MacDon M155 User manual

The harvesting specialists.
M155
Self-Propelled Windrower
Operator’s Manual
147649 Revision A
2016 Model Year
Original Instruction

This manual contains instructions for SAFETY, OPERATION, and MAINTENANCE/SERVICE for the
MacDon M155 Self-Propelled Windrower. Featuring the Dual Direction®and Ultra Glide®suspension on the M155.
Published June, 2015
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.

Declaration of Conformity
Figure 1: Declaration of Conformity (Page 1 of 2)
147649 iRevision A

Figure 2: Declaration of Conformity (Page 2 of 2)
147649 iiRevision A

Whole Body and Hand-Arm Vibration Levels
The weighted root mean square acceleration, to which the whole body is subjected, ranges from 0.57 to 1.06 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 1.45 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 70.1 to 73.1 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.
147649 iii Revision A

Introduction
This manual contains information on the MacDon M155 Self-Propelled Windrower which, when coupled with one
of MacDon’s auger, rotary, or draper headers, provides a package designed to cut and lay in windrows a variety of
grain, hay, and specialty crops.
The M155 Windrower is Dual Direction®, meaning that the windrower can be driven in the cab-forward or the
engine-forward modes. Right and left designations are therefore determined by 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.
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.
If you follow the instructions given here, your M155 Windrower will work well for many years.
Use this manual in conjunction with your header operator's manual.
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.
CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO USE THE MACHINE.
NOTE: Keep your MacDon publications up-to-date. The most current version can be downloaded from our website
www.macdon.com or from our Dealer-only site (https://portal.macdon.com) (login required).
NOTE:
Chinese and Russian translations of this manual can be ordered from MacDon, downloaded from the MacDon
Dealer Portal (https://portal.macdon.com)(login required), or downloaded from the MacDon international website
(http://www.macdon.com/world).
147649 ivRevision A

List of Revisions
At MacDon, we’re continuously making improvements: occasionally these improvements impact product
documentation. The following list provides an account of major changes from the previous version of this document.
Summary of Change Location
Declaration of Conformity revised. Declaration of Conformity, page i
Fuse panel cover decal was 183481. Fuse Box Decal, page 398
Reel to Ground Speed revised. Setting Reel to Ground Speed, page 282
Safety Decals 169502 and 169504 added to cab. 1.11 Safety Sign Locations, page 13
Product Overview was Description. 2 Product Overview, page 29
Letter “I” removed from illustrations. 1.11 Safety Sign Locations, page 13
Illustration added. Using the Auto Raise Height Feature, page 210
Setting Draper Index revised. Setting Draper Index, page 287
Legend removed from illustration. Setting the Auger Speed on A40-D Headers, page 294
Conversion Chart was 5.3.2 8.3 Conversion Chart, page 468
Step 4 in Turning Engine Manually revised. Turning the Engine Manually, page 333
Address deleted. 7.1.19 Swath Roller, page 450
Engine Fault Codes updated. 8.4 Engine Error Codes, page 469
Emergency Exit added. 3.12 Emergency Exit, page 59
Cab Display Module (CDM) chapter added and content
revised.
3.19 Cab Display Module (CDM), page 74
Reference chapter added. 8 Reference, page 453
7Options and Attachments revised. 7.1 Options and Attachments, page 447
147649 vRevision A

Serial Number
If you require MacDon technical assistance, please have the serial number 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 3: Machine Serial Number Location
The engine serial number plate (A) is located on top of the
engine cylinder head cover.
ENGINE SERIAL
NUMBER
DATE OF
MANUFACTURE
Figure 4: Engine Serial Number Location
147649 viRevision A

TABLE OF CONTENTS
Declaration of Conformity.................................................................................................................. i
Whole Body and Hand-Arm Vibration Levels .....................................................................................iii
Noise Levels ................................................................................................................................... iii
Introduction .....................................................................................................................................iv
List of Revisions .............................................................................................................................. v
Serial Number .................................................................................................................................vi
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................................................................................................................................ 10
1.9.1 High Pressure Rails................................................................................................................ 10
1.9.2 Engine Electronics ..................................................................................................................11
1.10 Safety Signs.................................................................................................................................. 12
1.10.1 Installing Safety Decals .......................................................................................................... 12
1.11 Safety Sign Locations .................................................................................................................... 13
1.12 Understanding Safety Signs ........................................................................................................... 17
2 Product Overview................................................................................................................................29
2.1 Definitions ..................................................................................................................................... 29
2.2 Specifications ................................................................................................................................ 31
2.3 Windrower Dimensions .................................................................................................................. 34
2.4 Component Location...................................................................................................................... 36
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 Fore-Aft ................................................................................................................................. 42
3.3.2 Seat Suspension and Height................................................................................................... 42
3.3.3 Vertical Dampener.................................................................................................................. 43
3.3.4 Armrest ................................................................................................................................. 43
3.3.5 Fore-Aft Isolator Lock ............................................................................................................. 44
3.3.6 Seat Tilt ................................................................................................................................. 44
3.3.7 Armrest Angle ........................................................................................................................ 45
3.3.8 Lumbar Support ..................................................................................................................... 45
3.4 Training Seat................................................................................................................................. 46
3.5 Seat Belts ..................................................................................................................................... 47
3.6 Steering Column Adjustment .......................................................................................................... 48
3.7 Lighting......................................................................................................................................... 49
3.7.1 Cab-Forward Lighting: Field.................................................................................................... 49
3.7.2 Engine-Forward Lighting: Road............................................................................................... 50
3.7.3 Cab-Forward Lighting: Road (Optional) ................................................................................... 51
3.7.4 Beacon Lighting (Optional)...................................................................................................... 52
3.7.5 HID Auxiliary Lighting (Optional).............................................................................................. 53
3.8 Windshield Wipers ......................................................................................................................... 54
3.9 Rear View Mirrors .......................................................................................................................... 55
3.10 Cab Temperature........................................................................................................................... 56
147649 vii Revision A

TABLE OF CONTENTS
3.10.1 Heater Shut-Off...................................................................................................................... 56
3.10.2 Air Distribution ....................................................................................................................... 56
3.10.3 Climate Controls .................................................................................................................... 57
3.11 Interior Lights ................................................................................................................................ 58
3.12 Emergency Exit ............................................................................................................................. 59
3.13 Operator Amenities........................................................................................................................ 60
3.14 Radio............................................................................................................................................ 62
3.14.1 AM/FM Radio......................................................................................................................... 62
3.14.2 Antenna Mounting .................................................................................................................. 62
3.15 Horn ............................................................................................................................................. 64
3.16 Engine Controls and Gauges.......................................................................................................... 65
3.17 Windrower Controls ....................................................................................................................... 66
3.18 Header Controls ............................................................................................................................ 68
3.18.1 Header Drive Switch............................................................................................................... 68
3.18.2 Header Drive Reverse Button..................................................................................................68
3.18.3 Ground Speed Lever (GSL) Header Switches .......................................................................... 69
Display Selector Switch................................................................................................... 70
Reel Position Switches.................................................................................................... 70
Header Position Switches................................................................................................ 71
Reel and Disc Speed Switches ........................................................................................ 71
3.18.4 Console Header Switches....................................................................................................... 72
Deck Shift/Float Preset Switch......................................................................................... 72
Double Windrow Attachment (DWA) / Swath Roller Switch (if installed) .............................. 73
3.19 Cab Display Module (CDM)............................................................................................................ 74
3.19.1 Engine and Windrower Functions ............................................................................................ 74
3.19.2 Header Functions................................................................................................................... 75
3.19.3 Operating Screens ................................................................................................................. 76
Ignition ON, Engine Not Running ..................................................................................... 76
Engine Running – At Initial Start Up ................................................................................. 76
Engine-Forward, Engine Running .................................................................................... 77
Cab-Forward, Engine Running, Header Disengaged ......................................................... 77
Cab-Forward, Engine Running, Header Engaged, Auger Header Index Switch OFF............ 77
Cab-Forward, Engine Running, Header Engaged, Auger Header Index Switch ON ............. 79
Engine Running, Header Engaged, Auger Header ............................................................ 80
Cab-Forward, Engine Running, Header Engaged, Draper Header, Index Switch OFF........... 81
Cab-Forward, Engine Running, Header Engaged, Draper Header, Index Switch ON ........... 82
Cab-Forward, Engine Running, Header Engaged, Rotary Header Installed......................... 83
Miscellaneous Operational Information............................................................................. 83
3.19.4 Cab Display Module (CDM) Warning/Alarms ............................................................................ 85
Engine Warning Lights .................................................................................................... 85
Display Warnings and Alarms .......................................................................................... 86
3.19.5 Cab Display Module (CDM) Programming................................................................................ 89
3.19.6 Cab Display Options............................................................................................................... 90
Setting the Cab Display Language ................................................................................... 90
Changing the Windrower Display Units............................................................................. 91
Adjusting the Cab Display Buzzer Volume ........................................................................ 92
Adjusting the Cab Display Backlighting............................................................................. 93
Adjusting the Cab Display Contrast .................................................................................. 94
3.19.7 Calibrating the Header Sensors...............................................................................................95
Calibrating the Header Height Sensor .............................................................................. 95
Calibrating the Header Tilt Sensor.................................................................................... 98
Calibrating the Header Float Sensors..............................................................................100
3.19.8 Programming the Windrower..................................................................................................101
Activating the Hydraulic Center-Link on an M155 .............................................................101
147649 viii Revision A

TABLE OF CONTENTS
Activating the Rotary Header Drive Hydraulics on an M155 ..............................................102
Setting the Knife Overload Speed ...................................................................................103
Setting the Rotary Disc Overload Speed..........................................................................104
Setting the Header Knife Speed......................................................................................105
Setting the Hydraulic Overload Pressure .........................................................................106
Setting the Header Index Mode ......................................................................................107
Setting the Return to Cut Mode.......................................................................................108
Setting the Header Cut Width .........................................................................................109
Activating the Double Windrower Attachment (DWA)........................................................ 110
Setting the Auto Raise Height.........................................................................................112
Activating the Hay Conditioner........................................................................................112
Displaying Reel Speed...................................................................................................113
Setting the Windrower’s Tire Size ...................................................................................114
Setting the Engine Intermediate Speed Control (ISC) RPM on an M155/M205...................115
Clearing Sub-Acres........................................................................................................116
3.19.9 Activating Cab Display Lock Outs...........................................................................................117
Activating Knife Speed Control Lock Out .........................................................................117
Activating Rotary Disc Speed Control Lock Out................................................................118
Activating the Header Float Control Lock Out ..................................................................119
Activating the Draper Speed Control Lock Out .................................................................121
Activating the Auger Speed Control Lock Out ..................................................................122
Activating the Reel Speed Control Lock Out ....................................................................123
Activating the Reel Fore-Aft Control Lock Out ..................................................................125
Activating the Header Tilt Control Lock Out......................................................................126
3.19.10 Displaying Activated Cab Display Lock Outs ...........................................................................127
3.19.11 Troubleshooting Windrower Problems ....................................................................................129
Displaying the Windrower and Engine Error Codes ..........................................................129
Switching the Installed Header Sensors On or Off............................................................131
Displaying Header Sensors Input Signals ........................................................................132
Forcing a Header ID.......................................................................................................134
3.19.12 Troubleshooting Header Problems .........................................................................................135
Testing the Header Up/Down Activate Function Using the Cab Display
Module (CDM) ...........................................................................................................135
Testing the Reel Up/Down Activate Function Using the Cab Display Module (CDM) ...........137
Testing the Header Tilt Activate Function Using the Cab Display Module (CDM) ................139
Testing the Reel Fore-Aft Activate Function Using the Cab Display Module (CDM).............140
Activating the Hydraulic Purge Using the Cab Display Module (CDM) ...............................142
Testing the Knife Drive Circuit Using the Cab Display Module (CDM) ................................144
Testing the Draper Drive Circuit Activate Function Using the Cab Display Module
(CDM) .......................................................................................................................146
Testing the Reel Drive Circuit Activate Function Using the Cab Display Module
(CDM) .......................................................................................................................147
Testing the Rotary Disc Drive Circuit Activate Function Using the Cab Display
Module (CDM) ...........................................................................................................149
Testing the Double Windrower Attachment (DWA) Drive Activate Function Using the Cab
Display Module (CDM)................................................................................................151
3.19.13 Engine Error Codes...............................................................................................................152
3.19.14 Cab Display Module (CDM) and Windrower Control Module (WCM) Fault Codes ......................152
4 Operation ...........................................................................................................................................153
4.1 Owner/Operator Responsibilities....................................................................................................153
4.2 Symbol Definitions ........................................................................................................................154
4.2.1 Engine Functions ..................................................................................................................154
4.2.2 Windrower Operating Symbols...............................................................................................155
4.2.3 Header Functions..................................................................................................................156
147649 ixRevision A

TABLE OF CONTENTS
4.3 Operating the Windrower...............................................................................................................157
4.3.1 Operational Safety ................................................................................................................157
4.3.2 Break-In Period.....................................................................................................................158
4.3.3 Preseason Checks/Annual Service.........................................................................................158
Air Conditioning Compressor Coolant Cycling..................................................................159
4.3.4 Daily Checks and Maintenance ..............................................................................................159
4.3.5 Engine Operation ..................................................................................................................160
Starting the Engine ........................................................................................................160
Engine Warmup.............................................................................................................162
Engine Intermediate Speed Control (ISC)........................................................................163
Shutting Down the Engine ..............................................................................................163
Filling the Fuel Tank .......................................................................................................163
Engine Temperature.......................................................................................................164
Engine Oil Pressure .......................................................................................................165
Electrical .......................................................................................................................165
Engine Warning Lights ...................................................................................................165
4.3.6 Driving the Windrower ...........................................................................................................165
Entering and Exiting the Windrower ................................................................................167
Driving Forward in Cab-Forward Mode............................................................................168
Driving Reverse in Cab-Forward Mode............................................................................169
Driving Forward in Engine-Forward Mode........................................................................170
Driving in Reverse in Engine-Forward Mode....................................................................171
Spin Turning..................................................................................................................172
Stopping .......................................................................................................................172
4.3.7 Adjusting Caster Tread Width.................................................................................................173
4.3.8 Transporting..........................................................................................................................175
Driving on the Road .......................................................................................................175
Towing Header with Windrower.......................................................................................178
Towing the Windrower (Emergency)................................................................................190
Final Drives ...................................................................................................................191
4.3.9 Storing the Windrower ...........................................................................................................191
4.4 Operating with a Header ...............................................................................................................193
4.4.1 Header Safety Props .............................................................................................................193
4.4.2 Header Float.........................................................................................................................195
Float Operating Guidelines .............................................................................................195
Checking Float ..............................................................................................................195
Float Options.................................................................................................................198
4.4.3 Levelling the Header..............................................................................................................199
4.4.4 Header Drive ........................................................................................................................202
Engaging and Disengaging the Header ...........................................................................202
Reversing the Header ....................................................................................................203
4.4.5 Adjusting Header Angle .........................................................................................................203
Checking Self-Locking Center-Link Hook.........................................................................205
4.4.6 Cutting Height .......................................................................................................................206
4.4.7 Return to Cut .......................................................................................................................207
Programming the Return to Cut Feature..........................................................................207
Using the Return to Cut Feature .....................................................................................208
4.4.8 Auto Raise Height .................................................................................................................209
Programming the Auto Raise Height Feature...................................................................209
Using the Auto Raise Height Feature ..............................................................................210
4.4.9 Header Drop Rate .................................................................................................................210
4.4.10 Double Windrowing ...............................................................................................................211
Double Windrow Attachment (DWA) Deck Position ..........................................................211
Double Windrow Attachment (DWA) Draper Speed ..........................................................212
147649 xRevision A

TABLE OF CONTENTS
4.4.11 Swath Roller Operation..........................................................................................................212
4.5 Attaching and Detaching Headers..................................................................................................213
4.5.1 Attaching a D-Series Header..................................................................................................213
Attaching Header Boots .................................................................................................213
Attaching a D-Series Header: Hydraulic Center-Link with Optional Self-Alignment .............214
Attaching a D-Series Header: Hydraulic Center-Link without Self-Alignment......................219
Attaching a D-Series Header: Mechanical Center-Link .....................................................225
4.5.2 Detaching a D-Series Header ................................................................................................229
Detaching a D-Series Header: Hydraulic Center-Link.......................................................230
Detaching a D-Series Header: Mechanical Center-Link....................................................233
4.5.3 Attaching an A-Series Header ................................................................................................237
Hydraulic Link with Optional Self-Alignment Kit ................................................................238
Attaching an A-Series Header: Hydraulic Center-Link without Self-Alignment ....................238
Attaching an A-Series Header: Mechanical Center-Link ...................................................245
4.5.4 Detaching an A-Series Header...............................................................................................249
Detaching an A-Series Header: Hydraulic Center-Link .....................................................250
Detaching an A-Series Header: Mechanical Center-Link ..................................................253
4.5.5 Attaching an R-Series Header................................................................................................257
Attaching an R-Series Header: Hydraulic Center-Link with Optional Self-Alignment ...........257
Attaching an R-Series Header: Hydraulic Center-Link without Self-Alignment ....................262
Attaching an R-Series Header: Mechanical Center-Link ...................................................267
4.5.6 Detaching an R-Series Header...............................................................................................271
Detaching an R-Series Header: Hydraulic Center-Link .....................................................272
Detaching an R-Series Header: Mechanical Center-Link ..................................................275
4.6 Operating with a D-Series Header..................................................................................................279
4.6.1 Configuring Hydraulics...........................................................................................................279
4.6.2 Attaching Header Boots.........................................................................................................280
4.6.3 Header Position ....................................................................................................................281
4.6.4 Adjusting the Reel Fore-Aft Position .......................................................................................281
4.6.5 Adjusting the Reel Height ......................................................................................................282
4.6.6 Reel Speed...........................................................................................................................282
Setting Reel to Ground Speed ........................................................................................282
Setting the Reel Only Speed...........................................................................................285
4.6.7 Draper Speed .......................................................................................................................286
Setting Draper to Ground Speed.....................................................................................286
Setting Draper Minimum Speed ......................................................................................286
Setting Draper Index ......................................................................................................287
Setting Draper Speed Independent of Ground Speed.......................................................288
4.6.8 Knife Speed..........................................................................................................................289
Setting Knife Speed “On the Go”.....................................................................................290
4.6.9 Deck Shift Control .................................................................................................................291
Deck Shift .....................................................................................................................291
Setting Float Options with Deck Shift...............................................................................291
4.7 Operating with an A-Series Header................................................................................................294
4.7.1 Auger Speed.........................................................................................................................294
Auger Speed on A30-D Headers.....................................................................................294
Setting the Auger Speed on A40-D Headers....................................................................294
4.7.2 Reel Speed...........................................................................................................................295
Reel Speed on A30-D Headers.......................................................................................295
Reel Speed on A40-D Headers.......................................................................................295
4.7.3 Knife Speed..........................................................................................................................300
Setting Knife Speed “On the Go”.....................................................................................300
4.8 Operating with an R-Series Header................................................................................................302
4.8.1 Disc Speed ...........................................................................................................................302
147649 xiRevision A

TABLE OF CONTENTS
Setting Disc Speed ........................................................................................................303
5 Maintenance and Servicing................................................................................................................305
5.1 Preparation For Servicing..............................................................................................................305
5.2 Engine Compartment Hood ...........................................................................................................306
5.2.1 Opening Hood (Lower Position)..............................................................................................306
5.2.2 Closing Hood (Lower Position) ...............................................................................................307
5.2.3 Opening Hood (Highest Position) ...........................................................................................307
5.2.4 Closing Hood (Highest Position).............................................................................................308
5.3 Maintenance Platforms .................................................................................................................309
5.3.1 Opening Platforms (Standard Position) ...................................................................................309
5.3.2 Closing Platforms (Standard Position).....................................................................................310
5.3.3 Opening Platforms (Major Service Position) ............................................................................311
5.3.4 Closing Platforms (Major Service Position)..............................................................................312
5.4 Windrower Lubrication ..................................................................................................................314
5.4.1 Lubricating the Windrower .....................................................................................................314
5.4.2 Lubrication Points..................................................................................................................315
5.5 Operator’s Station.........................................................................................................................316
5.5.1 Seat Belts .............................................................................................................................316
5.5.2 Safety Systems .....................................................................................................................316
Checking Operator Presence System..............................................................................316
Checking Engine Interlock..............................................................................................317
5.5.3 Ground Speed Lever (GSL) Adjustments ................................................................................317
Adjusting Ground Speed Lever (GSL) Lateral Movement..................................................317
Adjusting Ground Speed Lever (GSL) Fore-Aft Movement................................................318
5.5.4 Steering Adjustments ............................................................................................................319
Checking Steering Link Pivots ........................................................................................319
Checking Steering Chain Tension ...................................................................................321
5.5.5 Park Brake............................................................................................................................322
Adjusting and Replacing Interlock Switch ........................................................................322
5.5.6 Heating, Ventilating, and Air Conditioning (HVAC) System .......................................................325
Fresh Air Intake Filter.....................................................................................................325
Return Air Cleaner/Filter.................................................................................................327
Air Conditioning Condenser............................................................................................329
Air Conditioning (A/C) Evaporator Core ...........................................................................329
Air Conditioning (A/C) Compressor .................................................................................331
5.5.7 Engine..................................................................................................................................332
General Engine Inspection .............................................................................................332
Turning the Engine Manually ..........................................................................................333
Engine Oil .....................................................................................................................335
Air Intake System...........................................................................................................337
Fuel System ..................................................................................................................345
Engine Cooling System ..................................................................................................353
Gearbox........................................................................................................................363
Exhaust System.............................................................................................................364
Belts .............................................................................................................................365
Engine Speed................................................................................................................368
5.5.8 Electrical System...................................................................................................................368
Preventing Electrical System Damage.............................................................................368
Battery ..........................................................................................................................369
Headlights: Engine-Forward ...........................................................................................376
Field Lights: Cab-Forward ..............................................................................................380
Flood Lights: Forward ....................................................................................................381
High-Intensity Discharge (HID) Auxiliary Lighting (Optional - MD #B5596) .........................383
Flood Lights: Rear .........................................................................................................386
147649 xii Revision A

TABLE OF CONTENTS
Replacing Bulbs in Red and Amber Lights.......................................................................388
Replacing Red Tail Lights (if installed) .............................................................................388
Replacing the Bulbs in Beacon Lights (if installed) ...........................................................389
Replacing a Console Gauge Light...................................................................................394
Replacing the Cabin Dome Light.....................................................................................395
Replacing the Ambient Light Fixture................................................................................395
Turn Signal Indicators ....................................................................................................396
Accessing Circuit Breakers and Fuses ............................................................................396
5.5.9 Hydraulic System ..................................................................................................................400
Checking and Filling Hydraulic Oil...................................................................................401
Hydraulic Oil Cooler .......................................................................................................403
Draining Hydraulic Oil ....................................................................................................403
Changing Hydraulic Oil Filters.........................................................................................404
Header and Reel Hydraulics...........................................................................................407
Traction Drive Hydraulics................................................................................................409
Hoses and Lines............................................................................................................411
5.5.10 Wheels and Tires ..................................................................................................................411
Drive Wheel ..................................................................................................................411
Caster Wheel ................................................................................................................418
5.5.11 Maintenance Schedule ..........................................................................................................425
Break-In Inspections ......................................................................................................426
Maintenance Schedule/Record .......................................................................................427
6 Troubleshooting.................................................................................................................................429
6.1 Engine Troubleshooting ................................................................................................................429
6.2 Electrical Troubleshooting .............................................................................................................435
6.3 Hydraulics Troubleshooting ...........................................................................................................436
6.4 Header Drive Troubleshooting .......................................................................................................437
6.5 Traction Drive Troubleshooting ......................................................................................................438
6.6 Steering and Ground Speed Control Troubleshooting......................................................................441
6.7 Cab Air Troubleshooting................................................................................................................442
6.8 Operator’s Station Troubleshooting................................................................................................446
7Option
s and Attachments ..................................................................................................................447
7.1 Options and Attachments ..............................................................................................................447
7.1.1 AM/FM Radio........................................................................................................................447
7.1.2 Automated Steering Systems.................................................................................................447
7.1.3 Booster Spring Kit (External)..................................................................................................447
7.1.4 Booster Spring Kit (Internal) ...................................................................................................447
7.1.5 Draper Header Case Drain Kit................................................................................................447
7.1.6Double Windrow Attachment (DWA) .......................................................................................448
7.1.7Draper Header Reel Drive and Lift Plumbing...........................................................................448
7.1.8Engine Block Heater..............................................................................................................448
7.1.9Engine Fan Air Baffle.............................................................................................................448
7.1.10 Header Drive Reverser ..........................................................................................................448
7.1.11 HID Auxiliary Lighting ............................................................................................................449
7.1.12 Hydraulic Center-Link ............................................................................................................449
7.1.13 Light Header Flotation ...........................................................................................................449
7.1.14 Lighting and Marking for Cab-Forward Road Travel.................................................................449
7.1.15 Mechanical Center-Link .........................................................................................................449
7.1.16 Pressure Sensor Kit ..............................................................................................................449
7.1.17 Rotary Header Drive Hydraulics (13-foot)................................................................................450
7.1.18 Self-Aligning Center-Link .......................................................................................................450
7.1.19 Swath Roller .........................................................................................................................450
7.1.20 Towing Harness ....................................................................................................................450
147649 xiii Revision A

TABLE OF CONTENTS
7.1.21 Warning Beacons..................................................................................................................450
7.1.22 Weight Box ...........................................................................................................................451
7.1.23 Windshield Shades................................................................................................................451
8 Reference...........................................................................................................................................453
8.1 Recommended Torques ................................................................................................................453
8.1.1 Torque Specifications ............................................................................................................453
SAE Bolt Torque Specifications.......................................................................................453
Metric Bolt Specifications ...............................................................................................455
Metric Bolt Specifications Bolting into Cast Aluminum ......................................................458
Flare-Type Hydraulic Fittings ..........................................................................................458
O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) ..........................................................460
O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable)...................................................462
O-Ring Face Seal (ORFS) Hydraulic Fittings ...................................................................463
8.2 Recommended Fuel, Fluids, and Lubricants ...................................................................................465
8.2.1 Storing Lubricants and Fluids.................................................................................................465
8.2.2 Fuel Specifications ................................................................................................................465
8.2.3 Lubricants, Fluids, and System Capacities ..............................................................................466
8.2.4 Filter Part Numbers ...............................................................................................................467
8.3 Conversion Chart..........................................................................................................................468
8.4 Engine Error Codes ......................................................................................................................469
8.5 Cab Display Module (CDM) Error Codes ........................................................................................481
8.6 Cab Display Module (CDM) and Windrower Control Module (WCM) Fault Codes..............................484
Index ..................................................................................................................................................485
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1Safety
1.1 Safety Alert Symbols
This safety alert symbol indicates important safety
messages in this manual and on safety signs on the .
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
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SAFETY
1.2 Signal Words
Three signal words, DANGER,WARNING, and CAUTION, are used to alert you to hazardous situations. The
appropriate signal word for each situation has been selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
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.
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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 the protective clothing and personal safety
devices that could be necessary for the job at hand.
Don’t 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 the
fire extinguisher is properly maintained. Be familiar with
its proper use.
• Keep young children away from the machinery at
all times.
• Be aware that accidents often happen when the
Operator is tired or in a hurry. Take the time to
consider the safest way. Never ignore the 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 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.
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 the engine is running.
•DoNOT modify the machine. Non-authorized
modifications may impair machine function and/or
safety. It may also shorten the machine’s life.
• To avoid bodily injury or death from unexpected startup
of machine, always stop engine and remove key from
ignition before leaving operator’s seat for any reason.
Figure 1.6: Safety Around Equipment
• Keep the 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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