MacDon M Series User manual

Form 169242 Revision D
Published: September, 2010
M Series Self-Propelled Windrower
UNLOADING AND ASSEMBLY
INSTRUCTIONS
for
CONTAINER SHIPMENTS

Form 169242 Revision D
MACDON SELF PROPELLED AUGER HEADER
MACDON SELF-PROPELLED WINDROWER

Form 169242 Revision D
1
INTRODUCTION
Thisinstructionalmanualdescribestheunloading,set-upandpre-deliveryrequirementsfortheMacDonMSeries
Self-Propelled Windrowers.
Use the Table of Contents to guide you to specific areas.
Retain this instruction for future reference.
CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE, OR
USE THE MACHINE.
TABLE OF CONTENTS
INTRODUCTION........................................................................................................................................................1
GENERAL SAFETY...................................................................................................................................................3
RECOMMENDED TORQUES ...................................................................................................................................5
A.GENERAL...............................................................................................................................................5
B.SAE BOLTS............................................................................................................................................5
C.METRIC BOLTS.....................................................................................................................................5
D.FLARE TYPE HYDRAULIC FITTINGS..................................................................................................6
E.O-RING TYPE HYDRAULIC FITTINGS.................................................................................................6
ENGLISH/METRIC EQUIVALENTS..........................................................................................................................7
DEFINITIONS ............................................................................................................................................................7
STEP 1.UNLOAD CONTAINER..............................................................................................................................8
STEP 2.MOVE TO ASSEMBLY AREA...................................................................................................................8
A.CRANE METHOD ..................................................................................................................................8
B.FORKLIFT METHOD..............................................................................................................................9
STEP 3.REMOVE WHEEL AND STEP ASSEMBLY............................................................................................11
STEP 4.REMOVE DRIVE WHEELS.....................................................................................................................13
STEP 5.REMOVE PLATFORM / LIGHT ASSEMBLY ..........................................................................................14
STEP 6.INSTALL LIGHT AND MIRROR ASSEMBLIES ......................................................................................15
STEP 7.REMOVE LEG ASSEMBLIES.................................................................................................................17
STEP 8.REMOVE WHEEL AND PLATFORM SUPPORT....................................................................................18
STEP 9.ASSEMBLE WINDROWER SUPPORT STAND.....................................................................................18
STEP 10.LIFT WINDROWER ONTO STAND ........................................................................................................19
A.CRANE METHOD ................................................................................................................................19
B.FORKLIFT METHOD............................................................................................................................20
STEP 11.INSTALL LEGS........................................................................................................................................21
STEP 12.INSTALL FRONT WHEELS.....................................................................................................................23
STEP 13.INSTALL CASTER WHEELS ..................................................................................................................25
STEP 14.INSTALL HYDRAULICS..........................................................................................................................27
A.M150, M200..........................................................................................................................................27
B.M100.....................................................................................................................................................31
STEP 15.INSTALL PLATFORMS...........................................................................................................................34
STEP 16.INSTALL STEPS......................................................................................................................................36
STEP 17.INSTALL TOOLBOX................................................................................................................................36
STEP 18.INSTALL BATTERIES.............................................................................................................................37
A.M150, M200..........................................................................................................................................37
B.M100.....................................................................................................................................................38
STEP 19.PRIME HYDRAULIC SYSTEM................................................................................................................39
STEP 20.START ENGINE ......................................................................................................................................41
STEP 21.CHECK TRACTION DRIVE.....................................................................................................................43
STEP 22.REMOVE WINDROWER FROM STAND................................................................................................44
A.FACTORY STAND...............................................................................................................................44
B.FIELD CONSTRUCTED STAND..........................................................................................................44

Form 169242 Revision D
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STEP 23.INSTALL AM/FM RADIO .........................................................................................................................45
STEP 24.INSTALL BEACONS................................................................................................................................47
STEP 25. INSTALL SLOW MOVING VEHICLE (SMV) SIGN.................................................................................47
STEP 26.ATTACH HEADER...................................................................................................................................48
A.HEADER ATTACHMENT - D SERIES.................................................................................................48
B.HEADER ATTACHMENT - A SERIES.................................................................................................54
C.HEADER ATTACHMENT - R SERIES (M150, M200 ONLY) ..............................................................58
STEP 27. LUBRICATE MACHINE...........................................................................................................................62
STEP 28.PROGRAM CAB DISPLAY MODULE (CDM)..........................................................................................64
A.M150, M200 DETAILED PROGRAMMING INSTRUCTIONS..............................................................65
B.M100 DETAILED PROGRAMMING INSTRUCTIONS.........................................................................71
STEP 29.PERFORM HYDRAULIC PURGE...........................................................................................................76
STEP 30.PERFORM PRE-DELIVERY CHECKS ...................................................................................................78
A.FINAL DRIVE LUBRICANT LEVEL......................................................................................................78
B.TIRE PRESSURES AND BALLAST REQUIREMENTS.......................................................................78
I.Tire Pressures.............................................................................................................................78
II.Ballast Requirements..................................................................................................................78
C.ENGINE COOLANT .............................................................................................................................79
D.AIR CLEANER......................................................................................................................................80
E.HYDRAULIC OIL LEVEL......................................................................................................................80
F.FUEL SEPARATOR .............................................................................................................................81
G.GEAR BOX LUBRICANT LEVEL (M150, M200)..................................................................................81
H.A/C COMPRESSOR BELT...................................................................................................................81
I.FAN BELT (M100)................................................................................................................................82
J.PERFORM SAFETY SYSTEM CHECKS.............................................................................................83
K.OPERATIONAL CHECKS....................................................................................................................84
I.Engine Warning Lights................................................................................................................84
II.Start Engine................................................................................................................................84
III.Engine Speed .............................................................................................................................84
IV.Guages and CDM Display ..........................................................................................................84
V.Electrical .....................................................................................................................................84
VI.Operator’s Presence System Checks.........................................................................................85
VII.Exterior Lights.............................................................................................................................86
VIII.Interior Lights..............................................................................................................................89
IX.A/C and Heater...........................................................................................................................90
L.MANUALS ............................................................................................................................................91
M.CAB INTERIOR....................................................................................................................................91

Form 169242 Revision D
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 the protective clothing
and personal safety devices that COULD
be necessary for the job at hand. Don't
take chances.
•You may need:
oa hard hat.
oprotective shoes with slip resistant
soles.
oprotective glasses or goggles.
oheavy gloves.
owet weather gear.
orespirator or filter mask.
ohearing protection. Be aware that
prolonged exposure to loud noise
can cause impairment or loss of
hearing. Wearing a suitable
hearing protective device such as
ear muffs (A) or ear plugs (B)
protects against objectionable or
loud noises.
•Provide a first-aid kit for use in case of
emergencies.
•Keep a fire extinguisher on the machine.
Be sure the extinguisher is properly
maintained and be familiar with its proper
use.
•Keep young children away from machinery
at all times.
•Be aware that accidents often happen
when the Operator is tired or in a hurry to
get finished. Take the time to consider the
safest way. Never ignore warning signs of
fatigue.
•Wear close-fitting clothing
and cover long hair. Never
wear dangling items such
as scarves or bracelets.
•Keep hands, feet, clothing
and hair away from
moving parts.
•Never attempt to clear obstructions or
objects from a machine while the engine is
running.
•Keep all shields in place. Never alter or
remove safety equipment. Make sure
driveline guards can rotate independently
of the shaft and can telescope freely.
•Use only service and repair parts made or
approved by the equipment manufacturer.
Substituted parts may not meet strength,
design, or safety requirements.
(continued next page)
A B

Form 169242 Revision D
4
•Do not modify the machine. Unauthorized
modifications may impair the function
and/or safety and affect machine life.
•Stop engine, and remove keyfrom ignition
before leaving Operator's seat for any
reason. A child or even a pet could engage
an idling machine.
•Keep the area used for servicing
machinery clean and dry. Wet or oily floors
are slippery. Wet spots can be dangerous
when working with electrical equipment.
Be sure all electrical outlets and tools are
properly grounded.
•Use adequate light for the job at hand.
•Keep machinery clean. Do not allow oil or
grease to accumulateon service platforms,
ladders or controls. Cleanmachines before
storage.
•Never use gasoline, naphthaor anyvolatile
material for cleaning purposes. These
materials may be toxic and/or flammable.
•When storing machinery, cover sharp or
extending components to prevent injury
from accidental contact.

Form 169242 Revision D
5
RECOMMENDED TORQUES
A. GENERAL
The tables shown below give correct torque
values for various bolts and capscrews.
•Tighten all bolts to the torques specified in
chart unless otherwise noted throughout this
manual.
•Check tightness of bolts periodically, using
bolt torque chart as a guide.
•Replace hardware with the same strength
bolt.
•Torque figures are valid for non-greased or
non-oiledthreadsandheadsunlessotherwise
specified. Do not grease or oil bolts or
capscrews unless specified in this manual.
•Whenusinglocking elements,increase torque
values by 5%.
B. SAE BOLTS
BOLT
DIA. "A"
in.
NC BOLT TORQUE*
SAE 5 SAE 8
ft·lbf N·m ft·lbf N·m
1/4 9 12 11 15
5/16 18 24 25 34
3/8 32 43 41
56
7/16 50 68 70 95
1/2 75 102 105 142
9/16 110 149 149 202
5/8 150 203 200 271
3/4 265 359 365 495
7/8 420 569 600 813
1 640 867 890 1205
* Torque categories for bolts and capscrews are identified by their
head markings.
C. METRIC BOLTS
BOLT
DIA. "A"
NC BOLT TORQUE*
8.8 10.9
ft·lbf N·m ft·lbf N·m
M3 0.4 0.5 1.3 1.8
M4 2.2 3 3.3 4.5
M5 4 6 7 9
M6 7 10 11 15
M8 18 25 26 35
M10 37 50 52 70
M12 66 90 92 125
M14 103 140 148 200
M16 166 225 229 310
M20 321 435 450 610
M24 553 750 774 1050
M30 1103 1495 1550 2100
M36 1917 2600 2710 3675
* Torque categories for bolts and capscrews are identified by their
head markings.
SAE-5 SAE-8

Form 169242 Revision D
6
D. FLARE TYPE HYDRAULIC FITTINGS
a. Check flare and flare seat for defects that might
cause leakage.
b. Align tube with fitting before tightening.
c. Lubricate connection and hand tighten swivel nut
until snug.
d. To preventtwisting thetube(s), use two wrenches.
Placeonewrench on the connector bodyand with
the second, tighten the swivel nut to the torque
shown.
SAE
NO.
TUBE
SIZE
O.D.
(in.)
THD
SIZE
(in.)
NUT
SIZE
ACROSS
FLATS
(in.)
TORQUE
VALUE*
RECOMMENDED
TURNS TO
TIGHTEN
(AFTER FINGER
TIGHTENING)
ft·lbf N·m Flats Turns
3 3/16 3/8 7/16 6 8 1 1/6
4 1/4
7/16 9/16 9 12 1 1/6
5 5/16 1/2 5/8 12 16 1 1/6
6 3/8
9/16 11/16 18 24 1 1/6
8 1/2 3/4 7/8 34 46 1 1/6
10 5/8 7/8 1 46 62 1 1/6
12 3/4
1-1/16 1-1/4 75 102 3/4 1/8
14 7/8
1-3/8 1-3/8 90 122 3/4 1/8
16 1
1-5/16 1-1/2 105 142 3/4 1/8
* The torque values shown are based on lubricated connections
as in reassembly.
E. O-RING TYPE HYDRAULIC FITTINGS
a. Inspect O-ring and seat for dirt or obvious defects.
b. Onanglefittings, back off the lock nutuntilwasher
(A) bottoms out at top of groove (B) in fitting.
c. Hand tighten fitting until back up washer (A) or
washer face (if straight fitting) bottoms on part
face (C) and O-ring is seated.
d. Positionangle fittings by unscrewing no more than
one turn.
e. Tighten straight fittings to torque shown.
f. Tighten angle fittings to torque shown in the
following table while holding body of fitting with a
wrench.
SAE
NO.
THD
SIZE
(in.)
NUT SIZE
ACROSS
FLATS
(in.)
TORQUE
VALUE*
RECOMMENDED
TURNS TO TIGHTEN
(AFTER FINGER
TIGHTENING)
ft·lbf N·m Flats Turns
3 3/8 1/2 6 8 2 1/3
4 7/16 9/16 9 12 2 1/3
5 1/2 5/8 12 16 2 1/3
6 9/16 11/16 18 24 2 1/3
8 3/4 7/8 34 46 2 1/3
10 7/8 1 46 62 1-1/2 1/4
12 1-1/16 1-1/4 75 102 1 1/6
14 1-3/16 1-3/8 90 122 1 1/6
16 1-5/16 1-1/2 105 142 3/4 1/8
20 1-5/8 1-7/8 140 190 3/4 1/8
24 1-7/8 2-1/8 160 217 1/2 1/12
* The torque values shown are based on lubricated connections
as in reassembly.
FLARE
FLARESEAT BODY
NUT
A
BC
LOCKNUT
SEAT
WASHE
R
O-RING
GROOVE
FITTING

Form 169242 Revision D
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ENGLISH/METRIC EQUIVALENTS
QUANTITY INCH-POUND UNITS FACTOR SI UNITS (METRIC)
UNIT NAME ABBR. UNIT NAME ABBR.
Area acres acres x 0.4047 = hectares ha
Flow US gallons per minute (gpm) x 3.7854 = liters per minute L/min
Force pounds force lbf x 4.4482 = Newtons N
Length inch in. x 25.4 = millimeters mm
foot ft x 0.305 = meters m
Power horsepower hp x 0.7457 = kilowatts kW
Pressure pounds per square inch psi x 6.8948 = kilopascals kPa
x .00689 = megapascals MPa
Torque pound feet or foot pounds lbf·ft or ft·lbf x 1.3558 = newton meters N·m
pound inches or inch pounds lbf·in. or in·lbf x 0.1129 = newton meters N·m
Temperature degrees Fahrenheit ˚F (˚F- 32) x 0.56 = Celsius ˚C
Velocity
feet per minute ft/min x 0.3048 = meters per minute m/min
feet per second ft/s x 0.3048 = meters per second m/s
miles per hour mph x 1.6063 = kilometers per hour km/h
Volume
US gallons US gal. x 3.7854 = liters L
ounces oz. x 29.5735 = milliliters ml
cubic inches in.3x 16.3871 = cubic centimeters cm3or cc
Weight pounds lb x 0.4536 = kilograms kg
DEFINITIONS
TERM DEFINITION
API American Petroleum Institute
ASTM American Society of Testing And Materials
Cab-Forward Windrower operation with the Operator and cab facing in the direction of travel.
CDM Cab Display Module
DWA Double Windrow Attachment
Engine-Forward Windrower operation with the Operator and engine facing in the direction of travel.
ISC Integrated Speed Control
N-DETENT The slot opposite the neutral position on Operator’s console.
rpm revolutions per minute
SAE Society Of Automotive Engineers
WCM Windrower Control Module
Windrower Windrower with header attached.
Windrower Tractor Power unit only. (Windrower without the header attached)

UNLOADING AND ASSEMBLY
Form 169242 Revision D
8
STEP 1. UNLOAD CONTAINER
CAUTION
To avoid injury to bystanders from being
struck by machinery, do not allow persons to
stand in unloading area.
a. Move trailer into position and block trailer wheels.
b. Lower trailer storage stands.
c. Open container doors and remove all blocking.
d. Check container floor for nails or other
obstructions and remove if necessary.
e. Position platform or ramp at container opening.
f. Attach chain/pull strap toslots in supportchannels
as shown.
g. Pull windrower from container onto platform.
STEP 2. MOVE TO ASSEMBLY
AREA
A. CRANE METHOD
CAUTION
To avoid injury to bystanders from being
struck by machinery, do not allow persons to
stand in unloading area.
CAUTION
Equipment used for unloading must meet or
exceed the requirements specified below.
Using inadequate equipment may result in
chain breakage, vehicle tipping or machine
damage.
LIFTING VEHICLE
Minimum Lifting Capacity 20,000 lb (9072 kg)
CHAIN
Type Overhead Lifting
Quality (1/2 inch)
Minimum Working Load 7100 lb (3221 kg)
a. Attach chains or cable to the four lift points on the
liftingframe(MacDon Part # 163871) and connect
loop ends to crane hook. Use cable or chain with
a minimum lifting capacity of 7100 lb (3221 kg).
(continued next page)

UNLOADING AND ASSEMBLY
Form 169242 Revision D
9
b. Attach lifting frame assembly (MacDon Part #
163871) to the four designated lift points on
windrower shipping frame.
c. Lift windrower off platform, and move to setup
area.
d. Lower assembly onto 5 - 6 inch (127 - 152 mm)
blocks as shown.
e. Remove chains from shipping frame.
f. Check for shipping damage and missing parts.
B. FORKLIFT METHOD
CAUTION
To avoid injury to bystanders from being
struck by machinery, do not allow persons to
stand in unloading area.
CAUTION
Equipment used for unloading must meet or
exceed the requirements specified below.
Using inadequate equipment may result in
chain breakage, vehicle tipping or machine
damage.
LIFTING VEHICLE
Minimum Lifting Capacity * 20,000 lb (9072 kg)
* At 48 inches (1220 mm) from back end of forks.
IMPORTANT
Forklifts are normally rated for a load
located 24 inches (610 mm) ahead of
back end of the forks.
To obtain the forklift capacity at 48
inches (1220 mm), check with your
forklift distributor.
WARNING
Be sure forks are secure before moving away
from load. Stand clear when lifting.
a. Approachwindrowerfrom the hood end, and slide
forks underneath lifting framework.
b. Raise windrower off platform, and move to
assembly area. (continued next page)

UNLOADING AND ASSEMBLY
Form 169242 Revision D
10
c. Lower assembly onto 5 - 6 inch (127 - 152 mm)
blocks as shown.
d. Check for shipping damage and missing parts.

UNLOADING AND ASSEMBLY
Form 169242 Revision D
11
STEP 3. REMOVE WHEEL AND
STEP ASSEMBLY
a. Remove shipping wire and bolt securing hose
support to shipping frame, and remove hose
support.
b. Lay hose support off to the side.
c. Remove the two ¾ in. x 16.5 long bolts (one per
side) at front frame beam. Retain for
reinstallation.
d. Remove the 1 inch (25.4 mm) pin at the center-
link.
e. Remove the four (two per side) carriage bolts at
the rear of the wheel/step assembly.
f. Remove plastic cable tie and shipping wire
securing hose bundles to frame.
(continued next page)

UNLOADING AND ASSEMBLY
Form 169242 Revision D
12
g. Attach a chain to wheel/step assembly, and pull
away from shipping assembly with lifting device.
h. Lift center-link so that it clears wheel/step
assembly frame.
i. Remove bolts, and remove tool box and holder
from shipping frame. Loosely install bolts in
holder, and set aside for later installation.
j. Reinstall leg bolts, washers, and nuts to secure
the lifting plate onto the mainframe.

UNLOADING AND ASSEMBLY
Form 169242 Revision D
13
STEP 4. REMOVE DRIVE WHEELS
IMPORTANT
Remove the drive wheels as a pair from
above the hood.
a. Remove the two bolts at front cross member over
the hood.
b. Remove one bolt at rear of hood directly under
center of drive wheel.
c. Attach a lifting device to lift hooks located in the
center of each drive wheel.
d. Carefully lift wheels off frame.
IMPORTANT
Ensure that tire is guided away from
cab roof when lifting wheels to prevent
damage to the cab. Chain on forward
wheel should be snug and loose on the
aft wheel.
e. Set wheels aside for later installation.

UNLOADING AND ASSEMBLY
Form 169242 Revision D
14
STEP 5. REMOVE PLATFORM /
LIGHT ASSEMBLY
a. Remove the two support tubes on either side of
hood.
b. To prevent paint damage, attach slings to platform
at locations shown, and to a lifting device with a
minimum lifting capacity of 5000 lb(2268 kg), and
a lift height of 13 feet (4 m).
c. Remove two 5/8 in. x 5.0 bolts at top of vertical
support, and two bolts on bottom ofsupport brace.
d. Cut plastic cable ties, and movehose bundle clear
of platform.
NOTE
The M100 windrower is equipped with
only one platform.
e. Carefullylift platform/light assemblyoff frame until
rails clear windrower legs.
f. Back away from windrower, and set assembly on
a level surface. Protect handrails with foam or
cardboard to prevent paint damage.

UNLOADING AND ASSEMBLY
Form 169242 Revision D
15
STEP 6. INSTALL LIGHT AND
MIRROR ASSEMBLIES
a. Removetwoboltssecuringmirror/lightassemblies
to shipping stand, and remove assemblies.
b. The cab roof must be raised to install the light
assemblies. Proceed as follows:
1. Remove plastic covers from six bolt locations
in roof.
2. Remove nuts andwashers at these locations.
3. Lift roof, and support with wooden block
covered with foam to prevent scuffing of roof.
c. Move existing harness in roof to gain access to
mirror/light support clamps. Loosen U-bolt.
d. Install mirror / light intoU-bolt, and tighten nuts on
U-bolt so that support tube is securely fastened.
Tighten jam-nuts located under roof plate.
(continued next page)

UNLOADING AND ASSEMBLY
Form 169242 Revision D
16
e. Thread wiring harness through support tube so
that connector is visible at light assembly.
f. Stuff foam into end of tube to help prevent dust
and noise from entering the cab.
g. Connect harness to connector at light.
h. Repeat steps c. to g. for opposite light assembly.
i. Remove roof support and lower roof.
IMPORTANT
Ensure roof bolts clear grommets in
frame.
j. Reinstall washers and nuts at the six locations.
k. Reinstall plastic caps.

UNLOADING AND ASSEMBLY
Form 169242 Revision D
17
STEP 7. REMOVE LEG
ASSEMBLIES
a. Ensure that lift bar is attached to leg assembly as
shown, and that clevis pin isinstalled withhead on
near side.
b. Attach chain to lifting bar on leg assembly, and
hook up to lifting device with a minimum lifting
capacity of 5000 lb (2268 kg).
c. Remove two bolts at lower support channel.
d. Remove two bolts near top of leg, and remove
bars from leg.
NOTE
Insert cardboard or foam between leg
assembly and hood toprevent damage
to hood.
e. Lift off leg assembly, and set securely on level
ground.
f. Repeat above steps for second leg assembly.

UNLOADING AND ASSEMBLY
Form 169242 Revision D
18
STEP 8. REMOVE WHEEL AND
PLATFORM SUPPORT
a. Removecross brace, and the two upright supports
from frame.
b. Remove thecrossmemberoverthehood,andthe
two uprights on either side.
STEP 9. ASSEMBLE WINDROWER
SUPPORT STAND
Special stands for assembling the windrower are
available from the factory. If this stand is not
available, an equivalent support system can be
used.
The stand must be capable of holding a 20,000 lb
(9072 kg) load.
Assemble factory stand as follows:
a. Remove all shipping materials from stand.
b. Arrange forward and rear stands on level ground,
so that attachment lugs on each stand face each
other.
c. Attach four support tubes to stands as shown with
hardware provided, and tighten.
d. Set up air control valve tripod. Remove plug on
valve, and install a 100 psi (689 kPa) air line.
e. The stand is now operational. Instructions for use
are given in the appropriate sections.
WARNING
•Use stand only as instructed in this
manual. Do not use stand for any other
purpose.
•Do not pressurize air bags beyond 120 psi
(827 kPa).
FORWARD STAND
REAR STAND
SUPPORT