). 2. Tighten and torque back bolts (B) to 330 ft∙lbf (447 N∙m).
Page 72: Transporting
If width of attached header impedes other • position. vehicle traffic, remove header and install b. Before driving windrower on a roadway: a MacDon approved weight box. 1. Clean flashing amber lamps, red tail lamp CAUTION and head lamps and check that they work properly.
Page 73 With header removed, steering control is • reduced if weight is not added to drive wheels. If you must drive the windrower without header MacDon weight system; Operate in low speed range. Do not exceed 1500 rpm engine HAZARD WARNING LIGHTS SWITCH speed.
Page 74 To avoid bodily injury from fall of raised exceed 20 mph (32 km/h). header, always engage header lift cylinder The windrower can be used to tow a MacDon stops when working on or around raised Harvest Header with the Slow Speed Transport header.
Page 75 WINDROWER OPERATION Raise the center-link off the header using the REEL UP switch on the GSL. m. Slowly back windrower away from header, shut off engine and remove key from ignition. n. Attach header transport hitch to header as follows: g.
Page 76 WINDROWER OPERATION 4. Remove the L-pin from end (L) of aft section if installed. 8. Make the electrical connection at the joint (Q) and at the header wheel (P). 5. Position end (M) of the forward section into end (L) of the aft section. IMPORTANT To prevent damage to the lift system when lowering header lift linkages without a...
Page 77 WINDROWER OPERATION o. Drive windrower so that windrower lift arms are positioned into the weight box pockets. REEL UP REEL DOWN HEADER HEADER TILT UP TILT DOWN Raise lift arms fully, shut off engine, and remove key from ignition. s. Move float pins from storage location (C) to p.
Page 78 WINDROWER OPERATION 6.3.8.2.2 From Transport Mode To Field Operation DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine. a. Shut down engine and remove key from ignition. d.
Page 79 WINDROWER OPERATION Move float pins from location (G) to disengage the float and store pins at location (H). IMPORTANT To prevent damage to the lift system when lowering header lift linkages without a header weight attached windrower, ensure that float engagement pin is installed in storage location (H), and not installed at hole location (G).
Page 80 WINDROWER OPERATION IMPORTANT 6.3.8.3 Towing the Windrower Failure to disengage final drives before towing will result in serious transmission In emergency situations, for example, towing out damage. of a field or into a shop, windrower may be towed without a trailer, providing the following IMPORTANT precautions are followed: Do not exceed 16 mph (26 km/h) when...
Page 81: Storage
WINDROWER OPERATION CAUTION 6.3.8.4 Final Drives Disengage and engage final drives as follows: Remember when working around storage batteries that all of the exposed metal parts are "live". Never lay a metal object across the terminals because a spark and short circuit will result.
Page 82: Header Operation
HEADER – GENERAL 6.4 HEADER OPERATION The M205 Windrower is designed to use the MacDon A-Series Auger Header, R-Series Rotary Header, and D-Series Rigid Draper header with or without a Hay Conditioner. This section describes attachment detachment procedures operating instructions for these header types.
Page 83: Header Flotation
HEADER – GENERAL 6.4.2.2 Float Adjustment 6.4.2 HEADER FLOTATION The M Series windrowers are equipped with Float is intended for cutting crops that require primary (coarse) secondary (fine) the cutterbar to be in contact with the ground. adjustment systems. The primary or coarse Optimum float is for the cutterbar to maintain adjustment uses drawbolts to change the contact with the ground with minimum bouncing...
Page 84 HEADER – GENERAL DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine. 6. Grasp the divider rod and lift. The force to lift should be as noted in the following table, and should be approximately the same at both ends.
Page 85 HEADER – GENERAL d. Using HEADER DOWN switch, lower header 6.4.2.3 Float Options fully with lift cylinders fully retracted. For draper headers without the deck shift option, auger headers, and rotary headers, the float can pre-programmed three types DISPLAY windrowing conditions. For example; •...
Page 86: Levelling
HEADER – GENERAL DANGER 6.4.3 LEVELLING Stop engine and remove key from ignition The windrower linkages are factory set to before leaving operator's seat for any provide the proper level for the header and reason. A child or even a pet could engage should not normally require adjustment.
Page 87: Header Drive
HEADER – GENERAL b. Reverse the header operation as follows: 6.4.4 HEADER DRIVE NOTE The headers are hydraulically driven and The optional hydraulic reversing kit must controlled from windrower with be installed for auger and draper with mechanical drive shafts. conditioner equipped windrowers.
Page 88: Header Angle
HEADER – GENERAL a. To decrease (flatten) header angle, operate 6.4.5 HEADER ANGLE HEADER TILT UP switch on GSL handle so that cylinder (A) retracts. The CDM display will show Header angle is defined as the angle between a reading on the lower line of decreasing value the ground and the drapers/cutterbar and is between 00.0 and 10.0.
Page 89 HEADER – GENERAL 2. Lower the handle into the lock position. 3. Push up on pin (B) only. Handle should catch on casting and pin should not lift. 4. Push up on actuator rod (C) and pin should lift with the handle. Form 169469/169470/169471 Revision C...
Page 90: Cutting Height
HEADER – GENERAL a. Program the RETURN TO CUT feature as 6.4.6 CUTTING HEIGHT follows: The header is raised or lowered with the IMPORTANT HEADER UP or HEADER DOWN switches on The windrower must be running with the the GSL. See illustration. The CDM indicates header engaged.
Page 91 HEADER – GENERAL 2. If the header is below the pre-set height, 6. Press to change value on press and hold the HEADER UP switch to lower line. Range is 4.0 to 10.0 where 10.0 raise the header. Release switch to stop is fully raised.
Page 92: Double Windrowing
DWA UP windrower wheels as it would be without the side delivery system. Refer to MacDon M Series Windrower Double Windrow Attachment Manual (Form #169216) complete operating maintenance instructions.
Page 93: D Series Header Operation
1. Remove pin (C) from boot (D). (continued next page) DRAPER HEADER REEL HYDRAULICS 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...
Page 94 HEADER OPERATION – D SERIES HEADER UP HEADER HEADER TILT UP TILT DOWN HEADER DOWN c. Start the engine and activate HEADER DOWN button on the GSL to fully retract header lift cylinders. 2. Locate boot (D) on lift linkage (E) and reinstall pin (C).
Page 95 HEADER OPERATION – D SERIES (continued next page) Form 169469/169470/169471 Revision C...
Page 96 HEADER OPERATION – D SERIES 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 Secure with hairpin.
Page 97: Header Detachment
HEADER OPERATION – D SERIES 6.5.2 HEADER DETACHMENT HEADER UP HEADER HEADER TILT UP TILT DOWN HEADER DOWN e. Remove pin from location (D) to disengage float springs, and insert in storage hole (E). Secure with lynch pin. a. Raise the header fully with the HEADER UP IMPORTANT switch on the GSL.
Page 98 HEADER OPERATION – D SERIES Operate the link lift cylinder with REEL UP switch on GSL to disengage the center link from the header. m. Slowly back windrower away from header. NOTE If hay conditioner is installed, watch clearances on both sides. Disconnect reel hydraulics (H) and store on bracket at windrower LH side.
Page 99: Header Position
HEADER OPERATION – D SERIES IMPORTANT 6.5.3 HEADER POSITION Under certain conditions, with reel raised to full height, the reel tines may contact Refer to Section 6.4 HEADER OPERATION for the cab roof. Exercise care to avoid procedures for controlling header height, header damage to the machine.
Page 100: Reel Speed
HEADER OPERATION – D SERIES NOTE 6.5.6 REEL SPEED DISPLAY will flash ##.## MIN REEL (MPH or KPH) to prompt the operator to The speed of the reel is controlled with switches change the minimum set point or increase on the CDM in the cab. On D Series draper ground speed if Ground Speed Plus Index headers, it can be set relative to the ground is less than the Minimum Reel Speed Set...
Page 101 HEADER OPERATION – D SERIES Examples: 6.5.6.2 Reel Only Speed Windrower is operating at 8 mph with Header Set the speed of the reel independently of Index on and set at 5.5. Display shows; ground speed as follows: 13.5 5.5 REEL IND CAUTION where 13.5 (8+5.5) is the reel speed in mph, and 5.5 is the header index setting.
Page 102: Draper Speed
HEADER OPERATION – D SERIES NOTE 6.5.7 DRAPER SPEED DISPLAY will flash ##.# MIN CONV (MPH or KPH) to prompt the operator to change Draper speed affects the orientation of stalks in the minimum set point or increase ground the windrow. Faster draper speeds tend to form speed if Ground Speed Plus Index is less herringbone or dovetail configurations.
Page 103 HEADER OPERATION – D SERIES 6.5.7.2 Draper Speed Independent of Ground Examples: Speed Windrower is operating at 8 mph with Header Set the speed of the draper independently of Index on and set at 1.5. Display shows; ground speed as follows: 9.5 1.5 DRAP INDX NOTE where 9.5 (8+1.5) is the draper speed in mph,...
Page 104: Knife Speed
HEADER OPERATION – D SERIES 6.5.8 KNIFE SPEED Display and set knife speed on-the-go as follows: The ideal cutting speed of the knife should be such that a clean cut is achieved. Crop types CAUTION and conditions usually influence the knife and forward speeds.
Page 105: Deck Shift (Optional)
HEADER OPERATION – D SERIES 6.5.9 DECK SHIFT (OPTIONAL) 6.5.9.1 Float Options With Deck Shift The hydraulic deck shift option allows the For draper headers equipped with the deck shift operator to control deck position and draper option, the header float can be set for each rotation from the operator’s station.
Page 106: A Series Header Operation
Remove hairpin from pin (A), and remove pin AUGER HEADER HYDRAULICS 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...
Page 107 HEADER OPERATION – A SERIES CAUTION Check to be sure all bystanders have cleared the area. REEL UP REEL DOWN 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 108 HEADER OPERATION – A SERIES m. Disengage lift cylinder stops. n. Start engine, and activate HEADER DOWN switch on GSL to lower 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 109: Header Detachment
HEADER OPERATION – A SERIES 6.6.2 HEADER DETACHMENT HEADER UP HEADER HEADER TILT UP TILT DOWN HEADER DOWN d. Lower stand (C) by pulling pin (D), inverting stand and re-locating on bracket. Reinsert pin a. Raise the header fully with the HEADER UP (D) and secure with hairpin.
Page 110 HEADER OPERATION – A SERIES REEL DOWN REEL UP HEADER HEADER TILT UP TILT DOWN h. Activate HEADER TILT switch on GSL to m. Re-install pins (A) in header boots (B). release load on center link cylinder (G). Lift hook release (H). Operate the link lift cylinder with REEL UP switch on GSL to disengage the center link from the header.
Page 111: Auger Speed
HEADER OPERATION – A SERIES 6.6.3.2 A30-S and A30-D Headers 6.6.3 AUGER SPEED On A30 Series auger headers, the auger speed CAUTION is fixed to the knife speed. NOTE Check to be sure all bystanders have cleared The auger speed can be independently the area.
Page 112: Reel Speed
HEADER OPERATION – A SERIES reel speed do not affect auger speed. 6.6.4 REEL SPEED 6.6.4.1 A40-D Header The A40 reel drive is hydraulically driven and is dependent on the auger and knife speeds. IMPORTANT To prevent overspeeding the auger, initially set the speed of the reel and auger as follows: Subsequent adjustments to...
Page 113 HEADER OPERATION – A SERIES Adjust the reel speed “on the go” as follows: HEADER INDEX SWITCH - OFF ON GSL PRESS SLOW OR FAST DISPLAY SHOWS ##.## REEL RPM ##.## = 15.00 – 85.00 SPEED DONE 6.6.4.2 A30-S and A30-D Headers The reel is driven by the auger, and both are dependent on the main header drive speed.
Page 114: Knife Speed
HEADER OPERATION – A SERIES Display and set knife speed on-the go as 6.6.5 KNIFE SPEED follows: The ideal cutting speed of the knife should be CAUTION such that a clean cut is achieved. Crop types and conditions usually influence the knife and forward speeds.
Page 115: R Series Header Operation
If required, obtain kit number B5456 from your IMPORTANT MacDon dealer and install it in accordance with To prevent damage to the lift system when the instructions supplied with the kit. lowering header lift linkages without a above.
Page 116 HEADER OPERATION – R SERIES CAUTION Check to be sure all bystanders have cleared REEL DOWN REEL UP the area. HEADER UP HEADER UP HEADER HEADER TILT UP TILT DOWN HEADER HEADER TILT UP HEADER DOWN TILT DOWN d. 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 117 HEADER OPERATION – R SERIES 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. Remove pin (F) from storage position in linkage and insert in hole (G) to engage float springs. Secure with hairpin.
Page 118: Header Detachment
HEADER OPERATION – R SERIES 6.7.2 HEADER DETACHMENT REEL DOWN REEL UP HEADER UP HEADER HEADER TILT UP TILT DOWN d. Remove pin from location (C) to disengage float springs, and insert in storage hole (D). Secure a. Raise the header fully with the HEADER UP with hairpin.
Page 119 HEADER OPERATION – R SERIES Disconnect header drive hydraulics electrical harness. Refer to your Rotary Disc Header Operator’s Manual. k. Slowly back windrower away from header. Re-install pins (A) in header boots (B). Form 169469/169470/169471 Revision C...
Page 120: Disc Speed
HEADER OPERATION – R SERIES Display and set the desired disc speed as 6.7.3 DISC SPEED follows: The header is allocated a code that the WCM CAUTION reads when the header is first attached to the windrower, disc speed set-point automatically becomes the minimum disc speed Check to be sure all bystanders have cleared for the header.
Page 121: Maintenance/Service
MAINTENANCE/SERVICE • Wear protective shoes with slip-resistant 7 MAINTENANCE/SERVICE soles, a hard hat, protective glasses or goggles and heavy gloves. The following instructions are provided to assist the operator in the use of the M205 Windrower. Detailed maintenance, service, parts information contained Service...
Page 122: Maintenance Specifications
MAINTENANCE/SERVICE 7.3.1.3 Lubricants 7.3 MAINTENANCE SPECIFICATIONS LUBRICANT SPEC/DESCRIPTION SAE Multi-Purpose. 7.3.1 RECOMMENDED FUEL, FLUIDS AND High Temp. Extreme As Required Unless Pressure (EP2) Performance LUBRICANTS Grease Otherwise With 1% Max Molybdenum Specified. Disulphide (NLGI Grade 2) 7.3.1.1 Fuel Lithium Base. FUEL SPEC SULPHUR...
Page 123: Recommended Torques
MAINTENANCE/SERVICE 7.3.2.1.2 Metric Bolts 7.3.2 RECOMMENDED TORQUES STD COARSE BOLT TORQUE* BOLT 7.3.2.1 Bolts DIA. 10.9 "A" The tables shown below give correct torque lbf∙ft N·m lbf∙ft N·m values for various bolts and capscrews. • Tighten all bolts to the torques specified in chart unless otherwise noted throughout this manual •...
Page 124 MAINTENANCE/SERVICE 7.3.2.2 Hydraulic Fittings 7.3.2.2.2 O-Ring Type 7.3.2.2.1 Flare Type FITTING LOCKNUT WASHER FLARE O-RING GROOVE SEAT BODY FLARESEAT a. Check flare and flare seat for defects that might cause leakage. a. Inspect O-ring and seat for dirt or obvious defects.
Page 125: Conversion Chart
MAINTENANCE/SERVICE 7.3.3 CONVERSION CHART INCH-POUND UNITS SI UNITS (METRIC) QUANTITY FACTOR UNIT NAME ABBR. UNIT NAME ABBR. Area acres acres x 0.4047 = hectares Flow US gallons per minute (gpm) x 3.7854 = liters per min L/min Force pounds force x 4.4482 = Newtons inch...
Page 126: Engine Compartment Hood
MAINTENANCE/SERVICE c. Open the hood at the highest position as follows: 7.4 ENGINE COMPARTMENT HOOD 1. Open hood to lowest position. The engine hood has two open positions. The lowest is for general maintenance such as checking and adding fluid, servicing the cooling box, etc.
Page 127: Maintenance Platforms
MAINTENANCE/SERVICE 7.5 MAINTENANCE PLATFORMS 7.5.2 OPENING/CLOSING PLATFORM FOR MAJOR SERVICING Swing away platform/stair units are provided on both sides of the windrower for access to the To improve access to the hydraulics plumbing or operator’s station and engine bay maintenance. battery, the platforms can be swung away from the windrower.
Page 128 MAINTENANCE/SERVICE CAUTION Do not stand on the platform in the unlocked position. It is unstable and may result in a fall. e. Close platform as follows: 1. Swing link (C) all the way forward. 2. Move platform front (cab-forward) end inboard while moving it away from the walking beam.
Page 129: Lubricating The Windrower
MAINTENANCE/SERVICE 7.6 LUBRICATING THE WINDROWER WARNING To avoid personal injury, before servicing windrower or opening drive covers, follow procedures in Section 7.1, Preparation for Servicing. Recommend Lubricant LUBRICANT SPEC DESCRIPTION High Temp. Extreme Pressure (EP2) As Required Performance With SAE Multi- Unless Grease 1% Max...
Page 130 MAINTENANCE/SERVICE Lubrication Points (continued) High Temp. 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 TWO PLACES (BOTH WHEELS) Form 169469/169470/169471...
Page 131: Operator's Station
See your MacDon dealer. dealer. NOTE A properly functioning system should operate as follows, if not, see your MacDon dealer. To restart the header, the operator must move the header engage switch to “OFF” The starter should engage ONLY when the •...
Page 132: Gsl Adjustments
MAINTENANCE/SERVICE 7.7.3.2 GSL Fore-Aft Movement 7.7.3 GSL ADJUSTMENTS The GSL should remain as positioned by the 7.7.3.1 GSL Lateral Movement operator and yet can be moved without excessive force. The spring is set at the factory The GSL should easily move into the N- to 1.25 in.
Page 133: Steering Adjustments
60-70 ft∙lbf (81-95 N∙m). If steering link ball joints (B) or steering rod ball joints (D) are loose, they should be replaced. See your MacDon dealer or refer to the Technical Service Manual for replacement procedures. g. After replacing parts or making adjustments, perform checks for neutral interlock and steering c.
Page 134 MAINTENANCE/SERVICE 7.7.4.2 Steering Chain Tension DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine. a. Check steering for binding or excessive play which may be the result of the steering chain being too tight or too loose.
Page 135: Park Brake
MAINTENANCE/SERVICE d. Adjust switch (E) as follows: 7.7.5 PARK BRAKE The brake is applied when the interlock is fully engaged. To engage the interlock and hence the brake, the GSL must be in the N-DETENT position and the steering wheel centered. 7.7.5.1 Interlock Switch DANGER...
Page 136 MAINTENANCE/SERVICE Position switch support (C) inside console and push rubber nuts (D) into holes. g. Check operation of switch. h. Reinstall control panel (B) with five screws (A). Form 169469/169470/169471 Revision C...
Page 137: Hvac System
MAINTENANCE/SERVICE IMPORTANT 7.7.6 HVAC SYSTEM Air pressure must not exceed 100 psi (700 kPa). Do not direct air against 7.7.6.1 Fresh Air Intake Filter outside of element, as dirt might be forced through to inside. The fresh air filter is located under the right cab- forward side platform and should be serviced 4.
Page 138 MAINTENANCE/SERVICE 7.7.6.2 Return Air Cleaner 7.7.6.3 A/C Condenser The return air filter is located behind the The air conditioning condenser should be operator’s seat on the cab wall and should be cleaned daily with compressed air and more serviced every 100 hours as follows: frequent cleaning may be necessary in severe conditions.
Page 139 MAINTENANCE/SERVICE 7.7.6.5 A/C Compressor Protection The compressor is protected from excessively low and high pressures by two switches that shut down the compressor to prevent damage to the system. These switches do not require any regular servicing or maintenance, so if problems occur and the switches are suspect, contact your dealer.
Page 140: Engine
MAINTENANCE/SERVICE 7.8 ENGINE CAUTION • Never operate engine closed building. Proper ventilation is required to avoid exhaust gas hazards. • Keep the engine clean. Straw and chaff on a hot engine are a fire hazard. • Never use gasoline, naphtha or any other volatile material for cleaning purposes.
Page 141: Manually Turning Engine
MAINTENANCE/SERVICE 7.8.2 MANUALLY TURNING ENGINE To manually turn the engine with the flywheel, an access hole is provided on the left cab- forward side for a barring tool that is available from Cummins. Manually turn engine as follows: IMPORTANT Ensure nothing falls into gearbox oil reservoir.
Page 142: Oil Level
MAINTENANCE/SERVICE g. Add oil as follows if level is below the LOW 7.8.3 OIL LEVEL mark: One U.S. qt. (1 litre) is will raise the level from LOW to HIGH. Check engine oil level frequently and watch for any signs of leakage. CAUTION NOTE During the break-in period, a higher than...
Page 143: Changing Oil And Oil Filter
MAINTENANCE/SERVICE Screw the new filter onto the filter mount until 7.8.4 CHANGING OIL AND OIL FILTER the gasket contacts the filter head. k. Tighten the filter an additional ½ to ¾ turn by NOTE hand. The engine should be warm prior to changing the oil.
Page 144: Air Intake System
MAINTENANCE/SERVICE 7.8.5.1 Air Filter Servicing 7.8.5 AIR INTAKE SYSTEM IMPORTANT DANGER Do not run engine with air cleaner disconnected or disassembled. 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 145 MAINTENANCE/SERVICE Inspect as follows: 1. Hold a bright light inside element and check carefully for holes. Discard any element which shows the slightest hole. 2. Be sure outer screen is not dented. Vibration would quickly wear a hole in the filter. 3.
Page 146 MAINTENANCE/SERVICE p. To remove the secondary element (K), pull it out Check secondary element of the canister. cleanliness. If there is visible dirt on the Insert secondary filter element (K) into canister, secondary element, replace both primary and seal first, and push until seal is seated inside secondary elements.
Page 147 MAINTENANCE/SERVICE 7.8.5.2 Charge Air Cooling s. Position end cap (F) onto filter housing with After the intake air passes through the air filter, it aspirator pointing approximately down. passes through the turbocharger (J) which Align arrow (H) to unlock position on end cap boosts the pressure.
Page 148: Fuel System
MAINTENANCE/SERVICE 7.8.6 FUEL SYSTEM 7.8.6.2 Fuel Filters 7.8.6.1 Fuel Tank Venting 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 annually. Change the filter as follows: DANGER Stop engine and remove key from ignition before leaving operator's seat for any...
Page 149 MAINTENANCE/SERVICE b. Change primary filter (C) as follows: c. Change secondary filter (D) as follows: 1. Clean around the filter head (F). 1. Clean around the filter head (J). 2. Disconnect Water In Fuel (WIF) sensor (G) from bottom of filter. 2.
Page 150 MAINTENANCE/SERVICE 7.8.6.3 Draining Fuel Tank Draining the fuel tank is necessary to remove old or contaminated fuel. DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine.
Page 151 MAINTENANCE/SERVICE 7.8.6.4 Separator WARNING The fuel pump high-pressure fuel lines and fuel rail contain extremely high pressure fuel. Never loosen any fittings. Personal injury and property damage can result. IMPORTANT Bleeding fuel system recommended nor required. Manual priming will be required if: The fuel filter is replaced.
Page 152: Engine Cooling System
MAINTENANCE/SERVICE 7.8.7 ENGINE COOLING SYSTEM 7.8.7.1 Coolant Level and Concentration The engine cooling system is designed to maintain the engine operating temperature within the specified operating range. NOTE Anti-freeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and by raising its boiling point.
Page 153 MAINTENANCE/SERVICE 7.8.7.2 Radiator Cap 7.8.7.3 Changing Coolant Coolant should be drained, and the system WARNING flushed and filled with new coolant every 2000 hours or 2 years. Change coolant, and flush the avoid personal injury from • system as follows: coolant, do not turn radiator cap until engine has cooled.
Page 154 MAINTENANCE/SERVICE e. Place a drain pan (about 8 U.S. gallons (30 When system is drained, replace hose on valve litres)) under the engine and radiator. (C) and close radiator drain valve (B). Fill system with clean water through the radiator and replace radiator cap.
Page 155: Gearbox
MAINTENANCE/SERVICE b. Add lubricant as follows: 7.8.8 GEARBOX 1. Raise engine compartment hood to highest position. Section ENGINE 7.8.8.1 Lubricant Level COMPARTMENT HOOD. CAUTION Park on a flat, level surface, header on the ground and the ground speed lever in N- DETENT position.
Page 156 MAINTENANCE/SERVICE 7.8.8.2 Changing Lubricant Change gearbox lubricant after the first 50 hours and then at 500 hours as follows: NOTE The engine should be warm prior to changing the oil. a. Stop the engine and remove the key. b. Place a 1 U.S. gallon (4 litres) drain pan under the gearbox.
Page 157: Exhaust System
MAINTENANCE/SERVICE 7.8.9 EXHAUST SYSTEM CAUTION To avoid burns, do not touch muffler when engine running before allowing sufficient cooling time after shut-down exhaust system requires regular maintenance should inspected periodically as follows: a. Open engine compartment hood to highest position. Section ENGINE COMPARTMENT HOOD.
Page 158: Belts
MAINTENANCE/SERVICE 7.8.10 BELTS 7.8.10.2 A/C Compressor Belt Replacement a. Shutdown engine open engine DANGER compartment access hood to lowest level. Refer to illustration opposite. Stop engine and remove key from ignition b. Loosen compressor mounting hardware (B) and before leaving operator's seat for any push compressor towards engine to release reason.
Page 159 MAINTENANCE/SERVICE g. Remove belt in order 1-2-3 as shown. Route fan belt around fan and remove belt. h. Install new belt (D) around fan and onto pulleys in order 3-2-1. Insert the drive end of a ½ inch drive ratchet wrench into the belt tensioner (C).
Page 160: Engine Speed
MAINTENANCE/SERVICE 7.8.11 ENGINE SPEED The maximum and idle engine speeds are factory set to the specifications. See Section 4.2 Specifications. If specified speeds cannot be maintained, see your Windrower dealer. IMPORTANT Do not remove any seals from injector pump; removal of seals will void the engine warranty.
Page 161: Cooling Box
MAINTENANCE/SERVICE 7.9 COOLING BOX 7.9.1 COOLING BOX SCREEN The cooling box screen is equipped with an automatic cleaning device which "vacuums" the screen by means of two rotors. They only operate when the engine is running. The rotors are electrically driven and the suction is provided by the engine cooling fan.
Page 162: Rotor To Screen Clearance
MAINTENANCE AND SERVICE 7.9.2 ROTOR TO SCREEN CLEARANCE 0.04-0.32 in. (1-8 mm) c. Close screen access door (F) and engage latch (G). d. Lower engine compartment hood. a. Check clearance between trailing edge of rotor (A) and screen. It should be .04-.32 inches (1-8 mm) at all locations when rotating.
Page 163: Cooling Box Maintenance
MAINTENANCE/SERVICE 7.9.3 COOLING BOX MAINTENANCE The radiator and oil cooler should be cleaned daily with compressed air and more frequent cleaning may be necessary in severe conditions. The charge air cooler and air conditioning condenser may also be cleaned at the same time.
Page 164 MAINTENANCE AND SERVICE Clean radiator (O) through access holes in cooling box with compressed air. g. Lift latch (K) and open access door (L) at left side of cooling box. Clean oil cooler/A/C condenser (P), charge air cooler (Q), fuel cooler (R), and cooling box (S) with compressed air.
Page 165 MAINTENANCE/SERVICE p. Unhook support rod (C) in screen door and store in screen door. q. Close screen door (B) until latch engages pin (A). Lower hood and hood latch will lock hood. m. Close side access door (G), and lock with lever (F).
Page 166: Electrical System
MAINTENANCE AND SERVICE When working around storage batteries, • 7.10 ELECTRICAL SYSTEM remember that all of the exposed metal parts are "live". Never lay a metal object Electrical schematics are attached at the back of across the terminals because a spark or this manual.
Page 167 MAINTENANCE/SERVICE 7.10.1.3 Charging 7.10.1.4 Boosting CAUTION A twelve volt battery can be connected in parallel (+ to +) with the windrower battery. Use heavy duty battery cables. Ventilate the area where batteries are • being charged. CAUTION Do not charge a frozen battery. Warm to •...
Page 168 MAINTENANCE AND SERVICE 7.10.1.5 Adding Electrolyte WARNING Keep smoking • materials, sparks and flames away from electrolyte container and battery, as gas given electrolyte explosive. Battery electrolyte causes severe burns. • Avoid contact with skin, eyes or clothing. Wear protective eyewear and heavy gloves.
Page 169 MAINTENANCE/SERVICE e. Remove bolts (C) securing strap (D) to frame, 7.10.1.6 Replacing Battery and remove strap. Lift batteries off holder (E). CAUTION RATING GROUP CCA VOLT MAX. DIMENSION Do not attempt to service battery unless you Heavy Duty, have the proper equipment and experience Off-Road, 13x6.81x9.44 in.
Page 170 MAINTENANCE AND SERVICE 7.10.1.7 Preventing Electrical System Damage a. Carefully observe polarity when attaching booster battery. b. Do not short across battery or alternator terminals, or allow battery positive (+) cable or alternator wire to become grounded. c. Be sure alternator connections are correct before cables are connected to battery.
Page 171: Headlights: Engine-Forward
MAINTENANCE/SERVICE 7.10.2 HEADLIGHTS: ENGINE-FORWARD DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine. 49.75 in. (1263 mm) maximum NOTE Header should be attached and raised to maintain proper windrower stance.
Page 172 MAINTENANCE AND SERVICE g. Replace rubber insulator boot (D). c. Pinch the wire retainer (E) and lift away from h. Push connector onto light bulb. hooks. d. Remove bulb (F) 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.
Page 173: Field Lights: Cab-Forward
MAINTENANCE/SERVICE 7.10.3 FIELD LIGHTS: CAB-FORWARD 7.10.3.2 Bulb Replacement DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine. 7.10.3.1 Adjustment The field lights are best adjusted with the machine in the field or the equivalent to suit operator preference.
Page 174: Flood Lights - Forward
MAINTENANCE AND SERVICE IMPORTANT 7.10.4 FLOOD LIGHTS - FORWARD Do not touch the glass of the halogen bulb as the oils or other chemicals from your The forward floodlights are not adjustable. skin will cause the bulb to fail prematurely. Replace bulbs as follows: a.
Page 175: Flood Lights - Rear
MAINTENANCE/SERVICE c. Remove light from receptacle. 7.10.5 FLOOD LIGHTS - REAR DANGER Stop engine and remove key from ignition reason. A child or even a pet could engage an idling machine. 7.10.5.1 Adjustment The rear floodlights are best adjusted with the machine in the field or the equivalent to suit operator preference.
Page 176: Red And Amber Lights
MAINTENANCE AND SERVICE 7.10.6 RED AND AMBER LIGHTS 7.10.7 RED TAIL LIGHTS (IF INSTALLED) DANGER DANGER Stop engine and remove key from ignition Stop engine and remove key from ignition before leaving operator's seat for any before leaving operator's seat for any reason.
Page 177: Beacons (If Installed)
MAINTENANCE/SERVICE 7.10.8 BEACONS (IF INSTALLED) a. Shutdown engine and remove the key. Turn off the beacons. c. Pinch retainer and remove it from lamp socket. d. Pull lamp out of socket. NOTE Hold onto the hand-holds on the cab front corners and stand on the header anti-slip strips or stand on the maintenance platform when accessing the red and...
Page 178 MAINTENANCE AND SERVICE 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. h. Line up the three lugs (one is longer) in the base with slots in lens and seat the lens against the rubber seal.
Page 179: Gauge Light
MAINTENANCE/SERVICE 7.10.9 GAUGE LIGHT 7.10.10 DOME LIGHT a. Shutdown engine. a. Shutdown engine and remove the key. Turn off the lights. b. Remove two screws (E) from plastic lens and remove lens. c. Replace bulb. d. Reinstall plastic lens with screws (E). 7.10.11 AMBIENT LIGHT a.
Page 180: Circuit Breakers And Fuses
MAINTENANCE AND SERVICE 7.10.13 CIRCUIT BREAKERS AND 7.10.13.1 Checking/Replacing Fuses FUSES DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine. The circuit breakers and fuses are located inside the fuse box that is mounted on the frame under the right cab-forward side platform.
Page 181 MAINTENANCE/SERVICE 7.10.13.3 Fuse Box Decal Form 169469/169470/169471 Revision C...
Page 182 MAINTENANCE AND SERVICE 7.10.13.4 Main Fuses - 125 Amp The 125 amp main fuse holders are located on the frame under the right cab-forward side platform beside the battery. Access the fuses as follows: DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason.
Page 183: Hydraulic System
MAINTENANCE/SERVICE 7.11.1 OIL LEVEL 7.11 HYDRAULIC SYSTEM Check hydraulic oil level daily as follows: The M205 Windrower hydraulic system provides oil for the windrower drive system, and header DANGER lift and drive systems. Stop engine and remove key from ignition WARNING before leaving operator's seat for any reason.
Page 184: Hydraulic Oil Cooler
MAINTENANCE AND SERVICE 7.11.4 HYDRAULIC OIL FILTERS Change hydraulic oil filters as follows: DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason. A child or even a pet could engage an idling machine. 7.11.4.1 Lift Filter g.
Page 185 MAINTENANCE/SERVICE 7.11.4.2 Charge Filter 7.11.4.3 Return Filter NOTE NOTE Change hydraulic oil filter after the first 50 The return filter is a part of the hydraulics hours of operation and every 500 hours package required to run a draper or auger thereafter.
Page 186: Header And Reel Hydraulics
MAINTENANCE AND SERVICE An optional load sensor may be installed to warn 7.11.5 HEADER AND REEL HYDRAULICS the operator that the system pressure is approaching an overload condition, by a tone 7.11.5.1 Relief Valves and flashing the pressure reading. The load will continue to rise if the operator does not reduce The pressure relief valves are pre-set for all ground speed and the relief valve opens at the...
Page 187 MAINTENANCE/SERVICE 7.11.5.3 Header Drop Rate The header should lower gradually when the lower header switch is pressed. From full height to ground should take approximately 3.5 seconds. Adjust as follows: DANGER Stop engine and remove key from ignition before leaving operator's seat for any reason.
Page 188: Traction Drive Hydraulics
If charge pressure still cannot be maintained, do e. If pressure is not within this range, see your not operate the windrower. Contact your MacDon dealer or refer to the Technical Service windrower dealer. Manual. Form 169469/169470/169471 Revision C...
Page 189: Hoses And Lines
MAINTENANCE/SERVICE 7.11.7 HOSES AND LINES Check hydraulic hoses and lines daily for signs of leaks. WARNING Avoid high-pressure fluids. Escaping fluid can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin- holes and nozzles which eject...
Page 190: Wheels And Tires
MAINTENANCE AND SERVICE 7.12 WHEELS AND TIRES 7.12.1 DRIVE WHEELS 7.12.1.1 Tire Inflation a. Visually check daily that tires have not lost pressure. Under-inflation of drive tires can cause side wall cracks. DANGER To avoid severe personal injury or death caused by machine runaway, shut off engine and remove key before performing any of the following checks and/or adjustments.
Page 191 MAINTENANCE/SERVICE b. Change the lubricant as follows: 7.12.1.3 Lubricant The drive wheel gearbox lubricant should be changed after the first 50 hours. Check the level every 200 hours or annually and change every 1000 hours. The windrower should be on level ground when checking lubricant level.
Page 192 MAINTENANCE AND SERVICE To install new tire, ensure that air valves are on 7.12.1.4 Drive Wheel Removal/Installation outside and tire tread point forward. For "Turf” tires (diamond tread), be sure arrow on sidewall DANGER points in forward rotation. To avoid severe personal injury or death caused by machine runaway, shut off engine and remove key before performing any of the following checks and/or adjustments.
Page 193: Caster Wheels
MAINTENANCE/SERVICE 7.12.2 CASTER WHEELS 7.12.2.1 Tire Inflation a. Visually check daily that tires have not lost pressure. Under-inflation of drive tires can cause side wall cracks. DANGER To avoid severe personal injury or death caused by machine runaway, shut off engine and remove key before performing any of the following checks and/or adjustments.
Page 194 MAINTENANCE AND SERVICE FLUID PER TIRE TOTAL WEIGHT TIRE SIZE AT 75% FILL OF BOTH TIRES 7.12.2.2 Ballast Requirements U.S. Gal. (Liters) lb (kg) * Fluid ballasting rear caster tires 7.5X16 10 (38) 200 (91) recommended to provide adequate machine 10X16 stability when using large headers on the 18 (69)
Page 195 MAINTENANCE/SERVICE 7.12.2.3 Wheel Nut Torque 7.12.2.4 Forked Caster Wheel Removal/Installation At first use, or when a wheel is removed, check caster wheel bolt torque as follows after 5 hours DANGER and then at 200 hour intervals: NOTE To avoid severe personal injury or death To avoid damage to wheel rims, do not caused by machine runaway, shut off engine over-tighten wheel nuts.
Page 196 MAINTENANCE AND SERVICE 7.12.2.5 Formed Caster Wheel 7.12.2.6 Caster Wheels Anti-Shimmy Removal/Installation Dampeners DANGER To avoid severe personal injury or death caused by machine runaway, shut off engine and remove key before performing any of the following checks and/or adjustments. a.
Page 197: Maintenance Schedule
MAINTENANCE/SERVICE IMPORTANT 7.13 MAINTENANCE SCHEDULE Recommended intervals are for average conditions. Service the machine more The maintenance schedule (see next page) often if operated under adverse conditions specifies the periodic maintenance procedures (severe dust, extra heavy loads, etc.). and service intervals. Regular maintenance is the best insurance against early wear and CAUTION untimely breakdowns.
Page 198: Interval Maintenance
MAINTENANCE AND SERVICE 7.13.2 INTERVAL MAINTENANCE INTERVAL SERVICE FIRST USE Refer To BREAK-IN INSPECTIONS (previous page). 1. Change Fuel Tank Vent Line Filter. 2. Check Battery Fluid Level. 3. Check Battery Charge. ANNUALLY * 4. Check Anti-Freeze Concentration. 5. Cycle A/C Blower Switch To Distribute Refrigerant Oil. 6.
Page 199 MAINTENANCE/SERVICE WINDROWER Serial N0._______________ Combine this record with the record in the Header Operator’s Manual. Refer to Section 7, MAINTENANCE AND SERVICE for details on each maintenance procedure. Copy this page to continue record. ACTION:  - Check  - Lubricate ...
Page 200 MAINTENANCE AND SERVICE ACTION:  - Check  - Lubricate  - Change  - Clean + - Add Hour Meter Reading Date Serviced By 500 HOURS Engine Oil and Filter (or Annually)  Fuel Filters   Gearbox Lubricant Charge System and Return (if applicable) Hydraulic ...
Page 201: Troubleshooting
Crankcase oil too light. Use recommended oil. 7.3.1.3 Consumption. Check for leaks around gaskets, seals, and Oil leaks 7.8.4 drain plugs. Internal parts worn. Contact MacDon dealer. See your MacDon dealer ** Refer to Windrower Technical Manual Form 169469/169470/169471 Revision C...
Page 202 Defective temperature gauge or sender. thermometer, replace gauge if necessary. Defective water pump. Contact MacDon dealer. Water only for coolant. Replace with antifreeze. 7.8.7 (continued next page) See your MacDon dealer ** Refer to Windrower Technical Manual Form 169469/169470/169471 Revision A...
Page 203 Switch at interlock not closed or defective. Adjust switch or replace. Air Filters Require Vacuator plugged. Clean out vacuator. 7.8.5.1 Frequent Pre-cleaner rotor not turning freely. Repair/replace. 7.9.1 Cleaning. See your MacDon dealer ** Refer to Windrower Technical Manual Form 169469/169470/169471 Revision C...
Page 204: Electrical
Check/clean cooling box. Temp Alarm. properly. Faulty bypass valve. Clean or replace. Hydraulic Oil Lo- Hydraulic oil too cold. Run engine until hydraulic oil warms up. Temp Alarm. See your MacDon dealer ** Refer to Windrower Technical Manual Form 169469/169470/169471 Revision A...
Page 205: Header Drive
Pump arms have broken shaft or Repair or tighten. loose hardware. Check pressure (min. 200 psi Brakes binding or not releasing fully. (1379 kPa)) on brake release valve. (continued next page) See your MacDon dealer ** Refer to Windrower Technical Manual Form 169469/169470/169471 Revision C...
Page 206: Steering And Ground Speed Control
Speed-range control in field 6.3.8.1 Move to road position. position. Steering Wheel Will Not Lock Transmission interlock misadjusted. Contact MacDon dealer. With GSL In N-DETENT. (continued next page) See your MacDon dealer ** Refer to Windrower Technical Manual Form 169469/169470/169471 Revision A...
Page 207: Cab Air
Broken or disconnected electrical wire. connections; check wiring for hidden breaks. Check ground wire to see if loose, Broken or disconnected ground wire. broken, or disconnected. (continued next page) See your MacDon dealer ** Refer to Windrower Technical Manual Form 169469/169470/169471 Revision C...
Page 208 Blower fan noisy due to excessive wear. or replacement as necessary. Excessive charge in system. Low charge in system. Contact MacDon dealer. Excessive moisture in system. (continued next page) See your MacDon dealer ** Refer to Windrower Technical Manual Form 169469/169470/169471 Revision A...
Page 209: Operator's Station
SOLUTION SECTION Rough Ride. Seat suspension not adjusted for operator's Adjust seat suspension. weight. 7.12.1 & High air pressure in tires. Deflate to proper pressure. 7.12.2 See your MacDon dealer ** Refer to Windrower Technical Manual Form 169469/169470/169471 Revision C...
Page 210: Options / Attachments
9.7 INTERNAL BOOSTER SPRING KIT 9.16 AUTO-STEER Internal spring for right side lift linkage to improve float capacity. Standard equipment on A MacDon approved auto-steer system is left side. available from your dealer, who is set up to provide installation and support services.
Page 211: Lighting And Marking Kit For Cab-Forward Road Travel
OPTIONS / ATTACHMENTS 9.17 LIGHTING AND MARKING KIT FOR CAB-FORWARD ROAD TRAVEL Allows the windrower to travel in the cab-forward mode on public roads and comply with vehicle lighting regulations. The kit includes red tail- lights, SMV markings, hardware, and installation instructions.
Page 212: Index
INDEX Abbreviations ..............14 Daily check ..............56 Air Cleaner ..............139 Deck Shift Switch ............34 Air Conditioning Definitions ............... 14 compressor belt ............153 Disc Header compressor protection ........27, 134 attachment ..............110 condenser ............133, 158 detaching ..............113 controls ..............
Page 213: Engine Error Codes
INDEX troubleshooting ............196 float switch ..............34 voltage ................ 60 flotation ............... 80 warm-up ..............58 functions ..............35 warning lights ............43, 60 height control .............. 87 Engine Cooling System ..........147 levelling ..............83 changing coolant ............148 lift cylinder stops ............
Page 214 INDEX Operating Screens ............36 fuel and lubricants ............ 117 Operator's Console ............20 windrower ..............78 Operator's Presence ............21 Symbol Definitions............53 checks ..............126 Tail Lights engine ................ 21 bulb replace .............. 171 header drive ............... 21 replace ..............171 transmission ..............
Page 215 CDM / WCM ENGINE ERROR CODES CDM Error Codes for the M150 / 200 Tractor units R A N G E N O T A L L O W E D HIGH range activated while in Cab forward (M150). R T C N O T A L L O W E D Return To Cut activated with the header off.
Page 216 M205 ENGINE ERROR CODES 110S 16F 28C Example: CDM displays the Error Code 110S – S STEP 1. column, then locate code in that column STEP 2. – is the column, then locate code in that column. STEP 3. – is occurrences, is the quantity.
Page 217 M205 ENGINE ERROR CODES Cummins J1939 SPN J1939 J1939 Lamp Engine Description Description Color Code Oil Pressure Low – Data Valid but Below Normal Operational Range - Most Severe Level Amber Oil Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect Oil Pressure Sensor Circuit - Voltage Above Normal, or Shorted to Amber High Source...
Page 218 M205 ENGINE ERROR CODES Cummins J1939 SPN J1939 J1939 Lamp Engine Description Description Color Code Fuel Pressure High - Data Valid but Above Normal Operational Range – Moderately Severe Level Injector Metering Rail 1 Pressure - Data Valid but Below Normal Amber 2249 Operational Range - Most Severe Level...
Page 219 M205 ENGINE ERROR CODES Cummins J1939 SPN J1939 J1939 Lamp Engine Description Description Color Code Auxiliary Temperature Sensor Input # 1 Circuit - Special Instructions Accelerator Pedal or Lever Idle Validation Circuit - Data Erratic, Amber Intermittent, or Incorrect Accelerator Data erratic, intermittent, or incorrect Pedal Low Idle Accelerator Pedal or Lever Idle Validation Circuit - Voltage Below...
Page 220 M205 ENGINE ERROR CODES Cummins J1939 SPN J1939 J1939 Lamp Engine Description Description Color Code Injector Current High Injector Cylinder #3 - Mechanical System Not Responding Properly Amber 1142 or Out of Adjustment Injector Solenoid Cylinder #4 Circuit – Current Below Normal, or Amber Open Circuit Injector...
Page 221 M205 ENGINE ERROR CODES Cummins J1939 SPN J1939 J1939 Lamp Engine Description Description Color Code Exhaust Gas Pressure Sensor Circuit - Voltage Above Normal, or Amber 2373 Exhaust Gas Shorted to High Source 1209 Pressure Exhaust Gas Pressure Sensor Circuit - Voltage Below Normal, or Amber 2374 Shorted to Low Source...

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