MacDon M Series User manual

The harvesting specialists.
M-Series
Self-Propelled Windrower
Unloading and Assembly Instructions (Container Shipments)
147962 Revision A
2017 Model Year
Original Instruction

Featuring the Dual Direction®and Ultra Glide®suspension on the M155 and M205.
Published in August, 2016

Introduction
This instruction manual describes the unloading, setup, and predelivery requirements for the MacDon M-Series
Self-Propelled Windrowers shipped in containers.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
Retain this instruction for future reference.
Conventions
The following conventions are used in this document: Right- and left-hand are determined from the operator’s
position. The front of the windrower is the side that faces the crop.
NOTE:
Keep your MacDon publications up-to-date. The most current version can be downloaded from our Dealer-only
site (https://portal.macdon.com) (login required).
This instruction is also available in Russian and can be downloaded from our Dealer-only site.
147962 iRevision A

EC Declaration of Conformity—Windrower Lift Sling
Figure 1: EC Declaration of Conformity – Windrower Lift Sling (Page 1 of 2)
147962 ii Revision A

Figure 2: EC Declaration of Conformity – Windrower Lift Sling (Page 2 of 2)
147962 iiiRevision A

EC Declaration of Conformity—Windrower Assembly Supports
Figure 3: EC Declaration of Conformity – Windrower Assembly Supports (Page 1 of 2)
147962 iv Revision A

Figure 4: EC Declaration of Conformity – Windrower Assembly Supports (Page 2 of 2)
147962 vRevision A

List of Revisions
The following list provides an account of major changes from the previous version of this document.
Summary of Change Location
Changed measurement format so that metric
measurements appear first followed by imperial in
parenthesis.
Revised figure titles for clarity.
Corrected general grammar and punctuation.
Throughout the book
Added paragraph stating that this instruction is also
available in Russian. Introduction, page i
Updated declarations of conformity. •EC Declaration of Conformity—Windrower Lift Sling,
page ii
•EC Declaration of Conformity—Windrower
Assembly Supports, page iv
Added new section for battery safety. 1.3 Battery Safety, page 4
Added footnote to lift sling part number stating that it is
not sold separately. •2.2.1MovingtoAssemblyArea: CraneMethod,page
8
•3.2.1 Lifting Windrower onto Stand: Crane Method,
page 28
Updated illustrations to show new battery hold-down. •3.7 Removing Battery Shipping Shield, page 61
•3.13.1 Connecting Batteries on an M205 or M155,
page72
Corrected step to attach red positive cable terminals to
positive posts (C), which was erroneously referenced
as (A).
3.13.2 Connecting Batteries on an M105, page 73
Removed reference to M200 and extra hose in the
Note under Step 2. 3.6.2 Installing Hydraulics on an M155, page 43
Updated procedure to show location of fuse box. 3.8 Unpacking Ignition Keys, page 62
Updated illustration to show new safety prop handle
and decal.
Reorganized sections for clarity.
Throughout 3.21 Attaching Headers, page 97
Added Hydraulic Union kit (MD #166844) to table of
kits that may be required to attach a D-Series Header
to an M205 Self-Propelled Windrower.
3.21.2 Attaching a D-Series Header, page 98
Added note recommending 18.4 x 26 drive tires when
attaching 13-ft R85 headers to the M155 or M205. 3.21.4 Attaching an R-Series Header, page 132
147962 vi Revision A

Summary of Change Location
Added new cross-reference and section for fluids,
lubricants, and system capacities. •3.22 Lubricating the Windrower, page 150
•5.2 Checking and Adding Wheel Drive Lubricant
Level, page 321
•6.4 Lubricants, Fluids, and System Capacities, page
374
Revised Note regarding cab display module and
windrower control module software to clarify software
version compatibility with different M-Series windrower
models.
4.2 Cab Display Options, page 156
Revised Notes specific to the M105 for clarity. •4.4.9 Setting the Header Index Mode, page 196
•4.7.3 Displaying Header Sensor Input Signals, page
260
Corrected references in Steps 7 and 8 from callouts C
and D to callouts A and B. •4.8.3 Testing the Header Tilt Activate Function Using
the Cab Display Module (CDM), page 278
•4.8.7 Testing the Reel Fore-Aft Activate Function
Using the Cab Display Module (CDM), page 288
Replaced arrows showing serial number locations with
callouts. 5.1 Recording Serial Numbers, page 319
Updated illustration to show new gearbox cover. 5.8 Checking Gearbox Lubricant Level on an
M155/M205, page 330
Corrected broken links to Table 5.5 Knife Speed
Setting, page 352.•Setting Knife Speed, page 352
•Adjusting Knife Speed, page 353
Replaced M105 Operator Console illustration to show
header drive switch. 5.11.8 Checking Operator's Presence System, page 341
Added new section for tapered pipe fittings. 6.1.8 Tapered Pipe Thread Fittings, page 369
Added new terms and acronyms. 6.3 Definitions, page 371
Added new section for fuel specifications. 6.5 Fuel Specifications, page 378
147962 viiRevision A

TABLE OF CONTENTS
Introduction...................................................................................................................................... i
EC Declaration of Conformity—Windrower Lift Sling ...........................................................................ii
EC Declaration of Conformity—Windrower Assembly Supports...........................................................iv
List of Revisions ..............................................................................................................................vi
1 Safety.................................................................................................................................................... 1
1.1 Signal Words................................................................................................................................... 1
1.2 General Safety ................................................................................................................................ 2
1.3 Battery Safety.................................................................................................................................. 4
1.4 Safety Signs.................................................................................................................................... 5
2 Unloading the Windrower...................................................................................................................... 7
2.1 Unloading Container........................................................................................................................ 7
2.2 Moving to Assembly Area................................................................................................................. 8
2.2.1 Moving to Assembly Area: Crane Method.................................................................................. 8
2.2.2 Moving to Assembly Area: Forklift Method............................................................................... 10
2.3 Removing Wheel and Step Assembly.............................................................................................. 12
2.4 Removing Drive Wheels................................................................................................................. 16
2.5 Removing Platforms....................................................................................................................... 18
2.6 Removing Hand Rails and Exhaust Stack........................................................................................ 20
2.7 Removing Leg Assemblies............................................................................................................. 21
2.8 Removing Wheel and Platform Support........................................................................................... 24
3 Assembling the Windrower................................................................................................................. 27
3.1 Assembling Support Stand............................................................................................................. 27
3.2 Lifting Windrower onto Stand.......................................................................................................... 28
3.2.1 Lifting Windrower onto Stand: Crane Method........................................................................... 28
3.2.2 Lifting Windrower onto Stand: Forklift Method.......................................................................... 30
3.3 Installing Legs ............................................................................................................................... 31
3.4 Installing Drive Wheels................................................................................................................... 34
3.5 Installing Caster Wheels................................................................................................................. 36
3.6 Installing Hydraulics....................................................................................................................... 40
3.6.1 Installing Hydraulics on an M205............................................................................................. 40
3.6.2 Installing Hydraulics on an M155............................................................................................. 43
3.6.3 Installing Hydraulics on an M105............................................................................................. 53
3.7 Removing Battery Shipping Shield.................................................................................................. 61
3.8 Unpacking Ignition Keys................................................................................................................. 62
3.9 Installing Platforms ........................................................................................................................ 64
3.10 Installing Steps.............................................................................................................................. 68
3.11 Installing Exhaust Stack ................................................................................................................. 69
3.12 Positioning Light and Mirror Assemblies.......................................................................................... 71
3.13 Connecting Batteries...................................................................................................................... 72
3.13.1 Connecting Batteries on an M205 or M155 .............................................................................. 72
3.13.2 Connecting Batteries on an M105............................................................................................ 73
3.14 Priming Hydraulic System .............................................................................................................. 75
3.14.1 Priming Hydraulic System on an M205 .................................................................................... 75
3.14.2 Priming Hydraulic System on an M155 .................................................................................... 76
3.14.3 Priming Hydraulic System on an M105 .................................................................................... 80
3.15 Starting Engine.............................................................................................................................. 84
3.16 Checking Traction Drive................................................................................................................. 87
3.17 Removing Windrower from Stand ................................................................................................... 88
3.17.1 Removing Windrower from Factory Stand................................................................................ 88
3.17.2 Removing Windrower from Field Stand.................................................................................... 89
3.18 Installing AM/FM Radio.................................................................................................................. 90
3.19 Installing Beacons.......................................................................................................................... 94
3.20 Installing the Slow Moving Vehicle (SMV) Sign ................................................................................ 96
147962 ix Revision A

TABLE OF CONTENTS
3.21 Attaching Headers......................................................................................................................... 97
3.21.1 Attaching Header Boots.......................................................................................................... 97
3.21.2 Attaching a D-Series Header................................................................................................... 98
Attaching a D-Series Header: Hydraulic Center-Link with Optional Self-Alignment.............. 99
Attaching a D-Series Header: Hydraulic Center-Link without Self-Alignment......................104
Attaching a D-Series Header: Mechanical Center-Link.....................................................110
3.21.3 Attaching an A-Series Header................................................................................................114
Attaching an A-Series Header: Hydraulic Center-Link with Optional Self-Alignment............116
Attaching an A-Series Header: Hydraulic Center-Link without Self-Alignment....................121
Attaching an A-Series Header: Mechanical Center-Link ...................................................127
3.21.4 Attaching an R-Series Header................................................................................................132
Attaching an R-Series HeaderHydraulic Center-Link with Optional Self-Alignment..............133
Attaching an R-Series Header: Hydraulic Center-Link without Self-Alignment....................138
Attaching an R-Series Header: Mechanical Center-Link...................................................144
3.22 Lubricating the Windrower.............................................................................................................150
3.22.1 Lubrication Procedure ...........................................................................................................150
3.22.2 Lubrication Points..................................................................................................................151
4 Cab Display Module (CDM).................................................................................................................153
4.1 Cab Display Module (CDM) Programming......................................................................................153
4.2 Cab Display Options.....................................................................................................................156
4.2.1 Setting the Cab Display Language..........................................................................................157
4.2.2 Changing the Windrower Display Units...................................................................................160
4.2.3 Adjusting the Cab Display Buzzer Volume...............................................................................163
4.2.4 Adjusting the Cab Display Backlighting...................................................................................166
4.2.5 Adjusting the Cab Display Contrast ........................................................................................169
4.3 Calibrating the Header Sensors.....................................................................................................172
4.3.1 Calibrating the Header Height Sensor.....................................................................................172
4.3.2 Calibrating the Header Tilt Sensor..........................................................................................176
4.3.3 Calibrating the Header Float Sensors.....................................................................................180
4.4 Programming the Windrower.........................................................................................................184
4.4.1 Selecting Header Type ..........................................................................................................184
4.4.2 Activating the Hydraulic Center-Link on an M105 and M155.....................................................185
4.4.3 Activating the Reel Fore-Aft Function on an M105...................................................................187
4.4.4 Activating the Rotary Header Drive Hydraulics on an M155......................................................188
4.4.5 Setting the Header Knife Speed.............................................................................................189
4.4.6 Setting the Knife Overload Speed...........................................................................................190
4.4.7 Setting the Rotary Disc Overload Speed.................................................................................193
4.4.8 Setting the Hydraulic Overload Pressure.................................................................................194
4.4.9 Setting the Header Index Mode..............................................................................................196
4.4.10 Setting the Return to Cut Mode..............................................................................................198
4.4.11 Setting the Header Cut Width.................................................................................................201
4.4.12 Activating the Double Windrow Attachment (DWA)..................................................................204
4.4.13 Setting the Auto Raise Height ................................................................................................207
4.4.14 Activating the Hay Conditioner...............................................................................................209
4.4.15 Displaying Reel Speed ..........................................................................................................211
4.4.16 Displaying the Speed of the Auger Header Reel......................................................................213
4.4.17 Setting the Windrower’s Tire Size...........................................................................................215
4.4.18 Setting the Engine Intermediate Speed Control (ISC) RPM on an M105....................................217
4.4.19 Setting the Engine Intermediate Speed Control (ISC) RPM on an M155/M205 ..........................218
4.4.20 Clearing Sub-Acres...............................................................................................................221
4.5 Activating Cab Display Lockouts....................................................................................................222
4.5.1 Activating Knife Speed Control Lockout ..................................................................................222
4.5.2 Activating Rotary Disc Speed Control Lockout.........................................................................224
4.5.3 Activating the Header Float Control Lockout............................................................................227
147962 xRevision A

TABLE OF CONTENTS
4.5.4 Activating the Draper Speed Control Lockout..........................................................................230
4.5.5 Activating the Auger Speed Control Lockout ...........................................................................234
4.5.6 Activating the Reel Speed Control Lockout .............................................................................237
4.5.7 Activating the Reel Fore-Aft Control Lockout...........................................................................241
4.5.8 Activating the Header Tilt Control Lockout...............................................................................245
4.6 Displaying Activated Cab Display Lockouts ....................................................................................249
4.7 Troubleshooting Windrower Problems............................................................................................253
4.7.1 Displaying the Windrower and Engine Error Codes..................................................................253
4.7.2 Switching the Installed Header Sensors ON or OFF.................................................................256
4.7.3 Displaying Header Sensor Input Signals.................................................................................260
4.7.4 Forcing a Header ID..............................................................................................................264
4.8 Troubleshooting Header Problems.................................................................................................268
4.8.1 Testing the Header Up/Down Activate Function Using the Cab Display Module (CDM) ..............268
4.8.2 Testing the Reel Up/Down Activate Function Using the Cab Display Module (CDM)...................273
4.8.3 Testing the Header Tilt Activate Function Using the Cab Display Module (CDM)........................278
4.8.4 Testing the Knife Drive Circuit Activate Function Using the Cab Display Module (CDM) on an
M105 ...............................................................................................................................283
4.8.5 Testing the Draper or Auger Drive Circuit Activate Function Using the Cab Display Module
(CDM) on an M105 ...........................................................................................................284
4.8.6 Testing the Reel Drive Circuit Activate Function Using the Cab Display Module (CDM) on an
M105 ...............................................................................................................................286
4.8.7 Testing the Reel Fore-Aft Activate Function Using the Cab Display Module (CDM)....................288
4.8.8 Activating the Hydraulic Purge Using the Cab Display Module (CDM).......................................293
4.8.9 Testing the Knife Drive Circuit Using the Cab Display Module (CDM)........................................297
4.8.10 Testing the Draper Drive Circuit Activate Function Using the Cab Display Module (CDM) ...........301
4.8.11 Testing the Reel Drive Circuit Activate Function Using the Cab Display Module (CDM)..............305
4.8.12 Testing the Rotary Disc Drive Circuit Activate Function Using the Cab Display
Module (CDM)..................................................................................................................309
4.8.13 Testing the Double Windrower Attachment (DWA) Drive Activate Function Using the Cab
Display Module (CDM) ......................................................................................................313
5 Performing Predelivery Checks..........................................................................................................319
5.1 Recording Serial Numbers ............................................................................................................319
5.2 Checking and Adding Wheel Drive Lubricant Level .........................................................................321
5.3 Checking Tire Pressures and Adding Tire Ballast............................................................................322
5.3.1 Checking Tire Pressures........................................................................................................322
5.3.2 Adding Tire Ballast................................................................................................................322
5.4 Checking Engine Air Intake ...........................................................................................................324
5.5 Checking Hydraulic Oil..................................................................................................................327
5.6 Checking Fuel Separator...............................................................................................................328
5.7 Checking Engine Coolant..............................................................................................................329
5.8 Checking Gearbox Lubricant Level on an M155/M205.....................................................................330
5.9 Checking Air Conditioning (A/C) Compressor Belts.........................................................................331
5.10 Checking Safety System ...............................................................................................................332
5.11 Performing Operational Checks.....................................................................................................334
5.11.1 Checking Engine Warning Lights............................................................................................336
5.11.2 Checking Fuel Level on an M105 ...........................................................................................336
5.11.3 Checking Windrower Startup..................................................................................................337
5.11.4 Checking Engine Speed ........................................................................................................338
5.11.5 Checking Gauges and Cab Display Module (CDM) Display......................................................338
5.11.6 Checking Cab Display Module (CDM) Display on an M105 ......................................................339
5.11.7 Checking Electrical System....................................................................................................340
5.11.8 Checking Operator's Presence System...................................................................................341
5.11.9 Checking Exterior Lights........................................................................................................342
Checking Exterior Lights on an M155/M205.....................................................................343
147962 xi Revision A

TABLE OF CONTENTS
Checking Exterior Lights on an M105..............................................................................346
5.11.10 Checking Horn......................................................................................................................349
5.11.11 Checking Interior Lights.........................................................................................................349
5.11.12 Checking Air Conditioning (A/C) and Heater............................................................................350
5.11.13 Setting and Adjusting Knife Speed..........................................................................................351
Setting Knife Speed.......................................................................................................352
Adjusting Knife Speed....................................................................................................353
5.12 Checking Manuals........................................................................................................................355
5.13 Performing Final Steps..................................................................................................................356
6 Reference...........................................................................................................................................357
6.1 Torque Specifications....................................................................................................................357
6.1.1 SAE Bolt Torque Specifications..............................................................................................357
6.1.2 Metric Bolt Specifications.......................................................................................................359
6.1.3 Metric Bolt Specifications Bolting into Cast Aluminum..............................................................362
6.1.4 Flare-Type Hydraulic Fittings..................................................................................................362
6.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)..................................................................364
6.1.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) ..........................................................366
6.1.7 O-Ring Face Seal (ORFS) Hydraulic Fittings...........................................................................367
6.1.8 Tapered Pipe Thread Fittings.................................................................................................369
6.2 Conversion Chart..........................................................................................................................370
6.3 Definitions....................................................................................................................................371
6.4 Lubricants, Fluids, and System Capacities......................................................................................374
6.5 Fuel Specifications........................................................................................................................378
Predelivery Checklist ....................................................................................................................379
147962 xiiRevision 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
Indicatesapo
tentially hazardous situation that, if not avoided, could result in death or serious injury. It
mayalsobeuse
d 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.
147962 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 protective clothing and personal safety devices
that could be necessary for job at hand. Do NOT take
chances. You may need the following:
• Hard hat
• Protective footwear with slip resistant soles
• Protective glasses or goggles
• Heavy gloves
• Wet weather gear
• Respirator or filter mask
Figure 1.1: Safety Equipment
• Be aware that exposure to loud noises can cause
hearing impairment or loss. Wear suitable hearing
protection devices such as ear muffs or ear plugs to
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 fire
extinguisher is properly maintained. Be familiar with its
proper use.
• Keep young children away from machinery at all times.
• Be aware that accidents often happen when Operator
istiredorinahurry.Taketimetoconsidersafestway.
Never ignore warning signs of fatigue.
Figure 1.3: Safety Equipment
147962 2Revision A

SAFETY
•Wearclose-fitting 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 shaft and can telescope freely.
• Use only service and repair parts made or approved
by 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 engine is running.
•DoNOT modify machine. Non-authorized modifications
may impair machine function and/or safety. It may also
shorten machine’s life.
• To avoid bodily injury or death from unexpected startup
of machine, ALWAYS stop engine and remove key from
ignition before leaving operator’s seat for any reason.
Figure 1.5: Safety around Equipment
• Keep service area 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 is 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
147962 3Revision A

SAFETY
1.3 Battery Safety
WARNING
• Keep all sparks and flames away from batteries, as
a gas given off by electrolyte is explosive.
• Ventilate when charging in enclosed space.
Figure 1.7: Safety around Batteries
WARNING
• Wear safety glasses when working near batteries.
• Do NOT tip batteries more than 45° to avoid
electrolyte loss.
• Battery electrolyte causes severe burns. Avoid
contact with skin, eyes, or clothing.
• Electrolyte splashed into eyes is extremely
dangerous. Should this occur, force eye open, and
flood with cool, clean water for five minutes. Call
a doctor immediately.
• If electrolyte is spilled or splashed on clothing or
body, neutralize it immediately with a solution of
baking soda and water, then rinse with clear water.
Figure 1.8: Safety around Batteries
WARNING
• To avoid injury from spark or short circuit,
disconnect battery ground cable before servicing
and part of electrical system.
• Do NOT operate engine with alternator or battery
disconnected. With battery cables disconnected
and engine running, a high voltage can be
built up if terminals touch frame. Anyone
touching frame under these conditions would be
severely shocked.
• When working around storagebatteries, remember
that all of the exposed metal parts are live. Never
layametalobjectacrossterminalsbecauseaspark
or short circuit will result.
• Keep batteries out of reach of children.
Figure 1.9: Safety around Batteries
147962 4Revision A

SAFETY
1.4 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 repair part also bears current
safety sign.
• Safety signs are available from your MacDon Dealer.
Figure 1.10: Operator’s Manual Decal
147962 5Revision A