MacDon M1240 User manual

The harvesting specialists.
M1240
Self-Propelled Windrower
Operator’s Manual
214053 Revision A
2017 Model Year
Original Instruction

This manual contains instructions for safety, operation, maintenance, and service for the MacDon M1240
Self-Propelled Windrower, featuring Dual Direction®and CrossFlex™rear suspension.
Published November 2016
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects,
and other reproductive harm. Battery posts, terminals, and related accessories contain lead and lead components.
Wash hands after handling.
Whole Body and Hand-Arm Vibration Levels
The weighted root mean square acceleration, to which the whole body is subjected, ranges from 0.46 to 1.52 m/s2
as measured on a representative machine during typical operations and analyzed in accordance with ISO 5008.
During the same operations, the weighted root means square hand-arm vibration was less than 1.79 m/s2when
analyzed in accordance with ISO 5349. These acceleration values depend on the roughness of the ground, the
speeds at which the windrower is operated, the operator's experience, weight, and driving habits.
Noise Levels
The A-weighted sound pressure levels inside the operator's station ranged from 69.3 to 69.7 dB(A) as measured
on several representative machines in accordance with ISO 5131. The sound pressure level depends upon the
engine speed and load, field and crop conditions, and the type of platform used.

Introduction
This instruction manual contains information on the MacDon M1240 Self-Propelled Windrower, which when coupled
with one of MacDon’s R85 Rotary Disc Headers, A40-D Auger Headers, or D1 Series Draper Headers, provides a
package designed to cut and lay a variety of crops into fluffy, uniform windrows.
Carefully read all the material provided before attempting to use the machine.
If you follow the instructions provided, your M1240 Self-Propelled Windrower will work well for many years.
Use this manual as your first source of information about the machine. 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.
Use this manual in conjunction with your header operator's manual.
When setting up the machine or making adjustments, review and follow the recommended machine settings in all
relevant MacDon publications. Failure to do so may compromise the machine function and machine life and may
result in a hazardous situation.
MacDon provides warranty for Customers who operate and maintain their equipment as described in this manual.
A copy of the MacDon Industries Limited Warranty Policy, which explains this warranty, should have been provided
to you by your Dealer. Damage resulting from any of the following conditions will void the warranty:
•Accident
•Misuse
• Abuse
• Improper maintenance or neglect
• Abnormal or extraordinary use of the machine
• Failure to use the machine, equipment, component, or part in accordance with the manufacturer’s instructions
A manual storage case is provided in the cab. 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.
Conventions
The M1240 Self-Propelled Windrower is Dual Direction®, meaning the windrower can be driven in cab-forward or
engine-forward modes. Right and left designations are therefore determined from the operator’s position, facing the
direction of travel. This manual uses the terms “right cab-forward”, “left cab-forward”, “right engine-forward”, and
“left engine-forward” when referencing specific locations on the machine.
214053 iRevision A

Serial Number
If you require MacDon technical assistance, please have the machine’s serial numbers recorded and ready before
you call.
Record the model number, model year, and serial number of the windrower and engine on the lines below.
The windrower serial number plate (A) is located on the left
side of the main frame near the walking beam.
Windrower Model Number
Windrower Serial Number
Year of Manufacture
Figure 1: Windrower Serial Number Location
The engine serial number plate (A) is located on top of the
engine cylinder head cover.
Engine Serial Number
Year of Manufacture
Figure 2: Engine Serial Number Location
214053 ii Revision A

TABLE OF CONTENTS
Introduction ...................................................................................................................................... i
Serial Number ................................................................................................................................. ii
1 Safety .................................................................................................................................................... 1
1.1 Safety Alert Symbols........................................................................................................................ 1
1.2 Signal Words................................................................................................................................... 2
1.3 General Safety ................................................................................................................................ 3
1.4 Maintenance Safety ......................................................................................................................... 5
1.5 Hydraulic Safety .............................................................................................................................. 6
1.6 Tire Safety....................................................................................................................................... 7
1.7 Battery Safety.................................................................................................................................. 8
1.8 Welding Precaution.......................................................................................................................... 9
1.9 Engine Safety................................................................................................................................ 14
1.9.1 High Pressure Rails................................................................................................................ 14
1.9.2 Engine Electronics ................................................................................................................. 15
1.10 Safety Signs.................................................................................................................................. 16
1.10.1 Installing Safety Decals .......................................................................................................... 16
1.11 Safety Sign Locations .................................................................................................................... 17
1.12 Understanding Safety Signs ........................................................................................................... 19
2 Product Overview................................................................................................................................29
2.1 Definitions ..................................................................................................................................... 29
2.2 Specifications ................................................................................................................................ 32
2.3 Windrower Dimensions .................................................................................................................. 36
2.4 Component Location...................................................................................................................... 37
3 Operator’s Station ............................................................................................................................... 39
3.1 Operator Console .......................................................................................................................... 39
3.2 Operator Presence System ............................................................................................................ 41
3.2.1 Header Drive ......................................................................................................................... 41
3.2.2 Engine and Transmission........................................................................................................ 41
3.3 Operator’s Seat Adjustments.......................................................................................................... 42
3.3.1 Armrest ................................................................................................................................. 42
3.3.2 Armrest Angle ........................................................................................................................ 43
3.3.3 Suspension and Height........................................................................................................... 43
3.3.4 Fore-Aft Slide Control ............................................................................................................. 44
3.3.5 Fore-Aft Isolator Control.......................................................................................................... 44
3.3.6 Tilt......................................................................................................................................... 45
3.3.7 Lumbar Support ..................................................................................................................... 45
3.3.8 Vertical Dampener.................................................................................................................. 46
3.3.9 Cushion Tilt (Deluxe Cab Only) ............................................................................................... 46
3.3.10 Cushion Extension (Deluxe Cab Only)..................................................................................... 47
3.3.11 Lateral Isolation Lockout (Deluxe Cab Only)............................................................................. 47
3.3.12 Heating/Cooling (Deluxe Cab Only) ......................................................................................... 48
3.4 Training Seat................................................................................................................................. 49
3.5 Seat Belts ..................................................................................................................................... 50
3.6 Adjusting the Steering Column and Steering Wheel ......................................................................... 51
3.7 Lighting......................................................................................................................................... 52
3.7.1 Cab-Forward Lighting – Field ..................................................................................................52
3.7.2 Cab-Forward Lighting – Road ................................................................................................. 53
3.7.3 Engine-Forward Lighting – Road ............................................................................................. 54
3.7.4 Tail/Beacon Lighting ............................................................................................................... 56
3.7.5 Turn Signal / Hazard Lighting ..................................................................................................57
3.8 Windshield Wipers ......................................................................................................................... 58
3.9 Rear View Mirrors .......................................................................................................................... 59
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TABLE OF CONTENTS
3.10 Cab Temperature........................................................................................................................... 60
3.10.1 Heater Shut-Off Valve............................................................................................................. 60
3.10.2 Air Distribution ....................................................................................................................... 60
3.10.3 Climate Controls .................................................................................................................... 61
3.11 Operator Amenities........................................................................................................................ 62
3.12 Radio............................................................................................................................................ 64
3.12.1 AM/FM/CD/USB Radio with Bluetooth®Wireless Technology .................................................... 64
Activating Bluetooth®Feature .......................................................................................... 64
Pairing a Bluetooth®Device............................................................................................. 65
3.13 Horn ............................................................................................................................................. 66
3.14 Engine Controls............................................................................................................................. 67
3.14.1 Using Eco Engine Control (EEC) ............................................................................................. 68
3.15 Windrower Controls ....................................................................................................................... 69
3.16 Header Controls ............................................................................................................................ 70
3.16.1 Header Engage Switch ........................................................................................................... 70
3.16.2 Header Drive Reverse Button..................................................................................................70
3.16.3 Ground Speed Lever (GSL) Switches ...................................................................................... 71
Header Position Six-Way Switch ...................................................................................... 72
Reel Position Four-Way Switch........................................................................................ 73
Reel and Disc Speed Switch............................................................................................ 73
One-Touch-Return Buttons (A, B, C) ................................................................................ 74
3.16.4 Console Header Buttons......................................................................................................... 75
Deck Shift / Float Presets................................................................................................. 76
Conveyer Speed Adjustment Buttons ............................................................................... 77
Auxiliary Lift Switches ..................................................................................................... 77
3.17 Harvest Performance Tracker (HPT) Display ................................................................................... 78
3.17.1 Harvest Performance Tracker (HPT) Screen Layout ................................................................. 78
3.17.2 Navigating the Harvest Performance Tracker (HPT) Display...................................................... 81
Scroll Knob, Scroll Wheel, and Select Button.................................................................... 81
Home, Back, and Select Buttons...................................................................................... 82
Soft Keys ....................................................................................................................... 82
QuickMenu System......................................................................................................... 83
Main Menu ..................................................................................................................... 84
Menu Icons .................................................................................................................... 84
Faults and Telltales ......................................................................................................... 88
3.17.3 Setting up the Harvest Performance Tracker (HPT) Screen....................................................... 89
Setting Screen Brightness and Volume............................................................................. 89
Setting Time and Date..................................................................................................... 91
Setting Language and Units of Measure........................................................................... 92
Resetting to Factory Defaults........................................................................................... 93
3.17.4 Calibrating the Windrower and Header .................................................................................... 94
3.17.5 Setting Windrower Tire Size.................................................................................................... 97
3.17.6 Activating Control Locks ......................................................................................................... 98
3.17.7 Machine Information Pages..................................................................................................... 99
Windrower Information .................................................................................................... 99
Header Information ........................................................................................................100
Software Information......................................................................................................101
Performance Information ................................................................................................102
3.17.8 F1 to F4 Function Buttons......................................................................................................103
4 Operation ...........................................................................................................................................105
4.1 Owner/Operator Responsibilities....................................................................................................105
4.2 Symbol Definitions ........................................................................................................................106
4.2.1 Windrower Operating Symbols...............................................................................................107
4.2.2 Harvest Performance Tracker Symbols...................................................................................108
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TABLE OF CONTENTS
4.3 Operating the Windrower...............................................................................................................110
4.3.1 Operational Safety ................................................................................................................110
4.3.2 Break-in Period ..................................................................................................................... 111
4.3.3 Preseason Checks/Annual Service......................................................................................... 111
Air Conditioning Compressor Coolant Cycling..................................................................112
4.3.4 Daily Checks and Maintenance ..............................................................................................112
Filling Fuel Tank.............................................................................................................113
Filling the Diesel Exhaust Fluid (DEF) Tank ..................................................................... 113
Checking Engine Oil Level..............................................................................................114
4.3.5 Engine Operation ..................................................................................................................115
Starting the Engine ........................................................................................................115
Programming the Eco Engine Control (EEC) ...................................................................119
Shutting down the Engine...............................................................................................120
Engine Temperature.......................................................................................................121
Engine Oil Pressure .......................................................................................................121
Exhaust System Cleaning ..............................................................................................122
RunScreen3–PerformanceData.................................................................................123
RunScreen4–CoolingData.........................................................................................124
4.3.6 Operating the Windrower .......................................................................................................125
Entering and Exiting the Windrower ................................................................................125
Adjusting Ground Speed Limit ........................................................................................126
Driving Forward in Cab-Forward Mode ............................................................................127
Driving in Reverse in Cab-Forward Mode ........................................................................128
Driving Forward in Engine-Forward Mode........................................................................129
Driving in Reverse in Engine-Forward Mode....................................................................130
Spin Turning..................................................................................................................131
Stopping .......................................................................................................................132
4.3.7 Transporting..........................................................................................................................133
Driving on Road in Engine-Forward Mode .......................................................................133
Driving on Road in Cab-Forward Mode............................................................................136
Towing Header with Windrower.......................................................................................138
Towing the Windrower (Emergency)................................................................................141
4.3.8 Storing the Windrower ...........................................................................................................142
4.4 Attaching and Detaching Headers..................................................................................................144
4.4.1 A40-D Auger Header .............................................................................................................144
Attaching an A40-D Auger Header ..................................................................................144
Connecting A40-D Hydraulics.........................................................................................149
Detaching an A40-D Auger Header.................................................................................151
4.4.2 D1X or D1XL Series Header ..................................................................................................155
Attaching Draper Header Supports .................................................................................155
Attaching a D1X or D1XL Series Header .........................................................................156
Connecting D1X or D1XL Series Hydraulics ....................................................................161
Detaching a D1X or D1XL Series Header ........................................................................163
4.4.3 R85 16-Foot Header..............................................................................................................167
Attaching an R85 16-Foot Header...................................................................................167
Connecting R85 16-Foot Header Hydraulics....................................................................173
Detaching R85 16-Foot Header ......................................................................................175
4.5 Operating with a Header ...............................................................................................................180
4.5.1 Engaging and Disengaging Header Safety Props ....................................................................180
4.5.2 Using Header Float ...............................................................................................................181
Checking Float ..............................................................................................................181
Setting the Float ............................................................................................................182
Removing and Restoring Float........................................................................................184
4.5.3 Header Drive ........................................................................................................................185
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TABLE OF CONTENTS
Engaging and Disengaging the Header ...........................................................................185
Reversing the Header ....................................................................................................185
4.5.4 Adjusting Header Angle .........................................................................................................186
Checking Self-Locking Center-Link Hook.........................................................................187
4.5.5 Setting Cutting Height............................................................................................................189
4.5.6 Double Windrowing ...............................................................................................................189
Double Windrow Attachment (DWA) Deck Position ..........................................................190
Double Windrow Attachment (DWA) Conveyor Speed......................................................190
4.5.7 Swath Roller Operation..........................................................................................................191
4.5.8 One-Touch-Return.................................................................................................................192
4.5.9 Adjusting Header Raise and Lower Rates...............................................................................192
4.6 Operating with D1X or D1XL Series Headers..................................................................................194
4.6.1 Header Position ....................................................................................................................194
4.6.2 Adjusting Reel Fore-Aft Position.............................................................................................194
4.6.3 Adjusting Reel Height ............................................................................................................194
4.6.4 Leveling the Header ..............................................................................................................195
4.6.5 Adjusting Reel Speed ............................................................................................................197
Setting Reel Speed in Auto Mode ...................................................................................198
Setting Reel Speed in Manual Mode ...............................................................................199
Adjusting Reel Alarm Pressure .......................................................................................201
4.6.6 Adjusting Draper Speed.........................................................................................................202
Setting Draper Speed in Auto Mode ................................................................................203
Setting Draper Speed in Manual Mode ............................................................................204
Adjusting Draper Alarm Pressure....................................................................................206
Draper Slip Warning.......................................................................................................207
4.6.7 Knife Speed..........................................................................................................................208
Setting Knife Speed .......................................................................................................208
Adjusting Knife Alarm Pressure – Draper Header.............................................................210
Adjusting Knife Speed Alarm .........................................................................................211
4.6.8 Deck Shift Control .................................................................................................................212
Deck Shift .....................................................................................................................212
Setting Float Options with Deck Shift...............................................................................213
4.6.9 Draper Header Run Screens..................................................................................................215
Run Screen 1 ................................................................................................................215
Run Screen 2 ................................................................................................................216
4.7 Operating with an A40-D Auger Header .........................................................................................217
4.7.1 Adjusting Reel Speed ............................................................................................................217
Setting Reel Speed in Auto Mode ...................................................................................217
Setting Reel Speed in Manual Mode ...............................................................................219
Adjusting the Reel/Auger Alarm Pressure........................................................................220
4.7.2 Knife Speed..........................................................................................................................222
Setting Knife Speed .......................................................................................................222
Adjusting Knife Alarm Pressure – Auger Header ..............................................................224
Adjusting Knife Speed Alarm .........................................................................................225
4.7.3 Auger Header Run Screens ...................................................................................................226
Run Screen 1 ................................................................................................................226
Run Screen 2 ................................................................................................................227
4.8 Operating with an R85 Header.......................................................................................................228
4.8.1 Setting Disc Speed................................................................................................................228
4.8.2 Adjusting Disc Pressure Alarm ..............................................................................................228
4.8.3 Setting Float Options with Fixed Deck.....................................................................................230
4.8.4 Disc Header Run Screens......................................................................................................232
Run Screen 1 ................................................................................................................232
Run Screen 2 ................................................................................................................233
214053 vi Revision A

TABLE OF CONTENTS
5 Maintenance and Servicing ................................................................................................................235
5.1 Recommended Fuel, Fluids, and Lubricants ...................................................................................235
5.1.1 Storing Lubricants and Fluids.................................................................................................235
5.1.2 Fuel Specifications ................................................................................................................235
5.1.3 Lubricants, Fluids, and System Capacities ..............................................................................236
5.1.4 Filter Part Numbers ...............................................................................................................237
5.2 Windrower Break-In Inspections and Maintenance Schedule ...........................................................238
5.2.1 Break-in Inspections..............................................................................................................239
5.2.2 Maintenance Schedule/Record...............................................................................................240
5.2.3 Electronic Maintenance Tool ..................................................................................................242
5.2.4 Preventing Electrical System Damage ....................................................................................243
5.3 Engine Compartment ....................................................................................................................244
5.3.1 Opening Hood.......................................................................................................................244
5.3.2 Closing Hood ........................................................................................................................245
5.4 Platform .......................................................................................................................................246
5.4.1 Opening Platform ..................................................................................................................246
5.4.2 Closing Platform....................................................................................................................246
5.4.3 Adjusting the Platform ...........................................................................................................247
5.4.4 Accessing Tool Box ...............................................................................................................248
5.5 Break-In Inspections .....................................................................................................................249
5.5.1 Tightening Drive Wheel Nuts..................................................................................................249
5.5.2 Tightening ............................................................................................................................249
5.5.3 Tightening Caster Wheel Anti-Shimmy Dampeners..................................................................250
5.5.4 Tightening Walking Beam Adjustment Bolts ............................................................................250
5.5.5 Tensioning Air Conditioner (A/C) Compressor Belts .................................................................250
5.5.6 Changing Engine Gearbox Lubricant ......................................................................................251
5.5.7 Changing Wheel Drive Lubricant ............................................................................................251
5.5.8 Changing Hydraulic Filters .....................................................................................................252
Charge Filter .................................................................................................................252
Return Oil Filter .............................................................................................................254
5.6 Every 10 Hours or Daily ................................................................................................................256
5.6.1 Checking Engine Oil Level.....................................................................................................256
Adding Engine Oil ..........................................................................................................257
5.6.2 Fuel/Water Separator ............................................................................................................257
Removing Water from Fuel System.................................................................................258
5.6.3 Checking Hydraulic Oil ..........................................................................................................258
5.6.4 Inflating Drive Wheel Tires .....................................................................................................259
5.6.5 Inflating Caster Tires .............................................................................................................261
5.6.6 Checking Engine Coolant Level..............................................................................................262
5.6.7 Hoses and Lines ...................................................................................................................263
5.6.8 Filling Fuel Tank ....................................................................................................................263
5.6.9 Filling the Diesel Exhaust Fluid (DEF) Tank.............................................................................264
5.7 Every 50 Hours.............................................................................................................................266
5.7.1 Fresh Air Intake Filter ............................................................................................................266
Removing Fresh Air Intake Filter.....................................................................................266
Inspecting And Cleaning Fresh Air Intake Filter Element...................................................267
Installing Fresh Air Intake Filter.......................................................................................267
5.7.2 Checking Engine Gearbox Lubricant Level and Adding Lubricant .............................................269
5.7.3 Greasing the Windrower ........................................................................................................269
Greasing Procedure.......................................................................................................270
Grease Points................................................................................................................270
5.8 Every 100 Hours...........................................................................................................................271
5.8.1 Servicing Return Air Filter ......................................................................................................271
5.8.2 Cleaning Cooler Module ........................................................................................................272
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TABLE OF CONTENTS
Cleaning Left Cooling Module.........................................................................................272
Cleaning Right Cooling Module.......................................................................................275
5.9 Every 250 Hours or Annually .........................................................................................................278
5.9.1 Changing Engine Oil..............................................................................................................278
Draining Engine Oil........................................................................................................278
Replacing Engine Oil Filter .............................................................................................278
Adding Engine Oil..........................................................................................................279
5.9.2 Maintaining Engine Air Filters.................................................................................................280
Removing Engine Primary Air Filter.................................................................................280
Installing Engine Primary Air Filter ..................................................................................281
Cleaning Primary Air Filter..............................................................................................283
Replacing Secondary Air Filter........................................................................................284
5.9.3 Checking Wheel Drive Lubricant Level....................................................................................284
5.9.4 Adding Wheel Drive Lubricant................................................................................................285
5.9.5 Inspecting Exhaust System....................................................................................................286
5.9.6 Changing Engine Gearbox Lubricant ......................................................................................287
5.10 Every 500 Hours or Annually .........................................................................................................288
5.10.1 Maintaining Fuel Filters..........................................................................................................288
Removing Primary Fuel Filter .........................................................................................288
Installing Primary Fuel Filter ...........................................................................................289
Removing Secondary Fuel Filter .....................................................................................289
Installing Secondary Fuel Filter .......................................................................................289
System Priming .............................................................................................................290
Priming Fuel System......................................................................................................290
5.10.2 Safety Systems .....................................................................................................................291
Checking Operator Presence System..............................................................................291
Checking Engine Interlock..............................................................................................292
5.11 Every 1000 Hours.........................................................................................................................293
5.11.1 Removing and Installing the Fuel Tank Vent Filter....................................................................293
5.11.2 DEF Supply Module Filter ......................................................................................................295
Checking the Supply Module Filter..................................................................................295
Removing the Supply Module Filter.................................................................................295
Cleaning and Inspecting the Supply Module Filter............................................................297
Installing the Supply Module Filter...................................................................................297
5.12 Every 2000 Hours.........................................................................................................................298
5.12.1 Changing Engine Coolant ......................................................................................................298
Draining Coolant............................................................................................................298
Adding Coolant..............................................................................................................299
5.12.2 Draining Hydraulic Oil............................................................................................................300
5.12.3 Filling Hydraulic Oil................................................................................................................302
5.12.4 Replacing the Diesel Exhaust Fluid (DEF) Vent Hose Filter .....................................................303
5.12.5 General Engine Inspection.....................................................................................................304
5.13 Annual Service .............................................................................................................................305
5.13.1 Batteries ...............................................................................................................................305
Maintaining a Battery .....................................................................................................305
Opening Battery Cover...................................................................................................306
Closing Battery Cover ....................................................................................................306
Charging a Battery.........................................................................................................307
Boosting a Battery .........................................................................................................308
Removing a Battery .......................................................................................................310
Installing a Battery .........................................................................................................310
Disconnecting a Battery .................................................................................................311
Connecting Batteries......................................................................................................311
5.13.2 Checking Steering Link Pivots................................................................................................312
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TABLE OF CONTENTS
5.13.3 Air Conditioning Evaporator ...................................................................................................313
Removing Air Conditioning (A/C) Cover...........................................................................313
Cleaning Air Conditioning (A/C) Evaporator Core.............................................................314
Installing Air Conditioning (A/C) Cover.............................................................................315
5.13.4 Checking Engine Coolant Strength.........................................................................................316
5.14 Maintenance as Required..............................................................................................................318
5.14.1 Seat Belts.............................................................................................................................318
5.14.2 Draining Fuel Tank ................................................................................................................318
5.14.3 Draining the Diesel Exhaust Fluid (DEF) Tank .........................................................................319
5.14.4 Refilling the Diesel Exhaust Fluid (DEF) Tank..........................................................................319
5.14.5 Belts.....................................................................................................................................320
Tensioning Alternator Belt...............................................................................................320
Replacing Engine Belt....................................................................................................320
Tensioning Air Conditioner (A/C) Compressor Belts..........................................................321
Replacing Air Conditioner (A/C) Compressor Belts...........................................................322
5.14.6 Engine Speed .......................................................................................................................323
5.14.7 Lighting ................................................................................................................................323
Aligning Headlights: Engine-Forward ..............................................................................323
Aligning Headlights: Cab-Forward ..................................................................................324
Adjusting Front Field Lights ............................................................................................325
Adjusting Rear Work Lights ............................................................................................326
Adjusting Rear Work Lights ............................................................................................327
Replacing Bulbs in Standard Work Lights ........................................................................327
Replacing Headlight Bulb (Engine-Forward) ....................................................................329
Replacing LED Lights (Deluxe Cab Only) ........................................................................330
Replacing Bulbs in Red and Amber Lights.......................................................................331
Replacing Red Tail Lights ...............................................................................................332
Replacing Beacon Lights................................................................................................333
Replacing the Cabin Dome Bulb and Light Assembly .......................................................333
Turn Signal Indicators ....................................................................................................335
5.14.8 Accessing Circuit Breakers and Fuses....................................................................................335
Checking and Replacing Fuses ......................................................................................337
Replacing Circuit Breakers and Relays............................................................................337
Fuse Panel and Relay Module Decals.............................................................................339
Inspecting and Replacing 125A Main Fuses ....................................................................344
5.14.9 Drive Wheels ........................................................................................................................345
Raising Drive Wheels.....................................................................................................345
Removing Drive Wheels .................................................................................................346
Installing Drive Wheels...................................................................................................347
Lowering Drive Wheels ..................................................................................................348
5.14.10 Caster Wheels ......................................................................................................................348
Adjusting Caster Tread Width .........................................................................................348
Servicing Caster Wheels ................................................................................................350
6 Options and Attachments ..................................................................................................................353
6.1 Cab .............................................................................................................................................353
6.1.1 Automated Steering Systems.................................................................................................353
6.2 Header Operation .........................................................................................................................354
6.2.1 Conversion Kit for Disc Ready to Disc, Auger, and Draper Ready.............................................354
6.2.2 Booster Spring Kit (External)..................................................................................................354
6.2.3 Double Booster Spring Kit (External) ......................................................................................355
6.2.4 Double Windrow Attachment (DWA) .......................................................................................355
6.2.5 Center-Link Lifter...................................................................................................................355
6.3 Transport .....................................................................................................................................356
6.3.1 Weight Box ...........................................................................................................................356
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TABLE OF CONTENTS
6.3.2 Towing Harness ....................................................................................................................356
6.3.3 Ballast ..................................................................................................................................356
7 Troubleshooting .................................................................................................................................359
7.1 Engine Troubleshooting ................................................................................................................359
7.2 Electrical Troubleshooting .............................................................................................................364
7.3 Hydraulics Troubleshooting ...........................................................................................................366
7.4 Header Drive Troubleshooting .......................................................................................................367
7.5 Traction Drive Troubleshooting ......................................................................................................368
7.6 Steering and Ground Speed Control Troubleshooting......................................................................370
7.7 Cab Air Troubleshooting................................................................................................................371
7.8 Operator’s Station Troubleshooting................................................................................................375
8 Reference...........................................................................................................................................377
8.1 Torque Specifications....................................................................................................................377
8.1.1 Metric Bolt Specifications.......................................................................................................377
8.1.2 Metric Bolt Specifications Bolting into Cast Aluminum..............................................................380
8.1.3 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)..................................................................381
8.1.4 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) ..........................................................383
8.1.5 O-Ring Face Seal (ORFS) Hydraulic Fittings...........................................................................384
8.1.6 Tapered Pipe Thread Fittings .................................................................................................386
8.2 Conversion Chart..........................................................................................................................387
8.3 Windrower Fault Codes.................................................................................................................388
8.4 Engine Fault Codes ......................................................................................................................439
Index ..................................................................................................................................................465
214053 xRevision A

1Safety
1.1 Safety Alert Symbols
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
Figure 1.1: Safety Symbol
214053 1Revision A

SAFETY
1.2 Signal Words
Three signal words, DANGER, WARNING,andCAUTION, are used to alert you to hazardous situations. The
appropriate signal word for each situation has been selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It
may also be used to alert against unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It
may be used to alert against unsafe practices.
214053 2Revision A

SAFETY
1.3 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 1.2: 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 1.3: Safety Equipment
•Provideafirst aid kit for use in case of emergencies.
• Keep a fire 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 1.4: Safety Equipment
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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 1.5: 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. Unauthorized 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 the engine and remove the
key from the ignition before leaving the operator’s seat
for any reason.
Figure 1.6: 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 1.7: Safety around Equipment
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SAFETY
1.4 Maintenance Safety
To ensure your safety while maintaining machine:
• Review operator’s manual and all safety items before
operation and/or maintenance of machine.
• Place all controls in Neutral, stop the engine, set
the park brake, remove the ignition key, and wait for
all moving parts to stop before servicing, adjusting,
and/or repairing.
• Follow good shop practices:
– Keep service areas clean and dry
– Be sure electrical outlets and tools are
properly grounded
– Use adequate lighting for job at hand Figure 1.8: Safety around Equipment
• Relieve pressure from hydraulic circuits before servicing
and/or disconnecting machine.
• Make sure all components are tight and that steel lines,
hoses, and couplings are in good condition before
applying pressure to hydraulic systems.
• Keep hands, feet, clothing, and hair away from all
moving and/or rotating parts.
• Clear area of bystanders, especially children, when
carrying out any maintenance, repairs or, adjustments.
• Install transport lock or place safety stands under frame
before working under machine.
• If more than one person is servicing machine at
same time, be aware that rotating a driveline or other
mechanically-driven component by hand (for example,
accessing a lube fitting) will cause drive components in
other areas (belts, pulleys, and knives) to move. Stay
clear of driven components at all times.
Figure 1.9: Equipment NOT Safe for Children
•Wearprotectivege
ar when working on machine.
• Wear heavy gloves when working on knife components.
Figure 1.10: Safety Equipment
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SAFETY
1.5 Hydraulic Safety
• Always place all hydraulic controls in Neutral
before dismounting.
• Make sure that all components in hydraulic system are
kept clean and in good condition.
• Replace any worn, cut, abraded, flattened, or crimped
hoses and steel lines.
•DoNOT attempt any makeshift repairs to hydraulic
lines, fittings, or hoses by using tapes, clamps, cements,
or welding. The hydraulic system operates under
extremely high pressure. Makeshift repairs will fail
suddenly and create hazardous and unsafe conditions.
Figure 1.11: Testing for Hydraulic Leaks
•Wearprop
er hand and eye protection when searching
for high-pressure hydraulic leaks. Use a piece of
cardboard as a backstop instead of hands to isolate
and identify a leak.
•Ifinjur
ed by a concentrated high-pressure stream of
hydraulic fluid, seek medical attention immediately.
Serious infection or toxic reaction can develop from
hydraulic fluid piercing the skin.
Figure 1.12: Hydraulic Pressure Hazard
• Make sure all components are tight and steel lines,
hoses, and couplings are in good condition before
applying pressure to a hydraulic system.
Figure 1.13: Safety around Equipment
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SAFETY
1.6 Tire Safety
WARNING
• Service tires safely.
• A tire can explode during inflation which could
cause serious injury or death.
• Follow proper procedures when mounting a tire on
a wheel or rim. Failure to do so can produce an
explosion that may result in serious injury or death.
Figure 1.14: Overinflated Tire
WARNING
• DoNOTstandovertire. Useaclip-onchuckand
extension hose.
• Never exceed air pressure of 241 kPa (35 psi) for
field tires and 276 kPa (40 psi) for transport tires
when seating bead on rim.
• Do NOT exceed maximum inflation pressure
indicated on tire label.
• Replace tires that have defects.
• Replace wheel rims that are cracked, worn, or
severely rusted.
• Never weld a wheel rim.
• Never use force on an inflated or partially
inflated tire.
• Make sure tire is correctly seated before inflating
to operating pressure.
• If tire is not correctly positioned on rim or is
overinflated, tire bead can loosen on one side
causing air to escape at high speed and with great
force. An air leak of this nature can thrust tire in
any direction endangering anyone in area.
• Make sure all air is removed from tire before
removing tire from rim.
• Do NOT remove, install, or repair a tire on a rim
unless you have proper equipment and experience
to perform job.
• Take tire and rim to a qualified tire repair shop.
Figure 1.15: Safely Filling a Tire with Air
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SAFETY
1.7 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 1.16: 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 1.17: 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 storage batteries, remember
that all of the exposed metal parts are live. Never
lay a metal object across terminals because a spark
or short circuit will result.
• Keep batteries out of reach of children.
Figure 1.18: Safety around Batteries
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