MacDon M 2014 Series Operation instructions

The harvesting specialists worldwide.
M-Series
Self-Propelled Windrower
Unloading and Assembly Instructions (Container Shipments)
169886 Revision A
Original Instruction

Featuring the Dual Direction®and Ultra Glide®suspension on the M155 and M205.
Published in June, 2014

EC Declaration of Conformity—Windrower Lift Sling
169886 iRevision A

EC Declaration of Conformity—Windrower Assembly Supports
169886 iiRevision A

Introduction
This instructional manual describes the unloading, setup, and pre-delivery requirements for MacDon M-Series
Self-Propelled Windrowers 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.
NOTE: Keep your MacDon publications up-to-date. The most current version can be downloaded from
our website (www.macdon.com) or from our Dealer-only site (https://portal.macdon.com) (login
required).
169886 iii Revision A

List of Revisions
The following list provides an account of major changes from the previous version of this document.
Summary of Change Location
Added Signal Words in Safety Section. 1 Safety, page 1
More terms added to Definitions Section. 4Definitions, page 19
Updated drive wheel images and added references to
a 10-bolt wheel assembly. •6.4 Installing Drive Wheels, page 48
•7.13 Final Steps, page 223
Removed reference to walking beam grease zerk. No
longer required with new design. 6.23.2 Lubrication Points, page 166
Removed procedure on attaching an A-Series header
on an M105 with hydraulic center-link and optional
self-alignment kit.
Restructured the header attach procedures to
improve readability. 6.22 Attaching Headers, page 111
AddedproceduresonattachingtheA-,D-,and
R-Series on windrowers with hydraulic center-link but
no self-alignment kit for M205.
•Attaching an A-Series Header: Hydraulic
Center-Link without Self-Alignment, page 136
•Attaching a D-Series Header: Hydraulic Center-Link
without Self-Alignment, page 118
•Attaching an R-Series Header: Hydraulic
Center-Link without Self-Alignment, page 153
M105 CDM and operator console images added. Various sections
Manual and catalog part numbers changed. 7.12 Manuals, page 221
Updated Trimble Mount kit and Label (GPS completion
kit) location. 7.13 Final Steps, page 223
Updated lift linkage image to include new decal. Various sections
169886 ivRevision A

TABLE OF CONTENTS
EC Declaration of Conformity—Windrower Lift Sling ........................................................................... i
EC Declaration of Conformity—Windrower Assembly Supports............................................................ii
Introduction.....................................................................................................................................iii
List of Revisions ..............................................................................................................................iv
1 Safety.................................................................................................................................................... 1
1.1 Signal Words................................................................................................................................... 1
1.2 General Safety ................................................................................................................................ 2
1.3 Safety Signs.................................................................................................................................... 4
2 Recommended Torques ........................................................................................................................ 5
2.1 Torque Specifications....................................................................................................................... 5
2.1.1 SAE Bolt Torque Specifications................................................................................................. 5
2.1.2 Metric Bolt Specifications.......................................................................................................... 7
2.1.3 Metric Bolt Specifications Bolting into Cast Aluminum............................................................... 10
2.1.4 Flare-Type Hydraulic Fittings................................................................................................... 10
2.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)................................................................... 12
2.1.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) ........................................................... 14
2.1.7 O-Ring Face Seal (ORFS) Hydraulic Fittings............................................................................ 15
3 Conversion Chart................................................................................................................................ 17
4Definitions........................................................................................................................................... 19
5 Unloading the Windrower.................................................................................................................... 21
5.1 Unloading Container...................................................................................................................... 21
5.2 Moving to Assembly Area............................................................................................................... 22
5.2.1 Moving to Assembly Area—Crane Method............................................................................... 22
5.2.2 Moving to Assembly Area—Forklift Method.............................................................................. 24
5.3 Removing Wheel and Step Assembly.............................................................................................. 26
5.4 Removing Drive Wheels................................................................................................................. 30
5.5 Removing Platforms....................................................................................................................... 32
5.6 Removing Hand Rails and Exhaust Stack........................................................................................ 34
5.7 Removing Leg Assemblies............................................................................................................. 35
5.8 Removing Wheel and Platform Support........................................................................................... 38
6 Assembling the Windrower................................................................................................................. 41
6.1 Assembling Support Stand............................................................................................................. 41
6.2 Lifting Windrower onto Stand.......................................................................................................... 42
6.2.1 Lifting Windrower onto Stand—Crane Method.......................................................................... 42
6.2.2 Lifting Windrower onto Stand—Forklift Method......................................................................... 43
6.3 Installing Legs ............................................................................................................................... 45
6.4 Installing Drive Wheels................................................................................................................... 48
6.5 Installing Caster Wheels................................................................................................................. 50
6.6 Installing Hydraulics....................................................................................................................... 54
6.6.1 Installing Hydraulics on an M205............................................................................................. 54
6.6.2 Installing Hydraulics on an M155............................................................................................. 57
6.6.3 Installing Hydraulics on an M105............................................................................................. 67
6.7 Removing Battery Shipping Shield.................................................................................................. 75
6.8 Unpacking Ignition Keys................................................................................................................. 76
6.9 Installing Platforms ........................................................................................................................ 77
6.10 Installing Steps.............................................................................................................................. 81
6.11 Installing Exhaust Stack ................................................................................................................. 82
6.12 Positioning Light and Mirror Assemblies.......................................................................................... 84
6.13 Connecting Batteries...................................................................................................................... 85
6.13.1 Connecting Batteries on an M205 or M155 .............................................................................. 85
6.13.2 Connecting Batteries on an M105............................................................................................ 86
6.14 Priming Hydraulic System .............................................................................................................. 87
169886 vRevision A

TABLE OF CONTENTS
6.14.1 Priming Hydraulic System on an M205 .................................................................................... 87
6.14.2 Priming Hydraulic System on an M155 .................................................................................... 88
6.14.3 Priming Hydraulic System on an M105 .................................................................................... 92
6.15 Starting Engine.............................................................................................................................. 97
6.16 Checking Traction Drive................................................................................................................100
6.17 Removing Windrower from Stand ..................................................................................................101
6.17.1 Removing Windrower from Factory Stand...............................................................................101
6.17.2 Removing Windrower from Field Stand...................................................................................102
6.18 Installing AM/FM Radio .................................................................................................................103
6.19 Installing Beacons.........................................................................................................................107
6.20 Installing Slow Moving Vehicle (SMV) Sign.....................................................................................109
6.21 Attaching Header Boots ................................................................................................................110
6.22 Attaching Headers........................................................................................................................111
6.22.1 Attaching a D-Series Header..................................................................................................111
Attaching a D-Series Header: Hydraulic Center-Link with Optional Self-Alignment.............113
Attaching a D-Series Header: Hydraulic Center-Link without Self-Alignment......................118
Attaching a D-Series Header: Mechanical Center-Link.....................................................124
6.22.2 Attaching an A-Series Header................................................................................................129
Attaching an A-Series Header: Hydraulic Center-Link with Optional Self-Alignment............130
Attaching an A-Series Header: Hydraulic Center-Link without Self-Alignment....................136
Attaching an A-Series Header: Mechanical Center-Link ...................................................141
6.22.3 Attaching an R-Series Header................................................................................................147
Attaching an R-Series Header: Hydraulic Center-Link with Optional Self-Alignment ...........148
Attaching an R-Series Header: Hydraulic Center-Link without Self-Alignment....................153
Attaching an R-Series Header: Mechanical Center-Link...................................................159
6.23 Lubricating the Windrower.............................................................................................................165
6.23.1 Lubrication Procedure ...........................................................................................................165
6.23.2 Lubrication Points..................................................................................................................166
6.24 Cab Display Module (CDM) Programming......................................................................................167
6.24.1 M205 Detailed Programming Menu Flow Chart .......................................................................170
6.24.2 M155 Detailed Programming Menu Flow Chart .......................................................................174
6.24.3 M105 Detailed Programming Menu Flow Chart .......................................................................179
6.25 Performing Hydraulic Purge...........................................................................................................184
7 Performing Predelivery Checks..........................................................................................................189
7.1 Recording Serial Numbers ............................................................................................................189
7.2 Checking Wheel Drive Lubricant Level...........................................................................................191
7.3 Tire Pressures and Ballast Requirements.......................................................................................192
7.3.1 Checking Tire Pressures........................................................................................................192
7.3.2 Checking Tire Ballast.............................................................................................................192
7.4 Checking Engine Air Intake ...........................................................................................................195
7.5 Checking Hydraulic Oil..................................................................................................................198
7.6 Checking Fuel Separator...............................................................................................................199
7.7 Checking Engine Coolant..............................................................................................................200
7.8 Checking Gearbox Lubricant Level on an M155/M205.....................................................................201
7.9 Checking Air Conditioning (A/C) Compressor Belt...........................................................................202
7.10 Checking Safety System ...............................................................................................................203
7.11 Operational Checks ......................................................................................................................205
7.11.1 Checking Engine Warning Lights............................................................................................206
7.11.2 Checking Engine Startup.......................................................................................................207
7.11.3 Checking Engine Speed ........................................................................................................208
7.11.4 Checking Gauges and Cab Display Module (CDM) Display......................................................208
7.11.5 Checking Electrical System....................................................................................................209
7.11.6 Checking Operator's Presence System...................................................................................210
7.11.7 Checking Exterior Lights........................................................................................................211
169886 viRevision A

TABLE OF CONTENTS
Checking Exterior Lights on an M155/M205.....................................................................211
Checking Exterior Lights on an M105..............................................................................215
7.11.8 Checking Horn......................................................................................................................218
7.11.9 Checking Interior Lights.........................................................................................................218
7.11.10 Checking Air Conditioning (A/C) and Heater............................................................................219
7.12 Manuals.......................................................................................................................................221
7.13 Final Steps...................................................................................................................................223
Predelivery Checklist ....................................................................................................................225
169886 vii Revision A

1Safety
1.1 Signal Words
Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. The
appropriate signal word for each situation has been selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death, or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death, or serious injury. It
may also be used to alert against unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor, or moderate injury. It
may be used to alert against unsafe practices.
169886 1Revision A

SAFETY
1.2 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.
Figure 1.1: Safety Equipment
• You may need:
– A hard hat
– Protective footwear with slip resistant soles
– Protective glasses or goggles
– Heavy gloves
– Wet weather gear
– A respirator or filter mask
– Hearing protection
Be aware that exposure to loud noise can cause
impairment or loss of hearing. Wearing suitable
hearing protection devices such as ear muffs or ear
plugs. These will help protect against objectionable
or loud noises.
Figure 1.2: Safety Equipment
•Provideafirst aid kit for use in case of emergencies.
•Keepafire extinguisher on the machine. Be sure the
fire extinguisher is properly maintained. Be familiar with
its proper use.
• Keep young children away from the machinery at
all times.
•Beawaretha
t accidents often happen when the
Operator is tiredorinahurrytogetfinished. Take the
time to consider the safest way. Never ignore warning
signs of fatigue.
Figure 1.3: Safety Equipment
169886 2Revision A

SAFETY
•Wearclosefitting clothing and cover long hair. Never
wear dangling items such as scarves or bracelets.
• 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.
Figure 1.4: Safety around Equipment
• Keep hands, feet, clothing, and hair away from moving
parts. Never attempt to clear obstructions or objects,
from a machine while the engine is running.
•DoNOT modify the machine. Non-authorized
modifications may impair machine function and/or
safety. It may also shorten the machine’s life.
• Stop the engine and remove thekey from ignition before
leaving operator’s seat for any reason. A child or even
a pet could engage an idling machine.
Figure 1.5: Safety around Equipment
• 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.
• Keep work area well lit.
• Keep machinery clean. Straw and chaff, on a hot
engine, are a fire hazard. Do NOT allow oil or grease to
accumulate on service platforms, ladders, or controls.
Clean machines before storage.
• Never use gasoline, naphtha, or any volatile 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.
Figure 1.6: Safety around Equipment
169886 3Revision A

SAFETY
1.3 Safety Signs
• Keep safety signs clean and legible at all times.
• Replace safety signs that are missing or
become illegible.
• If original parts on which a safety sign was installed are
replaced, be sure the repair part also bears the current
safety sign.
• Safety signs are available from your Dealer
Parts Department.
Figure 1.7: Operator’s Manual Decal
169886 4Revision A

2 Recommended Torques
2.1 Torque Specifications
The following tables give correct torque values for various bolts, cap screws, and hydraulic fittings.
• Tighten all bolts to the torques specified in chart (unless otherwise noted throughout this manual).
• Replace hardware with the same strength and grade bolt.
• Check tightness of bolts periodically, using the tables below as a guide.
• Torque categories for bolts and cap screws are identified by their head markings.
2.1.1 SAE Bolt Torque Specifications
Torque values shown in this table are valid for non-greased, or non-oiled threads and heads. Therefore, do NOT
grease or oil bolts or cap screws unless otherwise specified in this manual.
Table 2.1 SAE Grade 5 Bolt and Grade 5 Free
Spinning Nut
Torque (ft·lbf) (*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
1/4-20 *106 *117 11.9 13.2
5/16-18*218 *241 24.6 27.1
3/8-16 32 36 44 48
7/16-14 52 57 70 77
1/2-1379 87 106 118
9/16-12 114 126 153 170
5/8-11 157 173 212 234
3/4-10 281 311 380 420
7/8-9 449 496 606 669
1-8611676825912
Figure 2.1: Bolt Grades
A-NominalSize B-SAE-8
C - SAE-5 D - SAE-2
169886 5Revision A

RECOMMENDED TORQUES
Table 2.2 SAE Grade 5 Bolt and Grade 5 Distorted
Thread Nut
Torque (ft·lbf) (*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
1/4-20 *72 *80 8.1 9
5/16-18 *149 *164 16.7 18.5
3/8-16 22 24 30 33
7/16-14 35 39 48 53
1/2-13 54 59 73 80
9/16-12 77 86 105 116
5/8-11 107 118 144 160
3/4-10 192 212 259 286
7/8-9 306 338 413 456
1-8 459 507 619 684
Table 2.3 SAE Grade 8 Bolt and Grade 8 Distorted
Thread Nut
Torque (ft·lbf) (*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
1/4-20 *150 *165 16.8 18.6
5/16-18 18 19 24 26
3/8-16 31 34 42 46
7/16-14 50 55 67 74
1/2-13 76 84 102 113
9/16-12 109 121 148 163
5/8-11 151 167 204 225
3/4-10 268 296 362 400
7/8-9 432 477 583 644
1-8 647 716 874 966
Figure 2.2: Bolt Grades
A-NominalSize B-SAE-8
C - SAE-5 D - SAE-2
169886 6Revision A

RECOMMENDED TORQUES
Table 2.4 SAE Grade 8 Bolt and Grade 8 Free
Spinning Nut
Torque (ft·lbf) (*in·lbf) Torque (N·m)
Nominal
Size (A) Min. Max. Min. Max.
1/4-20 *150 *165 16.8 18.6
5/16-18 26 28 35 38
3/8-16 46 50 61 68
7/16-14 73 81 98 109
1/2-13 111 123 150 166
9/16-12 160 177 217 239
5/8-11 221 345 299 330
3/4-10 393 435 531 587
7/8-9 633 700 855 945
1-8 863 954 1165 1288
2.1.2 Metric Bolt Specifications
Table2.5MetricClass8.8BoltsandClass9Free
Spinning Nut
Torque (ft·lbf) (*in·lbf) Torque (N·m)
Nominal
Size Min. Max. Min. Max.
3-0.5 *13 *14 1.4 1.6
3.5-0.6 *20 *22 2.2 2.5
4-0.7 *29 *32 3.3 3.7
5-0.8 *59 *66 6.7 7.4
6-1.0 *101 *112 11.4 12.6
8-1.25 20 23 28 30
10-1.5 40 45 55 60
12-1.75 70 78 95 105
14-2.0 113 124 152 168
16-2.0175 193 236 261
20-2.5 341 377 460 509
24-3.0 589 651 796 879
Figure 2.3: Bolt Grades
A-NominalSize
169886 7Revision A

RECOMMENDED TORQUES
Table2.6MetricClass8.8BoltsandClass9Distorted
Thread Nut
Torque (ft·lbf) (*in·lbf) Torque (N·m)
Nominal
Size Min. Max. Min. Max.
3-0.5 *9 *10 11.1
3.5-0.6 *14 *15 1.5 1.7
4-0.7 *20 *22 2.3 2.5
5-0.8 *40 *45 4.5 5
6-1.0 *69 *76 7.7 8.6
8-1.25 *167 *185 18.8 20.8
10-1.5 28 30 37 41
12-1.7548536572
14-2.0 77 85 104 115
16-2.0 119 132 161 178
20-2.5 233 257 314 347
24-3.0 402 444 543 600
Table 2.7 Metric Class 10.9 Bolts and Class 10 Free
Spinning Nut
Torque (ft·lbf) (*in·lbf) Torque (N·m)
Nominal
Size Min. Max. Min. Max.
3-0.5 *18 *19 1.8 2
3.5-0.6 *27 *30 2.8 3.1
4-0.7 *41 *45 4.2 4.6
5-0.8 *82 *91 8.4 9.3
6-1.0 *140 *154 14.3 15.8
8-1.25 28 31 38 42
10-1.5 56 62 75 83
12-1.75 97 108 132 145
14-2.0 156 172 210 232
16-2.0 242 267 326 360
20-2.5 472 521 637 704
24-3.0 815 901 1101 1217
169886 8Revision A

RECOMMENDED TORQUES
Table 2.8 Metric Class 10.9 Bolts and Class 10
Distorted Thread Nut
Torque (ft·lbf) (*in·lbf) Torque (N·m)
Nominal
Size Min. Max. Min. Max.
3-0.5 *12 *13 1.3 1.5
3.5-0.6 *19 *21 2.1 2.3
4-0.7 *28 *31 3.1 3.4
5-0.8 *56 *62 6.3 7
6-1.0 *95 *105 10.7 11.8
8-1.25 19 21 26 29
10-1.5 38 42 51 57
12-1.7566739099
14-2.0 106 117 143 158
16-2.0 165 182 222 246
20-2.5 322 356 434 480
24-3.0 556 614 750 829
169886 9Revision A

RECOMMENDED TORQUES
2.1.3 Metric Bolt Specifications Bolting into Cast Aluminum
Table 2.9 Metric Bolt Bolting into Cast Aluminum
Bolt Torque
8.8
(Cast Aluminum) 10.9
(Cast Aluminum)
Nominal
Size
ft·lbf N·m ft·lbf N·m
M3 1
M4 2.6 4
M5 5.5 8
M6 6 9 9 12
M8 14 20 20 28
M10 28 40 40 55
M12 52 70 73 100
M14
M16
Figure 2.4: Bolt Grades
A-NominalSize
2.1.4 Flare-Type Hydraulic Fittings
1. Check flare (A) and flare seat (B) for defects that might
cause leakage.
2. Aligntube(C)withfitting (D) and thread nut (E) onto
fitting without lubrication until contact has been made
between the flared surfaces.
3. Torque the fitting nut (E) to the specified number
of FFFT or to a given torque value shown in the
following table.
4. To prevent the fitting (D) from rotating, use two
wrenches. Place one wrench on the fitting body (D)
and tighten the nut (E) with the other wrench to the
torque shown.
5. Assess the final condition of the connection. Figure 2.5: Hydraulic Fitting
A-Flare B - Flare Seat
C - Tube D - Body
E-Nut
169886 10 Revision A