MacDon M100 2009 User manual

Form 169304 1Model Year - 2009
1 INTRODUCTION
This manual contains information on the MacDon Model M100 Self-Propelled Windrower that is designed to cut
and lay in windrows, a wide variety of grain, hay and specialty crops. Windrowing allows starting the harvest
earlier, protects the crop from wind damage, and gives you more flexibility in scheduling combine time.
The power unit (referred to in this manual as the “tractor”), when coupled with one of the specially designed
auger, or draper headers, provides a package which incorporates many features and improvements in design.
This manual must be used in conjunction with your Header Operator's Manual.
CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE, OR
USE THE MACHINE.
Use this manual as your first source of information about the machine. If you follow the instructions given in this
manual, your M100 Windrower will work well for many years. If you require more detailed service information,
check with your dealer.
Use the Table of Contents and the Index to guide you to specific areas. Study the Table of Contents to familiarize
yourself with how the material is organized.
Keep this manual handy for frequent reference and to pass on to new operators or owners. Call your dealer if you
need assistance, information, or additional copies of this manual. A manual storage case is provided in the cab.
NOTE: Right-Hand and Left-Hand designations are determined by the operator’s position, facing the direction of
travel.
RECORD THE SERIAL NUMBERS IN THE SPACES BELOW.
Windrower Tractor_______________________
Serial Number plate is located on the left side of
the main frame, near the rear corner.
M100 Diesel Engine___________________________
Serial Number plate is located on the right side of the
engine block.
.

TABLE OF CONTENTS
Form # 169304 2 Model Year - 2009
Section/Title Page
1INTRODUCTION ....................................................................................................................................1
2SAFETY .................................................................................................................................................5
2.1 SAFETY ALERT SYMBOL ............................................................................................................5
2.2 SIGNAL WORDS...........................................................................................................................5
2.3 SAFETY SIGNS.............................................................................................................................5
2.3.1 Safety Sign Installation............................................................................................................................. 5
2.3.2 Safety Sign Locations .............................................................................................................................. 5
2.4 GENERAL SAFETY.....................................................................................................................10
3ACRONYMS AND ABBREVIATIONS.................................................................................................12
4SPECIFICATIONS ...............................................................................................................................13
4.1 TRACTOR DIMENSIONS............................................................................................................13
4.2 SPECIFICATIONS.......................................................................................................................14
5OPERATOR’S STATION .....................................................................................................................16
5.1 OPERATOR CONSOLE ..............................................................................................................16
5.2 SEAT ADJUSTMENTS................................................................................................................16
5.3 TRAINING SEAT (Optional) ........................................................................................................17
5.4 SEAT BELTS ...............................................................................................................................17
5.5 STEERING COLUMN ADJUSTMENT ........................................................................................17
5.6 OPERATOR PRESENCE............................................................................................................18
5.6.1 Header Drive .......................................................................................................................................... 18
5.6.2 Transmission.......................................................................................................................................... 18
5.6.3 Engine .................................................................................................................................................... 18
5.7 LIGHTS ........................................................................................................................................19
5.7.1 Field Lighting.......................................................................................................................................... 19
5.7.2 Road Lighting ......................................................................................................................................... 20
5.7.3 Beacon Lighting – Export ....................................................................................................................... 20
5.8 WINDSHIELD WIPERS ...............................................................................................................21
5.9 REAR VIEW MIRRORS...............................................................................................................21
5.10 CAB TEMPERATURE .................................................................................................................22
5.10.1 Controls.................................................................................................................................................. 22
5.10.2 Air Distribution........................................................................................................................................ 22
5.10.3 Heater Shut-Off Valve ............................................................................................................................ 22
5.10.4 A/C Compressor Protection.................................................................................................................... 23
5.11 INTERIOR LIGHTS......................................................................................................................23
5.12 OPERATOR AMENITIES ............................................................................................................23
5.13 RADIOS .......................................................................................................................................24
5.13.1 AM/FM Radio ......................................................................................................................................... 24
5.13.2 Antenna Mounting .................................................................................................................................. 24
5.14 HORN ..........................................................................................................................................24
5.15 ENGINE CONTROLS/GAUGES..................................................................................................25
5.16 WINDROWER CONTROLS ........................................................................................................26
5.17 HEADER CONTROLS.................................................................................................................27
5.17.1 Header Engage Switch .......................................................................................................................... 27
5.17.2 GSL Header Switches ............................................................................................................................ 27
5.17.3 Console Header Switches ...................................................................................................................... 29
5.18 CAB DISPLAY MODULE (CDM) .................................................................................................30
5.18.1 Engine and Windrower Tractor Functions .............................................................................................. 30
5.18.2 Header Functions................................................................................................................................... 30
5.18.3 Operating Screens ................................................................................................................................. 31
5.18.4 Cab Display Module (CDM) Warnings/Alarms ....................................................................................... 36
5.18.5 Cab Display Module (CDM) Programming ............................................................................................. 39
5.18.6 Engine Error Codes................................................................................................................................ 44
5.18.7 CDM & WCM Fault Codes ..................................................................................................................... 44
6OPERATION ........................................................................................................................................45
6.1 OWNER/OPERATOR RESPONSIBILITIES................................................................................45
6.2 SYMBOL DEFINITIONS ..............................................................................................................45
6.2.1 Engine Functions ................................................................................................................................... 45

TABLE OF CONTENTS
Form 169304 3Model Year - 2009
6.2.2 Windrower Tractor Operating Symbols ...................................................................................................45
6.2.3 Header Functions....................................................................................................................................46
6.3 WINDROWER TRACTOR OPERATION.....................................................................................47
6.3.1 Operational Safety ..................................................................................................................................47
6.3.2 Break-In Period .......................................................................................................................................47
6.3.3 Pre-Season Check..................................................................................................................................48
6.3.4 Daily Check.............................................................................................................................................48
6.3.5 Engine Operation ....................................................................................................................................49
6.3.6 Driving the Windrower.............................................................................................................................53
6.3.7 Adjustable Caster Tread Width (Optional) ..............................................................................................57
6.3.8 Transporting............................................................................................................................................58
6.3.9 Storage ...................................................................................................................................................61
6.4 HEADER OPERATION................................................................................................................62
6.4.1 Header Lift Cylinder Stops ......................................................................................................................62
6.4.2 Header Flotation .....................................................................................................................................63
6.4.3 Header Drive...........................................................................................................................................66
6.4.4 Header Angle..........................................................................................................................................66
6.4.5 Cutting Height .........................................................................................................................................68
6.5 D SERIES HEADER OPERATION..............................................................................................70
6.5.1 Header Attachment - D Series ................................................................................................................70
6.5.2 Header Detachment - D Series ...............................................................................................................73
6.5.3 Reel Speed .............................................................................................................................................75
6.5.4 Draper Speed .........................................................................................................................................77
6.5.5 Knife Speed ............................................................................................................................................79
6.5.6 Deck Shift (Optional)...............................................................................................................................81
6.6 A SERIES HEADER OPERATION ..............................................................................................82
6.6.1 Header Attachment – A Series ...............................................................................................................82
6.6.2 Header Detachment – A Series ..............................................................................................................84
6.6.3 Auger Speed...........................................................................................................................................86
6.6.4 Knife Speed ............................................................................................................................................87
7MAINTENANCE/SERVICE ..................................................................................................................89
7.1 PREPARATION FOR SERVICING .............................................................................................89
7.1.1 Welding Precautions ...............................................................................................................................89
7.2 RECOMMENDED SAFETY PROCEDURES ..............................................................................89
7.3 MAINTENANCE SPECIFICATIONS ...........................................................................................90
7.3.1 Recommended Fluids, Fuel, and Lubricants...........................................................................................90
7.3.2 Recommended Torques .........................................................................................................................91
7.3.3 Conversion Chart ....................................................................................................................................93
7.4 ENGINE COMPARTMENT HOOD ..............................................................................................94
7.5 MAINTENANCE PLATFORM ......................................................................................................95
7.5.1 Opening/Closing Platform .......................................................................................................................95
7.5.2 Opening/Closing Platform for Major Servicing ........................................................................................95
7.6 LUBRICATING THE WINDROWER............................................................................................96
7.6.1 Procedure ...............................................................................................................................................96
7.6.2 Lubrication Points ...................................................................................................................................97
7.7 OPERATOR’S STATION.............................................................................................................98
7.7.1 Seat Belts ...............................................................................................................................................98
7.7.2 Safety Systems .......................................................................................................................................98
7.7.3 Traction Drive Adjustments.....................................................................................................................99
7.7.4 Neutral Set-Up Procedure.....................................................................................................................104
7.7.5 HVAC System .......................................................................................................................................106
7.8 ENGINE .....................................................................................................................................109
7.8.1 General Engine Inspection....................................................................................................................109
7.8.2 Oil Level ................................................................................................................................................109
7.8.3 Changing Oil and Oil Filter....................................................................................................................110
7.8.4 Air Intake System..................................................................................................................................111
7.8.5 Fuel System..........................................................................................................................................114
7.8.6 Engine Cooling System.........................................................................................................................119
7.8.7 Exhaust System ....................................................................................................................................122
7.8.8 Belts......................................................................................................................................................123
7.8.9 Engine Speed .......................................................................................................................................124
7.9 COOLING BOX..........................................................................................................................125
7.9.1 Cooling Box Screen Cleaners ...............................................................................................................125

TABLE OF CONTENTS
Form # 169304 4 Model Year - 2009
7.9.2 Cooling Box Maintenance .................................................................................................................... 127
7.10 ELECTRICAL SYSTEM.............................................................................................................129
7.10.1 Battery.................................................................................................................................................. 129
7.10.2 Headlights ............................................................................................................................................ 134
7.10.3 Flood Lights - Forward ......................................................................................................................... 135
7.10.4 Flood Lights - Rear............................................................................................................................... 136
7.10.5 Swath Lights......................................................................................................................................... 137
7.10.6 Ambient Light ....................................................................................................................................... 139
7.10.7 Turn Signal Indicators .......................................................................................................................... 139
7.10.8 Circuit Breakers and Fuses .................................................................................................................. 140
7.11 HYDRAULIC SYSTEM ..............................................................................................................142
7.11.1 Oil Level ............................................................................................................................................... 142
7.11.2 Changing Hydraulic Oil ........................................................................................................................ 143
7.11.3 Hydraulic Oil Cooler ............................................................................................................................. 143
7.11.4 Hydraulic Oil Filters .............................................................................................................................. 143
7.11.5 Header and Reel Hydraulics ................................................................................................................ 144
7.11.6 Traction Drive Hydraulics ..................................................................................................................... 146
7.11.7 Hoses and Lines .................................................................................................................................. 147
7.12 WHEELS AND TIRES ...............................................................................................................148
7.12.1 Drive Wheels........................................................................................................................................ 148
7.12.2 Caster Wheels...................................................................................................................................... 151
7.13 MAINTENANCE SCHEDULE ....................................................................................................155
7.13.1 Break-In Inspection .............................................................................................................................. 155
7.13.2 Interval Maintenance............................................................................................................................ 156
8TROUBLESHOOTING.......................................................................................................................159
8.1 ENGINE .....................................................................................................................................159
8.2 ELECTRICAL.............................................................................................................................161
8.3 HYDRAULICS............................................................................................................................162
8.4 HEADER DRIVE ........................................................................................................................162
8.5 TRACTION DRIVE ....................................................................................................................163
8.6 STEERING AND GROUND SPEED CONTROL.......................................................................164
8.7 CAB AIR.....................................................................................................................................165
8.8 OPERATOR’S STATION...........................................................................................................167
9OPTIONS ...........................................................................................................................................168
9.1 REEL DRIVE & LIFT PLUMBING..............................................................................................168
9.2 TRACTOR HYDRAULIC COMPLETION FOR DRAPER HEADER REEL FORE/AFT ............168
9.3 BOOSTER SPRING KIT............................................................................................................168
9.4 INTERNAL BOOSTER SPRING KIT .........................................................................................168
9.5 LIGHT HEADER FLOTATION KIT ............................................................................................168
9.6 AM-FM RADIO...........................................................................................................................168
9.7 HYDRAULIC CENTER LINK .....................................................................................................168
9.8 TRAINING SEAT .......................................................................................................................168
9.9 KNIFE SPEED, REEL SPEED INDEX, AND TILT SENSOR MODULE ...................................168
9.10 ANTI-SHIMMY KIT FOR CASTERS..........................................................................................168
9.11 SWATH ROLLER ......................................................................................................................168
9.12 WARNING BEACONS...............................................................................................................168
9.13 AUTO-STEER............................................................................................................................168
9.14 ENGINE BLOCK HEATER ........................................................................................................168
INDEX .........................................................................................................................................................169
CDM/WCM FAULT CODES........................................................................................................................172
ENGINE ERROR CODES...........................................................................................................................173
HYDRAULIC AND ELECTRICAL SCHEMATICS

SAFETY
Form 169304 5Model Year - 2009
2 SAFETY
2.1 SAFETY ALERT SYMBOL
This safety alert symbol indicates important
safety messages in this manual and on safety
signs on the machine.
This symbol means:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Carefully read and follow the safety message
accompanying this symbol.
WHY IS SAFETY IMPORTANT TO YOU?
ACCIDENTS DISABLE AND KILL
ACCIDENTS COST
ACCIDENTS CAN BE AVOIDED
2.2 SIGNAL WORDS
Note the use of the signal words DANGER,
WARNING, and CAUTION with safety
messages. The appropriate signal word for each
message 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 is also used to alert against
unsafe practices.
CAUTION
Indicates a potentially hazardous situation
that, if not avoided, may result in minor or
moderate injury. It is also used as a reminder
of good safety practices.
2.3 SAFETY SIGNS
2.3.1 Safety Sign Installation
Refer to the illustration on this and following
pages and proceed as follows:
a. Be sure the installation area is clean and dry.
b. Decide on the exact location before you remove
the decal backing paper.
c. Remove the smaller portion of the split backing
paper.
d. Place the sign in position and slowly peel back
the remaining paper, smoothing the sign as it is
applied.
e. Small air pockets can be smoothed out or
pricked with a pin.
2.3.2 Safety Sign Locations
The safety signs (decals) appear on the
windrower tractor at the locations approximately
as shown.
a. Keep safety signs clean and legible at all times.
b. Replace safety signs that are missing or become
illegible.
c. If original parts on which a safety sign was
installed are replaced, be sure the repair part
also bears the current safety sign.
d. Safety signs are available from your Dealer
Parts Department.

SAFETY
Form # 169304 6 Model Year - 2009
Safety Sign Locations (continued)
LIFT LINKAGES #163561
FRONT OF PLATFORM #134070
BEHIND DOOR #109843
BELOW DOOR HANDLE #32744
IN CAB #32744

SAFETY
Form 169304 7Model Year - 2009
Safety Sign Locations (continued)
IN CAB #109844
IN CAB #109868

SAFETY
Form # 169304 8 Model Year - 2009
Safety Sign Locations (continued)
ON FRAME #42130
ON FAN SHROUD #134068
ON FRAME #110986

SAFETY
Form 169304 9Model Year - 2009
Safety Sign Locations (continued)
INSIDE FRAME #32743
ON FRAME #110986
ON LIFT LINKAGE #163562

SAFETY
Form # 169304 10 Model Year - 2009
2.4 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:
•a hard hat.
•protective shoes with slip
resistant soles.
•protective glasses or goggles.
•heavy gloves.
•wet weather gear.
•respirator or filter mask.
•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.
A
B
•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.