MacDon M 2009 Series User manual

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

Form 169242 2Revision E
MACDON M SERIES SELF-PROPELLED WINDROWER

Form 169542 3Revision F
INTRODUCTION
This instructional manual describes the unloading, set-up and pre-delivery requirements for the MacDon 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.

TABLE OF CONTENTS
Form 169542 4Revision F
INTRODUCTION........................................................................................................................................................3
GENERAL SAFETY ..................................................................................................................................................6
RECOMMENDED TORQUES ...................................................................................................................................8
A.GENERAL ...........................................................................................................................................8
B.SAE BOLTS.........................................................................................................................................8
C.METRIC BOLTS..................................................................................................................................8
D.FLARE TYPE HYDRAULIC FITTINGS...............................................................................................9
E.O-RING BOSS (ORB) HYDRAULIC FITTINGS..................................................................................9
F.O-RING FACE SEAL (ORFS) HYDRAULIC FITTINGS....................................................................10
CONVERSION CHART ...........................................................................................................................................11
DEFINITIONS...........................................................................................................................................................11
STEP 1.UNLOAD CONTAINER .........................................................................................................................12
STEP 2.MOVE TO ASSEMBLY AREA ..............................................................................................................13
STEP 2.MOVE TO ASSEMBLY AREA ..............................................................................................................13
A.CRANE METHOD.............................................................................................................................13
B.FORKLIFT METHOD ........................................................................................................................14
STEP 3.REMOVE WHEEL AND STEP ASSEMBLY .........................................................................................15
STEP 4.REMOVE DRIVE WHEELS ...................................................................................................................17
STEP 5.REMOVE PLATFORMS ........................................................................................................................18
STEP 6.REMOVE HAND RAILS AND EXHAUST STACK................................................................................19
STEP 7.REMOVE LEG ASSEMBLIES...............................................................................................................20
STEP 8.REMOVE WHEEL AND PLATFORM SUPPORT .................................................................................21
STEP 9.ASSEMBLE WINDROWER SUPPORT STAND...................................................................................21
STEP 10.LIFT WINDROWER ONTO STAND ......................................................................................................22
A.CRANE METHOD.............................................................................................................................22
B.FORKLIFT METHOD ........................................................................................................................23
STEP 11.INSTALL LEGS .....................................................................................................................................24
STEP 12.INSTALL FRONT WHEELS ..................................................................................................................26
STEP 13.INSTALL CASTER WHEELS................................................................................................................28
STEP 14.INSTALL HYDRAULICS .......................................................................................................................30
A.M205..................................................................................................................................................30
B.M155..................................................................................................................................................33
C.M105..................................................................................................................................................37
STEP 15.INSTALL PLATFORMS.........................................................................................................................40
STEP 16.INSTALL STEPS ...................................................................................................................................42
STEP 17.INSTALL EXHAUST STACK ................................................................................................................43
A.M205..................................................................................................................................................43
B.M155, M105.......................................................................................................................................44
STEP 18.POSITION LIGHT AND MIRROR ASSEMBLIES.................................................................................45
STEP 19.INSTALL BATTERIES...........................................................................................................................46
A.M205, M155.......................................................................................................................................46
B.M105..................................................................................................................................................47
STEP 20.PRIME HYDRAULIC SYSTEM..............................................................................................................48
A.M205..................................................................................................................................................48
B.M155..................................................................................................................................................49
C.M105..................................................................................................................................................51

TABLE OF CONTENTS
Form 169542 5Revision F
STEP 21.START ENGINE.....................................................................................................................................53
STEP 22.CHECK TRACTION DRIVE...................................................................................................................54
STEP 23.REMOVE WINDROWER FROM STAND..............................................................................................55
A.FACTORY STAND............................................................................................................................55
B.FIELD-CONSTRUCTED STAND......................................................................................................55
STEP 24.INSTALL AM/FM RADIO.......................................................................................................................56
STEP 25.INSTALL BEACONS.............................................................................................................................58
STEP 26.INSTALL SLOW MOVING VEHICLE (SMV) SIGN...............................................................................59
STEP 27.ATTACH HEADER ................................................................................................................................60
A.M205..................................................................................................................................................60
I.HEADER ATTACHMENT - D SERIES ....................................................................................... 60
II.HEADER ATTACHMENT - A SERIES ....................................................................................... 63
III.HEADER ATTACHMENT - R SERIES ....................................................................................... 66
B.M155, M105 ......................................................................................................................................69
I.HEADER ATTACHMENT: A SERIES ........................................................................................ 75
II.HEADER ATTACHMENT: R SERIES (M155 ONLY) ................................................................. 81
STEP 28. LUBRICATE MACHINE.........................................................................................................................86
STEP 29.PROGRAM CAB DISPLAY MODULE (CDM).......................................................................................88
A.M205, M155 DETAILED PROGRAMMING INSTRUCTIONS ..........................................................89
B.M105 DETAILED PROGRAMMING INSTRUCTIONS .....................................................................95
STEP 30.PERFORM HYDRAULIC PURGE.......................................................................................................100
STEP 31.PERFORM PRE-DELIVERY CHECKS ...............................................................................................102
A.FINAL DRIVE LUBRICANT LEVEL ................................................................................................102
B.TIRE PRESSURES AND BALLAST REQUIREMENTS.................................................................102
I.Tire Pressures ........................................................................................................................... 102
II.Ballast Requirements ................................................................................................................ 102
C.ENGINE AIR INTAKE......................................................................................................................104
D.HYDRAULIC OIL LEVEL.................................................................................................................105
E.FUEL SEPARATOR........................................................................................................................105
F.ENGINE COOLANT........................................................................................................................105
G.GEAR BOX LUBRICANT LEVEL....................................................................................................106
H.A/C COMPRESSOR BELT .............................................................................................................106
I.PERFORM SAFETY SYSTEM CHECKS .......................................................................................107
J.OPERATIONAL CHECKS...............................................................................................................108
I.Engine Warning Lights .............................................................................................................. 108
II.Start Engine .............................................................................................................................. 108
III.Engine Speed ........................................................................................................................... 108
IV.Gauges and CDM Display ........................................................................................................ 109
V.Electrical ................................................................................................................................... 109
VI.Operator’s Presence System Checks ....................................................................................... 110
VII.Exterior Lights ........................................................................................................................... 111
VIII.Interior Lights ............................................................................................................................ 114
IX.A/C and Heater ......................................................................................................................... 115
K.MANUALS.......................................................................................................................................116
L.CAB INTERIOR...............................................................................................................................116

Form 169542 6Revision F
GENERAL SAFETY
CAUTION
The following are general farm safety
precautions that should be part of your
operating procedure for all types of machinery.
 Protect yourself.
 When assembling, operating and servicing
machinery, wear all the protective clothing
and personal safety devices that COULD
be necessary for the job at hand. Don't
take chances.
 You may need:
o a hard hat.
o protective shoes with slip resistant
soles.
o protective glasses or goggles.
o heavy gloves.
o wet weather gear.
o respirator or filter mask.
o hearing protection. Be aware that
prolonged exposure to loud noise
can cause impairment or loss of
hearing. Wearing a suitable
hearing protective device such as
ear muffs (A) or ear plugs (B)
protects against objectionable or
loud noises.
 Provide a first-aid kit for use in case of
emergencies.
 Keep a fire extinguisher on the machine.
Be sure the extinguisher is properly
maintained and be familiar with its proper
use.
 Keep young children away from machinery
at all times.
 Be aware that accidents often happen
when the Operator is tired or in a hurry to
get finished. Take the time to consider the
safest way. Never ignore warning signs of
fatigue.
 Wear close-fitting clothing
and cover long hair. Never
wear dangling items such
as scarves or bracelets.
 Keep hands, feet, clothing
and hair away from
moving parts.
 Never attempt to clear obstructions or
objects from a machinewhile the engine is
running.
 Keep all shields in place. Never alter or
remove safety equipment. Make sure
driveline guards can rotate independently
of the shaft and can telescope freely.
 Use only service and repair parts made or
approved by the equipment manufacturer.
Substituted parts may not meet strength,
design, or safety requirements.
(continued next page)
A
B

Form 169542 7Revision F
 Do not modify the machine. Unauthorized
modifications may impair the function
and/or safety and affect machine life.
 Stop engine, and remove keyfrom ignition
before leaving Operator's seat for any
reason. A child or even a pet could engage
an idling machine.
 Keep the area used for servicing
machinery clean and dry. Wet or oily floors
are slippery. Wet spots can be dangerous
when working with electrical equipment.
Be sure all electrical outlets and tools are
properly grounded.
 Use adequate light for the job at hand.
 Keep machinery clean. Do not allow oil or
grease to accumulateon serviceplatforms,
ladders or controls. Clean machines before
storage.
 Never use gasoline, naphthaor anyvolatile
material for cleaning purposes. These
materials may be toxic and/or flammable.
 When storing machinery, cover sharp or
extending components to prevent injury
from accidental contact.

Form 169542 8Revision F
RECOMMENDED TORQUES
A. GENERAL
The tables shown below give correct torque
values for various bolts and capscrews.
 Tighten all bolts to the to rques specified in
chart (unless otherwise noted throughout this
manual).
 Check tightness of bolts periodically, using
bolt torque chart as a guide.
 Replace hardware with the sa me strength
bolt.
 Torque figures are valid for non -greased or
non-oiled threads and heads unless otherwise
specified. Do not grease or oil bolts or
capscrews unless specified in this manual.
 When using locking elements, increase torque
values by 5%.
B. SAE BOLTS
BOLT
DIA. "A"
in.
NC BOLT TORQUE*
SAE-5 SAE-8
ft·lbf N·m ft·lbf N·m
1/4 9 12 11 15
5/16 18 24 25 34
3/8 32 43 41 56
7/16 50 68 70 95
1/2 75 102 105 142
9/16 110 149 149 202
5/8 150 203 200 271
3/4 265 359 365 495
7/8 420 569 600 813
1 640 867 890 1205
* Torque categories for bolts and capscrews are identified by their
head markings.
C.METRIC BOLTS
BOLT
DIA. "A"
STD COARSE BOLT TORQUE*
8.8 10.9
ft·lbf N·m ft·lbf N·m
M3 0.4 0.5 1.3 1.8
M4 2.2 3 3.3 4.5
M5 4 6 7 9
M6 7 10 11 15
M8 18 25 26 35
M10 37 50 52 70
M12 66 90 92 125
M14 103 140 148 200
M16 166 225 229 310
M20 321 435 450 610
M24 553 750 774 1050
M30 1103 1495 1550 2100
M36 1917 2600 2710 3675
* Torque categories for bolts and capscrews are identified by their
head markings.
SAE-5 SAE-8

Form 169542 9Revision F
D.FLARE TYPE HYDRAULIC FITTINGS
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
until snug.
d. To prevent twisting th e tube(s), use t wo
wrenches. Place one wrench on the connector
body, and with the second, tighten the swivel nut
to the torque shown.
SAE
NO.
TUBE
SIZE
O.D.
(in.)
THD
SIZE
(in.)
NUT
SIZE
ACROSS
FLATS
(in.)
TORQUE
VALUE*
RECOMMENDED
TURNS TO
TIGHTEN
(AFTER FINGER
TIGHTENING)
ft·lbf N·m Flats Turns
3 3/16 3/8 7/16 6 8 1 1/6
4 1/4 7/16 9/16 9 12 1 1/6
5 5/16 1/2 5/8 12 16 1 1/6
6 3/8 9/16 11/16 18 24 1 1/6
8 1/2 3/4 7/8 34 46 1 1/6
10 5/8 7/8 1 46 62 1 1/6
12 3/4 1-1/16 1-1/4 75 102 3/4 1/8
14 7/8 1-3/8 1-3/8 90 122 3/4 1/8
16 1 1-5/16 1-1/2 105 142 3/4 1/8
* Torque values shown are based on lubricated connections as in
re-assembly.
E. O-RING BOSS (ORB) HYDRAULIC
FITTINGS
a. Inspect O-ring and seat for dirt or obvious
defects.
b. On angle fittings, back off the lock nut until
washer (A) bottoms out at top of groove (B) in
fitting.
c. Hand-tighten fitting until back up washer (A) or
washer face (if straight fitting) bottoms on part
face (C) and O-ring is seated.
d. Position angle fittings by unscrewing no more
than one turn.
e. Tighten straight fittings to torque shown.
f. Tighten angle fittings to torque shown in the
following table, while holding body of fitting with a
wrench.
SAE
NO.
THD
SIZE
(in.)
NUT SIZE
ACROSS
FLATS
(in.)
TORQUE
VALUE*
RECOMMENDED
TURNS TO TIGHTEN
(AFTER FINGER
TIGHTENING)
ft·lb
f
N·m Flats Turns
3 3/8 1/2 6 8 2 1/3
4 7/16 9/16 9 12 2 1/3
5 1/2 5/8 12 16 2 1/3
6 9/16 11/16 18 24 2 1/3
8 3/4 7/8 34 46 2 1/3
10 7/8 1 46 62 1-1/2 1/4
12 1-1/16 1-1/4 75 102 1 1/6
14 1-3/16 1-3/8 90 122 1 1/6
16 1-5/16 1-1/2 105 142 3/4 1/8
20 1-5/8 1-7/8 140 190 3/4 1/8
24 1-7/8 2-1/8 160 217 1/2 1/12
* Torque values shown are based on lubricated connections as in
re-assembly.
FLARE
FLARESEAT BODY
NUT
A
BC
LOCKNUT
SE
A
T
WASHE
R
O-RING
GROOVE
FITTING

Form 169542 10 Revision F
F. O-RING FACE SEAL (ORFS)
HYDRAULIC FITTINGS
* Torque values and angles sho wn are based on lubricated
connection, as in re-assembly.
** Alw ays default to the torque value for evalu ation of adequat e
torque
*** O-ring face seal type end not defined for this tube size.
a. Check components to en sure that the sealin g
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.
c. Align the tube or hose assembly. Ensure that flat
face of the m ating flange comes in full contact
with O-ring.
d. Thread tube or hose nut until hand-tight. The nut
should turn freely until it is bottomed out. Torque
fitting further to the specified number of F.F.F.T
(“Flats From Finger Tight”), or to a given torque
value in the table shown in the opposite column.
NOTE
If available, always hold the hex on the
fitting body to prevent unwanted
rotation of fitting body and hose when
tightening the fitting nut.
e. When assembling unions or two hoses together,
three wrenches will be required.
SAE
NO.
THD
SIZE
(in.)
TUBE
O.D.
(in.)
TORQUE VALUE*
RECOMMENDED
TURNS TO
TIGHTEN
(AFTER FINGER
TIGHTENING)**
ft·lbf N·m Tube
Nuts Swivel & Hose
3 *** 3/16 --- --- --- ---
4 9/16 1/4 11–12 14–16 1/4 -1/2 1/2–3/4
5 *** 5/16 --- --- --- ---
6 11/16 3/8 18–20 24–27
1/4–1/2
1/2–3/4
8 13/16 1/2 32–35 43–47
10 1 5/8 45–51 60–68
12
1-3/16
3/4
67–71 90–95
1/3–1/2
14 7/8
16 1-7/16 1 93–100 125–135
20 1-11/16 1-1/4 126–141 170–190
24 2 1-1/2 148–167 200–225
32 2-1/2 2 --- --- --- ---

Form 169542 11 Revision F
CONVERSION CHART
QUANTITY INCH-POUND UNITS FACTOR SI UNITS (METRIC)
UNIT NAME ABBR. UNIT NAME ABBR.
Area acres acres x 0.4047 = hectares ha
Flow US gallons per minute (gpm) x 3.7854 = liters per minute L/min
Force pounds force lbf x 4.4482 = Newtons N
Length inch in. x 25.4 = millimeters mm
foot ft x 0.305 = meters m
Power horsepower hp x 0.7457 = kilowatts kW
Pressure pounds per square inch psi x 6.8948 = kilopascals kPa
x .00689 = megapascals MPa
Torque pound feet or foot pounds lbf·ft or ft·lbf x 1.3558 = newton meters N·m
pound inches or inch pounds lbf·in. or in·lbf x 0.1129 = newton meters N·m
Temperature degrees Fahrenheit °F (°F - 32) x 0.56 = Celsius °C
Velocity
feet per minute ft/min x 0.3048 = meters per minute m/min
feet per second ft/s x 0.3048 = meters per second m/s
miles per hour mph x 1.6063 = kilometers per hour km/h
Volume
US gallons US gal. x 3.7854 = liters L
ounces oz. x 29.5735 = milliliters ml
cubic inches in.3 x 16.3871 = cubic centimeters cm3 or cc
Weight pounds lb x 0.4536 = kilograms kg
DEFINITIONS
TERM DEFINITION
API American Petroleum Institute
ASTM American Society of Testing And Materials
Cab-Forward Windrower operation with the Operator and the cab facing in the direction of travel.
CDM Cab Display Module
DWA Double Windrow Attachment
Engine-Forward Windrower operation with the Operator and the engine facing in the direction of travel.
ISC Integrated Speed Control
N-DETENT The slot opposite the NEUTRAL position on Operator’s console.
rpm revolutions per minute
SAE Society Of Automotive Engineers
WCM Windrower Control Module
Windrower Windrower with header attached.
Windrower Tractor Power unit only. (Windrower without the header attached)

UNLOADING AND ASSEMBLY
Form 169542 12 Revision F
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. Open container doors, and remove all blocking.
d. Check container floor for nails or other
obstructions, and remove if necessary.
e. Position platform or ramp at container opening.
f. Attach chain/pull strap to slots in support
channels (as shown).
g. Slowly pull windrower from co ntainer onto
platform.

UNLOADING AND ASSEMBLY
Form 169542 13 Revision F
STEP 2. MOVE TO ASSEMBLY
AREA
A. CRANE 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
exceed the requirements specified below.
Using inadequate equipment may result in
chain breakage, vehicle tipping or machine
damage.
LIFTING VEHICLE
Minimum Lifting
Capacity 20,000 lb
(9072 kg)
CHAIN
Type Overhead 1/2 in.
Lifting Quality
Minimum Working Load 7,100 lb
(3221 kg)
a. Attach chains or cable to the four lift points on the
lifting frame (MacDon Part # 1638 71) and
connect loop ends to crane hook. Use cable or
chain with a minimum lifting capacity of 7,100 lb
(3221 kg).
b. Attach lifting frame asse mbly (MacDon Part
#163871) to the four designated lift po ints on
windrower shipping frame.
c. Lift windrower off platform , and move to setup
area.
d. Lower assembly onto 5 –6 inch (1 27–152 mm)
blocks as shown.
e. Remove chains from shipping frame.
f. Check for shipping damage and missing parts.
83.5 in. (2120 mm) TYP.
59 in. (1500 mm) MIN.

UNLOADING AND ASSEMBLY
Form 169542 14 Revision F
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
exceed the requirements specified below.
Using inadequate equipment may result in
chain breakage, vehicle tipping or machine
damage.
LIFTING VEHICLE
Minimum Lifting Capacity * 20,000 lb
(9072 kg)
* At 48 inches (1220 mm) from back end of forks.
IMPORTANT
Forklifts are normally rated for a lo ad
located 24 inches (610 mm) ahead of
back end of the forks.
To obtain the forklift capa city at
48 inches (1220 mm), check with your
forklift distributor.
WARNING
Be sure forks are secure before moving away
from load. Stand clear when lifting.
a. Approach windrower from the h ood end, and
slide forks underneath lifting framework.
b. Raise windrower off platform, and move to
assembly area.
c. Lower assembly onto 5 –6 inch (127–152 mm)
blocks (as shown above).
d. Check for shipping damage and missing parts.

UNLOADING AND ASSEMBLY
Form 169542 15 Revision F
STEP 3. REMOVE WHEEL AND
STEP ASSEMBLY
a. Remove shipping wire and bolt se curing hose
support to shippin g frame, and rem ove hose
support.
b. Lay hose support off to the side.
c. Remove the two 3/4 in. x 16.5 long bolts (one per
side) at front fram e beam. Retain for
re-installation.
d. Remove the 1 inch (2 5.4 mm) pin at the
center-link.
e. Remove the four (two per side) carriage bolts at
the rear of the wheel/step assembly.
f. Remove plastic cable tie and shipping wire
securing hose bundles to frame.
(continued next page)

UNLOADING AND ASSEMBLY
Form 169542 16 Revision F
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.
i. Re-install leg bolts, washers, and nuts to secure
the lifting plate onto the mainframe.

UNLOADING AND ASSEMBLY
Form 169542 17 Revision F
STEP 4. REMOVE DRIVE
WHEELS
IMPORTANT
Remove the drive wheels as a pair from
above the hood.
a. Remove the two bolts at front cross member over
the hood.
b. Remove one bolt at rear of hood directly under
center of drive wheel.
c. Attach a lifting device to lift hooks located in the
center of each drive wheel.
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. Chain on forward
wheel should be snug and loose on the
aft wheel.
e. Set wheels aside for later installation.

UNLOADING AND ASSEMBLY
Form 169542 18 Revision F
STEP 5. REMOVE PLATFORMS
a. Remove the two support tubes on either side of
hood.
b. To prevent paint damage, attach two slings and a
chain to platf orm at l ocations shown, and to a
lifting device with a minimum lifting cap acity of
5,000 lb (2268 kg), and a lift height of 13 feet
(4 m).
c. Remove two 5/8 in. x 5.0 bolts at top of vertical
supports, and two 5/8 in. x 1.25 bolts at taching
angle braces to platforms.
NOTE
The M105 windrower is equipped with
only one platform.
d. Carefully lift platform off frame.
e. Back away from windrower, and set assembly on
a level surface.
f. Unhook one sling and chain.
g. Lift end of assembly so that it can be inverted
and laid down again, base on the floor. Use a
piece of cardboard under platform to protect the
paint.
h. Unhook remaining sling.

UNLOADING AND ASSEMBLY
Form 169542 19 Revision F
STEP 6. REMOVE HAND RAILS
AND EXHAUST STACK
a. Cut plastic cable ties, an d move hose bundle
clear of platform.
b. Remove shipping wire and foam f rom exhaust
stack.
c. Remove nuts from clamp, and remove exhaust
stack and clamp from shipping frame.
d. Re-install nuts onto clamp, and set stack aside
for later installation.
e. Remove the two bolt s securing hand rail to
shipping frame, and remove hand rail.
f. Repeat for o ther hand rail on oppo site side.
Retain hardware.
g. Set parts aside for later installation.

UNLOADING AND ASSEMBLY
Form 169542 20 Revision F
STEP 7. REMOVE LEG
ASSEMBLIES
a. Ensure that lift bar is 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
hook up to lifting device with a minimu m lifting
capacity of 5,000 lb (2,268 kg).
c. Remove two bolts at lower support channel.
d. Remove two bolts near top of leg, and remove
bars from leg.
NOTE
Insert cardboard or foam between leg
assembly and hood toprevent damage
to hood.
e. Lift off leg assembly, an d set securely on level
ground.
f. Repeat above steps for second leg assembly.