MacDon M Series User manual

Form # 169242 Model Year - 2009
M Series Self-Propelled Windrower
UNLOADING & ASSEMBLY
INSTRUCTIONS
for
CONTAINER SHIPMENTS

Form # 169242 Model Year - 2009
MACDON SELF PROPELLED AUGER HEADER
MACDON SELF PROPELLED WINDROWER TRACTOR

Form # 169242 Model Year - 2009
1
INTRODUCTION
This instruction describes the unloading, set-up and pre-delivery requirements for the MacDon M Series Self-
Propelled Windrowers. 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
INTRODUCTION........................................................................................................................................................1
GENERAL SAFETY...................................................................................................................................................3
RECOMMENDED TORQUES ...................................................................................................................................5
A. GENERAL...............................................................................................................................................5
B. SAE BOLTS............................................................................................................................................5
C. METRIC BOLTS .....................................................................................................................................5
D. HYDRAULIC FITTINGS .........................................................................................................................6
ACCRONYMS AND ABBREVIATIONS .....................................................................................................................7
STEP 1. UNLOAD CONTAINER..............................................................................................................................8
STEP 2. MOVE TO ASSEMBLY AREA...................................................................................................................8
A. CRANE METHOD ..................................................................................................................................8
B. FORKLIFT METHOD..............................................................................................................................9
STEP 3. REMOVE WHEEL & STEP ASSEMBLY .................................................................................................11
STEP 4. REMOVE DRIVE WHEELS ..................................................................................................................... 13
STEP 5. REMOVE PLATFORM/LIGHT ASSEMBLY ............................................................................................14
STEP 6. INSTALL LIGHT AND MIRROR ASSEMBLIES ...................................................................................... 15
STEP 7. REMOVE LEG ASSEMBLIES ................................................................................................................. 17
STEP 8. REMOVE WHEEL & PLATFORM SUPPORT.........................................................................................18
STEP 9. ASSEMBLE WINDROWER TRACTOR SUPPORT STAND................................................................... 18
STEP 10. LIFT WINDROWER TRACTOR ONTO STAND......................................................................................19
A. CRANE METHOD ................................................................................................................................19
B. FORKLIFT METHOD............................................................................................................................20
STEP 11. INSTALL LEGS........................................................................................................................................21
STEP 12. INSTALL FRONT WHEELS.....................................................................................................................23
STEP 13. INSTALL CASTER WHEELS ..................................................................................................................25
STEP 14. INSTALL HYDRAULICS ..........................................................................................................................27
A. M150, M200..........................................................................................................................................27
B. M100.....................................................................................................................................................31
STEP 15. INSTALL PLATFORMS ...........................................................................................................................34
STEP 16. INSTALL STEPS......................................................................................................................................36
STEP 17. INSTALL TOOLBOX................................................................................................................................36
STEP 18. INSTALL BATTERIES .............................................................................................................................37
A. M150, M200..........................................................................................................................................37
B. M100.....................................................................................................................................................37
STEP 19. PRIME HYDRAULIC SYSTEM................................................................................................................38
STEP 20. START ENGINE ......................................................................................................................................41
STEP 21. CHECK TRACTION DRIVE.....................................................................................................................43
STEP 22. REMOVE WINDROWER TRACTOR FROM STAND .............................................................................44
A. FACTORY STAND ...............................................................................................................................44
B. FIELD CONSTRUCTED STAND..........................................................................................................44
STEP 23. INSTALL AM/FM RADIO .........................................................................................................................45
STEP 24. INSTALL BEACONS................................................................................................................................47
STEP 25. ATTACH HEADER...................................................................................................................................48
A. HEADER ATTACHMENT - D SERIES.................................................................................................48
B. HEADER ATTACHMENT – A SERIES ................................................................................................52
C. HEADER ATTACHMENT – R SERIES (M150, M200 ONLY)..............................................................55
STEP 26. LUBRICATE MACHINE ...........................................................................................................................59
STEP 27. PROGRAM CDM .....................................................................................................................................61

Form # 169242 Model Year - 2009
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A. M150, M200 DETAILED PROGRAMMING INSTRUCTIONS..............................................................62
B. M100 DETAILED PROGRAMMING INSTRUCTIONS.........................................................................68
STEP 28. PERFORM HYDRAULIC PURGE ...........................................................................................................74
STEP 29. PERFORM PRE-DELIVERY CHECKS ...................................................................................................76
A. FINAL DRIVE LUBRICANT LEVEL......................................................................................................76
B. TIRE PRESSURES ..............................................................................................................................76
C. ENGINE COOLANT .............................................................................................................................76
D. AIR CLEANER......................................................................................................................................76
E. HYDRAULIC OIL LEVEL......................................................................................................................77
F. FUEL SEPARATOR .............................................................................................................................77
G. GEAR BOX LUBRICANT LEVEL (M150, M200)..................................................................................78
H. A/C COMPRESSOR BELT...................................................................................................................78
I. FAN BELT (M100) ................................................................................................................................78
J. PERFORM SAFETY SYSTEM CHECKS.............................................................................................79
K. OPERATIONAL CHECKS....................................................................................................................80
I. ENGINE WARNING LIGHTS ............................................................................................................................80
II. START ENGINE................................................................................................................................................80
III. GAUGES AND CDM DISPLAY .........................................................................................................................80
IV. ENGINE SPEED ...............................................................................................................................................80
V. OPERATOR’S PRESENCE SYSTEM CHECKS...............................................................................................81
VI. FIELD LIGHTS ..................................................................................................................................................82
VII. ROAD LIGHTS (M150, M200)...........................................................................................................................82
VIII. ROAD LIGHTS (M100)......................................................................................................................................84
IX. INTERIOR LIGHTS ...........................................................................................................................................84
X. A/C AND HEATER ............................................................................................................................................85
L. MANUALS ............................................................................................................................................86
M. CAB INTERIOR ....................................................................................................................................86

Form # 169242 Model Year - 2009
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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:
oa hard hat.
oprotective shoes with slip resistant
soles.
oprotective glasses or goggles.
oheavy gloves.
owet weather gear.
orespirator or filter mask.
ohearing 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 machine
while 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.
•Do not modify the machine. Unauthorized
modifications may impair the function
and/or safety and affect machine life.
A
B

Form # 169242 Model Year - 2009
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•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.
•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 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.

Form # 169242 Model Year - 2009
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RECOMMENDED TORQUES
A. GENERAL
The tables shown below give correct torque
values for various bolts and capscrews.
•Tighten all bolts to the torques 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 same 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
NC BOLT TORQUE*
SAE 5 SAE 8
BOLT
DIA. "A"
in. 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
NC BOLT TORQUE*
8.8 10.9
BOLT
DIA. "A"
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
8.8 10.9

Form # 169242 Model Year - 2009
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D. HYDRAULIC FITTINGS
FLARE TYPE
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 the tube(s), use two
wrenches. Place one wrench on the connector
body and with the second tighten the swivel nut
to the torque shown.
TORQUE
VALUE*
RECOMMENDED
TURNS TO
TIGHTEN
(AFTER FINGER
TIGHTENING)
TUBE
SIZE
O.D.
(in.)
NUT
SIZE
ACROSS
FLATS
(in.) lbf·ft N·m Flats Turns
3/16 7/16 6 8 1 1/6
1/4 9/16 9 12 1 1/6
5/16 5/8 12 16 1 1/6
3/8 11/16 18 24 1 1/6
1/2 7/8 34 46 1 1/6
5/8 1 46 62 1 1/6
3/4 1-1/4 75 102 3/4 1/8
7/8 1-3/8 90 122 3/4 1/8
* The torque values shown are based on lubricated connections
as in reassembly.
O-RING TYPE
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.
TORQUE
VALUE*
RECOMMENDED
TURNS TO
TIGHTEN (AFTER
FINGER
TIGHTENING)
THD
SIZE
(in.)
NUT SIZE
ACROSS
FLATS
(in.)
lbf·ft N·m Flats Turns
3/8 1/2 6 8 2 1/3
7/16 9/16 9 12 2 1/3
1/2 5/8 12 16 2 1/3
9/16 11/16 18 24 2 1/3
3/4 7/8 34 46 2 1/3
7/8 1 46 62 1-1/2 1/4
1-1/16 1-1/4 75 102 1 1/6
1-3/16 1-3/8 90 122 1 1/6
1-5/16 1-1/2 105 142 3/4 1/8
1-5/8 1-7/8 140 190 3/4 1/8
1-7/8 2-1/8 160 217 1/2 1/12
* The torque values shown are based on lubricated connections
as in reassembly.
LOCKNUT
SEAT
WASHER
O-RING
GROOVE
FITTING
A
BC
FLARE
FLARESEAT BODY
NUT

Form # 169242 Model Year - 2009
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ACCRONYMS AND
ABBREVIATIONS
ENGLISH/METRIC EQUIVALENTS
ENGLISH FACTOR SI UNITS (METRIC)
acres x 0.4047 = hectares (ha)
ft/min x 0.3048 = meters/min (m/min)
ft/s x 0.3048 = meters/sec (m/s)
US gal x 3.7854 = liters (L)
US
gal/min
(gpm)
x 3.7854 = liters/min (L/min)
hp x 0.7457 = kilowatts (kW)
in.3x 16.3871
= cubic centimeters (cm3
or cc)
lbf x 4.4482 = newtons (N)
lbf·in. or
in·lbf x 1.3558 = newton meters (N·m)
lbf·in. or
in·lbf x 0.1129 = newton meters (N·m)
mph x 1.6063 = kilometers/hour (km/h)
oz. x 29.5735 = milliliters (ml)
psi x 6.8948 = kilopascals (kPa)
psi x .00689 = megapascals (MPa).
DEFINITIONS
TERM DEFINITION
API American Petroleum Institute
ASTM American Society Of Testing And
Materials
C Celsius
Cab
Forward
Windrower operation with the
operator and cab facing in the
direction of travel.
CDM Cab Display Module
DWA Double Windrow Attachment
Engine
Forward
Windrower operation with the
operator and engine facing in the
direction of travel.
F Fahrenheit
ft/min feet per minute
ft/s feet per second
gpm U.S. gallons per minute
GSL Ground Speed Lever
hp horsepower
in.3cubic inches
lbf pounds force
lbf·ft or ft·lbf pound feet or foot pounds
lbf·in. or
in·lbf pound inches or inch pounds
ISC Integrated Speed Control
mph miles per hour
N-DETENT The slot opposite the neutral
position on operator’s console.
oz. ounces
psi pounds per square inch
rpm revolutions per minute
SAE Society Of Automotive Engineers
WCM Windrower Control Module
Windrower Windrower Tractor with header
attached.
Windrower
Tractor
Power unit only. (Windrower
without the header attached).

UNLOADING AND ASSEMBLY
Form # 169242 Model Year - 2009
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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 position and block 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. Pull tractor from container onto platform.
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
Min. Lifting Capacity 20,000 lb (9072 kg)
CHAIN
Type Overhead Lifting
Quality (1/2 inch)
Min. Working Load 7100 lb (3221 kg)
a. Attach chains or cable to the four lift points on
the lifting frame (MacDon Part # 163871) and
connect loop ends to crane hook. Use cable or
chain with a minimum lifting capacity of 7100 lb
(3221 kg).
(continued next page)

UNLOADING AND ASSEMBLY
Form # 169242 Model Year - 2009
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b. Attach lifting frame assembly (MacDon Part #
163871) to the four designated lift points on
windrower tractor shipping frame.
c. Lift windrower tractor off platform and move to
setup area.
d. Lower assembly onto 5-6 inch (127-152 mm)
blocks as shown.
e. Remove chains from shipping frame.
f. Check for shipping damage and missing parts.
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
Min. Lifting Capacity * 20,000 lb (9072 kg)
* At 48 inches (1220 mm) from back end of
forks.
IMPORTANT
Forklifts are normally rated for a load
located 24 inches (610 mm) ahead of
back end of the forks. To obtain the
forklift capacity 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 tractor from the hood end,
and slide forks underneath lifting framework.
b. Raise windrower tractor off platform and move to
assembly area.
(continued next page)

UNLOADING AND ASSEMBLY
Form # 169242 Model Year - 2009
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c. Lower assembly onto 5-6 inch (127-152 mm)
blocks as shown.
d. Check for shipping damage and missing parts.

UNLOADING AND ASSEMBLY
Form # 169242 Model Year - 2009
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STEP 3. REMOVE WHEEL & STEP
ASSEMBLY
a. Remove shipping wire and bolt securing hose
support to shipping frame and remove hose
support.
b. Lay hose support off to the side.
c. Remove the two ¾ in.x16.5 lg. bolts at front
frame beam. Retain for reinstallation.
d. Remove the 1 inch (25.4 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 # 169242 Model Year - 2009
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g. Attach a chain to wheel/step assembly and pull
away from shipping assembly with lifting device.
h. Lift center link so that it clears wheel/step
assembly frame.
i. Remove bolts and remove tool box & holder
from shipping frame. Loosely install bolts in
holder and set aside for later installation.
j. Reinstall leg bolts, washers, and nuts to secure
the lifting plate onto the mainframe.

UNLOADING AND ASSEMBLY
Form # 169242 Model Year - 2009
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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 guided away from
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 # 169242 Model Year - 2009
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STEP 5. REMOVE
PLATFORM/LIGHT
ASSEMBLY
a. Remove the two support tubes on either side of
hood.
b. Attach slings (to prevent paint damage) to
platform at locations shown and to a lifting
device with a minimum lifting capacity of 5000 lb
(2268 kg) and a lift height of 13 feet (4 m).
c. Remove two 5/8 in.x5.0 bolts at top of vertical
support and two bolts on bottom of support
brace.
d. Cut plastic cable ties and move hose bundle
clear of platform.
NOTE
The M100 windrower is equipped with
only one platform.
e. Carefully lift platform/light assembly off frame
until rails clear windrower tractor legs.
f. Back away from windrower tractor and set
assembly on a level surface. Protect handrails
with foam or cardboard to prevent paint damage.

UNLOADING AND ASSEMBLY
Form # 169242 Model Year - 2009
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STEP 6. INSTALL LIGHT AND
MIRROR ASSEMBLIES
a. Remove two bolts securing mirror/light
assemblies to shipping stand and remove
assemblies.
b. The cab roof must be raised to install the light
assemblies. Proceed as follows:
1. Remove plastic covers from six bolt
locations in roof.
2. Remove nuts and washers at these
locations.
3. Lift roof and support with wooden block
covered with foam to prevent scuffing of
roof.
c. Move existing harness in roof to gain access to
mirror/light support clamps. Loosen U-bolt.
d. Install mirror/light into U-bolt and tighten nuts on
U-bolt so that support tube is securely fastened.
Tighten jam-nuts located under roof plate.
(continued next page)

UNLOADING AND ASSEMBLY
Form # 169242 Model Year - 2009
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e. Thread wiring harness through support tube so
that connector is visible at light assembly.
f. Stuff foam into end of tube to help prevent dust
and noise from entering the cab.
g. Connect harness to connector at light.
h. Repeat steps c. to g. for opposite light assembly.
i. Remove roof support and lower roof.
IMPORTANT
Ensure roof bolts clear grommets in
frame.
j. Re-install washers and nuts at the six locations.
k. Re-install plastic caps.

UNLOADING AND ASSEMBLY
Form # 169242 Model Year - 2009
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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 minimum lifting
capacity of 5000 lb (2268 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 to prevent
damage to hood.
e. Lift off leg assembly and set securely on level
ground.
f. Repeat above steps for second leg assembly.

UNLOADING AND ASSEMBLY
Form # 169242 Model Year - 2009
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STEP 8. REMOVE WHEEL &
PLATFORM SUPPORT
a. Remove cross brace, and the two upright
supports from frame.
b. Remove the cross member over the hood and
the two uprights on either side.
STEP 9. ASSEMBLE WINDROWER
TRACTOR SUPPORT
STAND
Special stands for assembling the windrower
tractor are available from the factory. If this
stand is not available, an equivalent support
system can be used. The stand must be
capable of holding a 20,000 lb (9072 kg) load.
Assemble factory stand as follows:
a. Remove all shipping materials from stand.
b. Arrange forward and rear stands on level ground
so that attachment lugs on each stand face each
other.
c. Attach four support tubes to stands as shown
with hardware provided and tighten.
d. Set up air control valve tripod. Remove plug on
valve and install a 100 psi (689 kPa) air line.
e. The stand is now operational. Instructions for
use are given in the appropriate sections.
WARNING
Use stand only as instructed in this manual.
Do not use stand for any other purpose.
Do not pressurize air bags beyond 120 psi
(827 kPa).
FORWARD STAND
REAR STAND
SUPPORT