MacDon M155 Operators Manual
M155
Self-Propelled Windrower
Operator ’s Manual
169883 Revision A
Original Instruction
The harvesting specialists worldwide.
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, 2014
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
ntinued on next page.
Co
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Whole Body and Hand-Arm Vibration Levels
The weighted root mean square acceleration to which the whole body is subjected to ranges from 0.57 to 1.06 m/s
as measured on a representative machine during typical operations and analyzed in accordance with ISO 5008.
2
During the same operations, the weighted root means square hand-arm vibration was less than 1.45 m/s
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.
when
Noise Levels
The A-weigh
on several r
engine spee
t sound pressure levels inside the operator's station ranged from 70.1 to 73.1 dB(A) as measured
epresentative machines in accordance with ISO 5131. The sound pressure level depends upon the
d and load, field and crop conditions and the type of platform used.
2
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Introduction
This manual contains information on the MacDon M155 Self-Propelled Windrower, which is designed to cut and lay
in windrow s a wide variety of grain, hay, and specialty crops. Windrowing allows sta rting the harvest earlier, protects
the crop from wind damage, and gives you more flexibility in scheduling combine time.
The power unit (referred to in this manual as the “windrower”), when coupled with one of the specially designed
auger, rotary, or draper headers, provides a package which incorporates many features and improvements in design.
The M155 Windrow er is Dual Direction
engine-forward modes. Right-hand and left-hand 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 m anual as your first source of information about the machine. Use the Table of Contents and the Index to
guide you to specific areas. Stud y the Table of C on te nts to fa miliarize yourself with h o w 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).
®
, meaning that the windrower can be driven in the cab-forward or the
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List of Revisions
At MacDon, we’
documentatio
Summary of Change
Added new safety sign locations. 1.11 Safety Sign Locations, page 13
Updated lif
Restructured the header attach and detach procedures
to improve readability.
Removed r
in the Lub
with new d
Updated a
unit.
Added im
Replaced the missing Hydraulic Oil
Maintenance instruction.
Added the Adjusting Reel Drop Rate section. Adjusting Reel Drop Rate, page 367
Added image and instruction for 10–bolt wheel
tightening procedure and torque specifications
re continuously making improvements: occasionally these improvements impact product
n. The following list provides an account of major changes from the previous version of this document.
Location
t linkage images to include the new decal.
eference to the walking beam grease zerk
rication Points section. No longer required
esign.
ir conditioning unit images to show the new
age showing new battery boost post location.
Various locations throughout4.4.3 Levelling the Header,
page 143
4.5 Attaching and Detaching Headers, page 157
5.6.2 Lubrication Points, page 274
Air Conditioning Evaporator, page 288
Boostin
Checking and Filling Hydraulic Oil, page 360
Various locations throughout Tightening Drive Wheel
Nuts, page 371
g the Battery, page 331
Updated the replacing cabin dome light procedure. Dome Light, page 353
d case drain kit information to the Options and
Adde
chments section.
Atta
Added mechanical center-link to the Option and
Attachments section.
5 Case Drain Kit, page 405
7.1.
7.1.15 Mechanical Center-Link, page 407
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Serial Number
Record the mod
The serial num
main frame nea
WINDROWER MO
NUMBER
YEAR OF MANUFACTURE
The serial number plate (A) is located on top of the engine
cylinder head cover.
ENGINE SERIAL
NUMBER
DATE OF
MANUFACTURE
el number, model year, and serial number of the windrower and engine on the lines below.
ber plate (A) is located on the left side of the
r the walking beam.
DEL
Figure 2: Machine Serial Number Location
169883
Figure 3: Engine Serial Number Location
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Revision A
TABLE OF CONTENTS
Declaration of Conformity.................................................................................................................. i
Whole Body and Hand-Arm Vibration Levels ......................................................................................ii
Noise Levels .................................................................................................................................... ii
Introduction ..................................................................................................................................... iii
List of Revisions ..............................................................................................................................iv
Serial Number ................................................................................................................................. v
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 Interpreting Safety Signs ................................................................................................................ 17
2 Description.......................................................................................................................................... 27
2.1 D efinitions ..................................................................................................................................... 27
2.2 Specifications................................................................................................................................ 29
2.3 Windrower Dimensions .................................................................................................................. 32
2.4 Component Location...................................................................................................................... 34
3 Operator’s Station ............................................................................................................................... 37
3.1 Operator Console .......................................................................................................................... 37
3.2 Operator Presence System ............................................................................................................ 39
3.2.1 Header Drive ......................................................................................................................... 39
3.2.2 Engine and Transmission........................................................................................................ 39
3.3 Operator’s Seat Adjustments .......................................................................................................... 40
3.3.1 Fore-Aft ................................................................................................................................. 40
3.3.2 Seat Suspension and Height ................................................................................................... 40
3.3.3 Vertical Dampener.................................................................................................................. 41
3.3.4 Armrest ................................................................................................................................. 41
3.3.5 Fore-Aft Isolator Lock ............................................................................................................. 42
3.3.6 Seat Tilt................................................................................................................................. 42
3.3.7 Armrest Angle........................................................................................................................ 43
3.3.8 Lumbar Support ..................................................................................................................... 43
3.4 Training Seat................................................................................................................................. 44
3.5 Seat Belts ..................................................................................................................................... 45
3.6 Steering Column Adjustment .......................................................................................................... 46
3.7 Lighting ......................................................................................................................................... 47
3.7.1 Cab-Forward Lighting: Field.................................................................................................... 47
3.7.2 Engine-Forward Lighting: Road............................................................................................... 49
3.7.3 Cab-Forward Lighting: Road (Optional) ................................................................................... 50
3.7.4 Beacon Lighting: Export (N.A. Optional) .................................................................................. 51
3.7.5 Optional HID Auxiliary Lighting (if installed ) .............................................................................. 51
3.8 Windshield Wipers......................................................................................................................... 53
3.9 Rear View Mirrors .............................................................................................................
3.10 Cab Temperature........................................................................................................................... 55
............. 54
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TABLE OF CONTENTS
3.10.1 Heater Shut-Off...................................................................................................................... 55
3.10.2 Air Distribution ....................................................................................................................... 55
3.10.3 Controls................................................................................................................................. 56
3.11 Interior Lights ................................................................................................................................ 57
3.12 Operator Amenities ........................................................................................................................ 58
3.13 Radio ............................................................................................................................................ 60
3.13.1 AM/FM Radio......................................................................................................................... 60
3.13.2 Antenna Mounting .................................................................................................................. 60
3.14 Horn ............................................................................................................................................. 62
3.15 Engine Controls and Gauges.......................................................................................................... 63
3.16 Windrower Controls ....................................................................................................................... 64
3.17 Header Controls ............................................................................................................................ 66
3.17.1 Header Drive Switch............................................................................................................... 66
3.17.2 Header Drive Reverse Button..................................................................................................66
3.17.3 Ground Speed Lever (GSL) Header Switches .......................................................................... 67
Display Selector Switch................................................................................................... 68
Reel Position Switches.................................................................................................... 68
Header Position Switches................................................................................................ 69
Reel and Disc Speed Switches ........................................................................................ 69
3.17.4 Console Header Switches....................................................................................................... 70
Deck Shift/Float Preset Switch......................................................................................... 70
Double Windrow Attachment (DWA) / Swath Roller Switch (if installed) .............................. 71
3.18 Cab Display Module (CDM) ............................................................................................................ 72
3.18.1 Engine and Windrower Functions ............................................................................................ 72
3.18.2 Header Functions................................................................................................................... 73
3.18.3 Operating Screens ................................................................................................................. 74
Ignition ON, Engine Not Running ..................................................................................... 74
Engine-Forward, Engine Running .................................................................................... 75
Cab-Forward, Engine Running, Header Disengaged ......................................................... 75
Cab-Forward, Engine Running, Header Engaged, Auger Header Index Switch OFF............ 76
Cab-Forward, Engine Running, Header Engaged, Auger Header Index Switch ON ............. 77
Cab-Forward, Engine Running, Header Engaged, Draper Header, Index Switch OFF........... 78
Cab-Forward, Engine Running, Header Engaged, Draper Header, Index Switch ON ........... 79
Cab-Forward, Engine Running, Header Engaged, Rotary Header Installed......................... 80
Miscellaneous Operational Information............................................................................. 81
3.18.4 Cab Display Module (CDM) Warning/Alarms ............................................................................ 82
Engine Warning Lights .................................................................................................... 82
Display Warnings and Alarms .......................................................................................... 83
3.18.5 Cab Display Module (CDM) Programming................................................................................ 86
Programming Guidelines................................................................................................. 87
Detailed Programming Menu Flow Chart .......................................................................... 88
Operating Information Screens ........................................................................................ 94
3.18.6 Engine Error Codes................................................................................................................ 97
3.18.7 Cab Display Module (CDM) and Windrower Control Module (WCM) Fault Codes ....................... 97
4 Operation ............................................................................................................................................ 99
4.1 Owne r/Ope rato r Responsibilities..................................................................................................... 99
4.2 S ymbol Definitions........................................................................................................................100
4.2.1 Engine Functions ..................................................................................................................100
4.2.2 Windrower Operating Symbols ............................................................................................... 101
4.2.3 Header Functions..................................................................................................................102
4.3 Operating the Windrower...............................................................................................................103
4.3.1 Operational Safety ................................................................................................................103
4.3.2 Break-In Period.....................................................................................................................104
4.3.3 Preseason Checks/Annual Service.........................................................................................104
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TABLE OF CONTENTS
A/C Compressor Coolant Cycling....................................................................................105
4.3.4 Daily Check ..........................................................................................................................105
4.3.5 Engine Operation ..................................................................................................................106
Starting the Engine ........................................................................................................106
Engine Warm-Up ...........................................................................................................108
Engine Intermediate Speed Control (ISC)........................................................................ 108
Shutting Down the Engine ..............................................................................................109
Fuelling .........................................................................................................................109
Engine Temperature.......................................................................................................110
Engine Oil Pressure ....................................................................................................... 110
Electrical ....................................................................................................................... 111
Engine Warning Lights ................................................................................................... 111
4.3.6 Windrower Operation............................................................................................................. 111
Ingress/Egress ..............................................................................................................113
Driving Forward in Cab-Forward Mode ............................................................................ 114
Driving in Reverse in Cab-Forward Mode ........................................................................115
Driving Forward in Engine-Forward Mode........................................................................116
Driving in Reverse in Engine-Forward Mode .................................................................... 117
Spin Turning .................................................................................................................. 118
Stopping .......................................................................................................................118
4.3.7 Adjusting Caster Tread Width................................................................................................. 11 9
4.3.8 Transporting the Windrower ................................................................................................... 121
Driving on the Road .......................................................................................................121
Towing Header with Windrower.......................................................................................124
Towing the Windrower (Emergency)................................................................................ 134
Final Drives...................................................................................................................135
4.3.9 Storing the Windrower ...........................................................................................................135
4.4 Operating with a Header ...............................................................................................................137
4.4.1 Header Safety Props.............................................................................................................137
4.4.2 Header Float.........................................................................................................................139
Float Operating Guidelines ............................................................................................. 139
Checking Float ..............................................................................................................139
Float Options.................................................................................................................142
4.4.3 Levelling the Header..............................................................................................................143
4.4.4 Header Drive ........................................................................................................................145
Engaging and Disengaging the Header ...........................................................................145
Reversing the Header .................................................................................................... 147
4.4.5 Adjusting Header Angle.........................................................................................................147
Checking Self-Locking Center-Link Hook.........................................................................148
4.4.6 Cutting Height.......................................................................................................................150
Return to Cut ................................................................................................................150
Programming Return to Cut Feature ............................................................................... 151
Using Return to Cut Feature........................................................................................... 152
Auto Raise Height.......................................................................................................... 153
Programming Auto Raise Height Feature ........................................................................153
Using Auto Raise Height Feature....................................................................................154
Header Drop Rate..........................................................................................................154
4.4.7 Double Windrowing ...............................................................................................................154
Double Windrow Attachment (DWA) Deck Position ..........................................................155
Double Windrow Attachment (DWA) Draper Speed .......................................................... 155
4.4.8 Swath Roller Operation..........................................................................................................156
4.5 Attaching and Detaching Headers..................................................................................................157
4.5.1 Attaching a D-Series Header..................................................................................................157
Attaching a D-Series Header: Hydraulic Center-Link with Optional Self-Alignment .............157
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Attaching a D-Series Header: Hydraulic Center-Link without Self-Alignment......................162
Attaching a D-Series Header: Mechanical Center-Link ..................................................... 168
4.5.2 Detaching a D-Series Header ................................................................................................172
Detaching a D-Series Header: Hydraulic Center-Link ....................................................... 173
Detaching a D-Series Header: Mechanical Center-Link .................................................... 176
4.5.3 Attaching an A-Series Header ................................................................................................ 180
Attaching an A-Series Header: Hydraulic Center-Link with Optional Self-Alignment............180
Attaching an A-Series Header: Hydraulic Center-Link without Self-Alignment ....................185
Attaching an A-Series Header: Mechanical Center-Link ...................................................191
4.5.4 Detaching an A-Series Header............................................................................................... 196
Detaching an A-Series Header: Hydraulic Center-Link .....................................................197
Detaching an A-Series Header: Mechanical Center-Link ..................................................200
4.5.5 Attaching an R-Series Header................................................................................................204
Attaching an R-Series Header: Hydraulic Center-Link with Optional Self-Alignment ...........204
Attaching an R-Series Header: Hydraulic Center-Link without Self-Alignment ....................210
Attaching an R-Series Header: Mechanical Center-Link ................................................... 215
4.5.6 Detaching an R-Series Header...............................................................................................220
Detaching an R-Series Header: Hydraulic Center-Link.....................................................220
Detaching an R-Series Header: Mechanical Center-Link..................................................223
4.6 Operating with a D-Series Header..................................................................................................227
4.6.1 Configuring Hydraulics...........................................................................................................227
4.6.2 Attaching Header Boots.........................................................................................................228
4.6.3 Header Position ....................................................................................................................228
4.6.4 Reel Fore-Aft Position ...........................................................................................................229
4.6.5 Reel Height...........................................................................................................................229
4.6.6 Reel Speed...........................................................................................................................229
Reel to Ground Speed ...................................................................................................229
Reel Only Speed ...........................................................................................................231
4.6.7 Draper Speed .......................................................................................................................232
Draper to Ground Speed................................................................................................232
Setting Draper Minimum Speed......................................................................................233
Setting Draper Index ...................................................................................................... 234
Setting Draper Speed Independent of Ground Speed.......................................................235
4.6.8 Knife Speed..........................................................................................................................236
Setting Knife Speed “On the Go”.....................................................................................237
4.6.9 Deck Shift (Optional) .............................................................................................................238
Deck Shift .....................................................................................................................238
Setting Float Options with Deck Shift...............................................................................238
4.7 Operating with an A-Series Header................................................................................................240
4.7.1 Auger Speed.........................................................................................................................240
Auger Speed on A30-D Headers.....................................................................................240
Auger Speed on A40-D Headers.....................................................................................240
4.7.2 Reel Speed...........................................................................................................................241
Reel Speed on A30-D Headers.......................................................................................241
Reel Speed on A40-D Headers.......................................................................................241
4.7.3 Knife Speed..........................................................................................................................245
Setting Knife Speed “On the Go”.....................................................................................246
4.8 Operating with an R-Series Header................................................................................................247
4.9 Disc Speed...................................................................................................................................248
4.9.1 Setting Disc Speed................................................................................................................248
5 Maintenance and Servicing................................................................................................................249
5.1 Preparation For Servicing..............................................................................................................249
5.2 Torque Specifications .................................................................................................................... 250
5.2.1 SAE Bolt Torque Specifications ..............................................................................................250
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TABLE OF CONTENTS
5.2.2 Metric Bolt Specifications.......................................................................................................252
5.2.3 Metric Bolt Specifications Bolting into Cast Aluminum .............................................................. 255
5.2.4 Flare-Type Hydraulic Fittings..................................................................................................255
5.2.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)..................................................................257
5.2.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) .......................................................... 259
5.2.7 O-Ring Face Seal (ORFS) Hydraulic Fittings...........................................................................260
5.3 Maintenance Specifications ........................................................................................................... 262
5.3.1 Recommended Fuel, Fluids, and Lubricants............................................................................262
Storing Lubricants and Fluids .........................................................................................262
Fuel Specifications.........................................................................................................262
Lubricants, Fluids, and System Capacities.......................................................................263
Filter Part Numbers........................................................................................................ 264
5.3.2 Conversion Chart ..................................................................................................................264
5.4 Engine Compartment Hood ...........................................................................................................266
5.4.1 Opening Hood (Lower Position)..............................................................................................266
5.4.2 Closing Hood (Lower Position) ............................................................................................... 267
5.4.3 Opening Hood (Highest Position) ...........................................................................................267
5.4.4 Closing Hood (Highest Position).............................................................................................268
5.5 Maintenance Platforms .................................................................................................................269
5.5.1 Opening Platforms (Standard Position) ................................................................................... 269
5.5.2 Closing Platforms (Standard Position).....................................................................................270
5.5.3 Opening Platforms (Major Service Position) ............................................................................270
5.5.4 Closing Platforms (Major Service Position)..............................................................................272
5.6 Windrower Lubrication ..................................................................................................................273
5.6.1 Lubricating the Windrower .....................................................................................................273
5.6.2 Lubrication Points..................................................................................................................274
5.7 Operator’s Station.........................................................................................................................275
5.7.1 Seat Belts.............................................................................................................................275
5.7.2 Safety Systems.....................................................................................................................275
Checking Operator Presence System..............................................................................275
Checking Engine Interlock..............................................................................................276
5.7.3 Ground Speed Lever (GSL) Adjustments................................................................................276
Adjusting Ground Speed Lever (GSL) Lateral Movement..................................................276
Adjusting Ground Speed Lever (GSL) Fore-Aft Movement................................................277
5.7.4 Steering Adjustments ............................................................................................................278
Checking Steering Link Pivots ........................................................................................ 278
Checking Steering Chain Tension ...................................................................................280
5.7.5 Park Brake............................................................................................................................281
Adjusting and Replacing Interlock Switch ........................................................................281
5.7.6 Heating, Ventilating, and Air Conditioning (HVAC) System .......................................................284
Fresh Air Intake Filter.....................................................................................................284
Return Air Cleaner/Filter.................................................................................................286
Air Conditioning Condenser............................................................................................288
Air Conditioning Evaporator ............................................................................................288
Air Conditioning Compressor .......................................................................................... 290
5.7.7 Engine..................................................................................................................................291
General Engine Inspection .............................................................................................291
Turning Engine Manually................................................................................................ 292
Engine Oil .....................................................................................................................293
Air Intake System...........................................................................................................296
Fuel System ..................................................................................................................303
Engine Cooling System..................................................................................................310
Gearbox........................................................................................................................321
Exhaust System.............................................................................................................322
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TABLE OF CONTENTS
Belts .............................................................................................................................323
Engine Speed................................................................................................................326
5.7.8 Electrical System...................................................................................................................326
Battery..........................................................................................................................326
Headlights: Engine-Forward ...........................................................................................335
Field Lights: Cab-Forward ..............................................................................................339
Flood Lights: Forward .................................................................................................... 340
HID Auxiliary Lighting (Optional - MD #B5596).................................................................342
Flood Lights: Rear .........................................................................................................345
Red and Amber Lights ...................................................................................................347
Red Tail Lights (if installed)............................................................................................. 347
Beacons (if installed)......................................................................................................348
Console Gauge Light .....................................................................................................352
Dome Light....................................................................................................................353
Ambient Light ................................................................................................................353
Turn Signal Indicators ....................................................................................................354
Circuit Breakers and Fuses ............................................................................................354
5.7.9 Hydraulic System ..................................................................................................................359
Checking and Filling Hydraulic Oil ...................................................................................360
Hydraulic Oil Cooler ....................................................................................................... 361
Draining Hydraulic Oil ....................................................................................................362
Changing Hydraulic Oil Filters.........................................................................................362
Header and Reel Hydraulics...........................................................................................365
Traction Drive Hydraulics................................................................................................368
Hoses and Lines............................................................................................................369
5.7.10 Wheels and Tires ..................................................................................................................370
Drive Wheel ..................................................................................................................370
Caster Wheel ................................................................................................................376
5.7.11 Maintenance Schedule ..........................................................................................................382
Break-In Inspections ......................................................................................................383
Maintenance Schedule/Record.......................................................................................384
6 Troubleshooting.................................................................................................................................387
6.1 Engine Troubleshooting ................................................................................................................387
6.2 Electrical Troubleshooting .............................................................................................................393
6.3 Hydraulics Troubleshooting ...........................................................................................................394
6.4 Header Drive Troubleshooting .......................................................................................................395
6.5 Traction Drive Troubleshooting ......................................................................................................396
6.6 Steering and Ground Speed Control Troubleshooting......................................................................399
6.7 Cab Air Troubleshooting................................................................................................................400
6.8 Operator’s Station Troubleshooting................................................................................................404
7Opti
ons and Attachments ..................................................................................................................405
7.1 O pti
7.1.
7.1.
7.1
7.1
7.1
7.1
7.1
1.8
7.
1.9
7.
1.10
7.
1.11
7.
ons and Attachments ..............................................................................................................405
1
2
.3
.4
.5
.6
.7
M Radio........................................................................................................................405
AM/F
mated Steering Systems................................................................................................. 405
Auto
ster Spring Kit (External) ..................................................................................................405
Boo
ster Spring Kit (Internal)...................................................................................................405
Boo
e Drain Kit.......................................................................................................................405
Cas
ble Windrow Attachment (DWA) ....................................................................................... 406
Dou
per Header Reel Drive and Lift Plumbing ........................................................................... 406
Dra
gine Block Heater..............................................................................................................406
En
gine Fan Air Baffle ............................................................................................................. 406
En
ader Drive Reverser .......................................................................................................... 406
He
D Auxiliary Lighting ............................................................................................................406
HI
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7.1.12 Hydraulic Center-Link ............................................................................................................407
7.1.13 Light Header Flotation ...........................................................................................................407
7.1.14 Lighting and Marking for Cab-Forward Road Travel.................................................................407
7.1.15 Mechanical Center-Link.........................................................................................................407
7.1.16 Pre-Cleaner and Radiator/Charge Air Cooler Sweeps..............................................................407
7.1.17 Pressure Sensor ...................................................................................................................407
7.1.18 Rotary Header Drive Hydraulics (13-foot)................................................................................407
7.1.19 Self-Aligning Center-Link .......................................................................................................408
7.1.20 Swath Roller .........................................................................................................................408
7.1.21 Towing Harness ....................................................................................................................408
7.1.22 Warning Beacons..................................................................................................................408
7.1.23 Weight Box ...........................................................................................................................409
7.1.24 Windshield Shades................................................................................................................409
8 Engine Error Codes............................................................................................................................411
9CabDispla
Index ..................................................................................................................................................433
y Module (CDM) Error Codes ............................................................................................429
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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 windrower.
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.
• Accidentscanbeavoided.
Figure 1.
1: Safety Symbol
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SAFETY
1.2 Signal Words
Three signal words, DANGER, WARNING, a nd 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 pote
mayalsobeused
ntially hazardous situation that, if not avoided, could result in death, or serious injury. It
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:
– A hard hat
– Protective footwear with slip res ista nt soles
– Protective glasses or goggles
– Heavy gloves
– Wet weather gear
– A respirator or filter mask
– Hearing protection
Be aware that exposure to loud noise can cause
impairment or loss of hearing. Wearing suitable
hearing protection devices such as ear muffs or ear
plugs. These w ill help protect against objectionable
or loud noises.
•Provideafirs
• Keep a fire ext
fire extingui
its proper u s
• Keep young c
all times.
t aid kit for use in case of emergencies.
inguisher on the machine. Be sure the
sher is properly maintained. Be familiar with
e.
hildren away from the machinery at
Figure 1.2
Figure 1.3: Safety Equipment
: Safety Equipment
•Beawaretha
Operator is
time to cons
signs of fa
169883 3 Revision A
t accidents often happen when the
tiredorinahurrytogetfinished. Take the
ider the safest way. Never ignore warning
tigue.
Figure 1.4: Safety Equipment
SAFETY
•Wearclosefitting clothing and cove r lo ng 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.
• Keep hands, feet, clothing, and hair away from moving
parts. Never at te mpt to clear obstructions or ob jects,
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.
Figure 1.5: Safety around Equipment
• Stop the engine and remove the key from 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.
• Keep work area well lit.
• Keep machinery clean. Straw and chaff, on a hot
engine, are a fire hazard. Do NOT allow oil or grease to
accumulate on service pla tforms, ladde rs, or controls.
Clean machines before storage.
• Never use gasoline, naphtha, or any volatile material
for cleaning purposes. These materials may be toxic
and/or flammable.
• When storing machinery, cover sharp or extending
components to prevent injury from accidental contact.
Figure 1.6: Safety around Equipment
Figure 1.7: Safety around Equipment
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1.4 Maintenance Safety
To ensure your safety while maintaining the machine:
• Review the operator’s manual and all safety items
before operation and/or maintenance of the 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 area clean and dry.
– Be sure electrical outlets and tools are
properly grounded.
– Use adequate light for the job at hand.
• Relieve pressure from hydraulic circuits before servicing
and/or disconnecting the machine.
• Before applying pressure to a hydraulic system, make
sure all components are tight and that steel lines, hoses,
and couplings are in good condition.
Figure 1.8: Safety around Equipment
• Keep hands, feet, clothing, and hair away from all
moving and/or rotating parts.
• Clear the area of bystand ers especially children when
carrying out any maintenance and repairs or when
making any adjustments.
• Install transport lock or place safety stands under the
frame before working under the windrower.
• If more than one person is servicing the machine at the
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 knife) to move. Stay
clear of driven components at all times.
• Wear protective gea
• Wear heavy gloves w
r when working on the machine.
hen working on knife components.
Figure 1.9: Eq
uipment NOT Safe for Children
Figure 1.10: Saf
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SAFETY
1.5 Hydraulic Safety
• Always place all hydraulic controls in Neutral
before dismounting.
• Make sure that all components in the hydraulic system
are kept in good condition and clean.
• Replace any worn, cut, abraded, flattened, or crimped
hoses and steel lines.
•DoNOT attempt any makeshift repairs to the hydraulic
lines, fittings, or hoses by using tapes, clamps, cements,
or welding. The hydraulic system operates under
extremely hig h pressure. Such makeshift repairs will fail
suddenly and create a hazardous and unsafe condition.
Figure 1.11: Checking Hydraulic Leaks
•Wearprope
for a highcardboar
and ident
•Ifinjure
hydrauli
Serious
hydraul
• Before applying pressure to a hydraulic system, make
sure all components are tight and that steel lines, hoses,
and couplings are in good condition.
r hand and eye protection when searching
pressure hydraulic leak. U se a piece of
d as a backstop instead of hands to isolate
ify a leak.
d by a concentrated high-pressure stream of
c fluid, seek medical attention immediately.
infection or toxic reaction can develop from
ic fluid piercing the skin.
Figure
1.12: Hydraulic Pressure Hazard
ure 1.13: Safety Glasses
Fig
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1.6 Tire Safety
• Failure to follow proper procedures when mounting a tire
on a wheel or rim can produce an explosion that may
result in serious injury or death.
•DoNOT attempt to mount a tire unless you have the
proper training and equipment.
• Haveaqualified tire dealer or repair service perform
required tire maintenance.
Figure 1.14: Over-Inflated Tire
Figure 1.15: Safely Filling a Tire with Air
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1.7 Battery Safety
WARNING
• Keep all sparks and flames away from the
batteries, as a gas given off by electrolyte
is explosive.
• Ventilate when charging in enclosed space.
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 the eyes is extremely
dangerous. Should this occur, force the eye open,
and flood with cool, clean water for five minutes.
Call a doctor immediately.
• If electrolyte is spilled or splashed on clothing
or the body, neutralize it immediately with a
solution of baking soda and water, then rinse with
clear water.
WARNING
• To avoid injury from spark or short circuit,
disconnect battery ground cable before servicing
and part of electrical system.
Figure 1.1
Figure 1.17: Safety around Equipment
6: Safety around Equipment
• Do NOT operate the engine with alternator
or battery disconnected. With battery cables
disconnected and engine running, a high voltage
can be built up if terminals touch the frame.
Anyone touching the frame under these conditions
would be severely shocked.
• Whenworkingaroundstoragebatteries,remember
that all of the exposed metal parts are live. Never
lay a metal object across the terminals because a
spark or short circuit will result.
• Keep batteries out of reach of children.
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Figure 1.18: Safety around Equipment
SAFETY
1.8 Welding Precaution
High currents and voltage spikes associated with welding can cause damage to electronic components. Before
welding on any part of the windrower or an attached header, disconnect all electronic module harness connections
as well as the battery cables. Refer to your technical manual or MacDon Dealer for proper procedures.
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1.9 Engine Safety
WARNING
Do NOT use aerosol types of starting aids such as ether. Such use could result in an explosion and
personal injury.
CAUTION
• In the initialstart-upof a new, serviced, o r repairedengine always makeprovision to shut theengine off,
in order to stop an over-speed. This may be accomplished by shutting off the air and/or fuel supply to the
engine. Over-speed shut down shouldoccur automatically for engines that arecontrolledelectronically.
• Do NOT bypass or disable the automatic shutoff circuits. The circuits are provided in order to help
prevent personal injury. The circuits are also provided in order to help prevent engine damage. Refer
to the technical manual for repairs and adjustments.
• Inspect the engine for potential hazards.
• Before starting the engine, ensure that no one is on, underneath, or close to theengine. Ensure that the
area is free of personnel.
• All protective guards and all protective covers must be installed if the engine must be started in order
to perform service procedures.
• To help prevent an accident that is caused by parts in rotation, work around the parts carefully.
• If a warningtag is attached tothe engine startswitch or to thecontrols, do NOTstart the engine or move
the controls. Consult with the person who attached the warning tag before the engine is started.
• Start the engine from the operator’s compartment. Always start the engine according to the procedure
that is described in the Engine Starting section of theoperator’smanual. Knowingthe correct procedure
will help to prevent major damage to the engine components and prevent personal injury.
• To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working
correctly, check the water temperature gauge and/or the oil temperature gauge during the heater
operation. Engine exhaust contains products of combustion which can be harmful to your health.
Always start the engine and operate the engine in a well ventilated area. If the engine is started in an
enclosed area, vent the engine exhaust to the outside.
NOTE: The engine may be equipped with a device for cold starting. If the engine will be operated in very
cold conditions, then an additional cold starting aid may be required. Normally, the engine will be
equipped with the correct type of starting aid for your region of operation.
1.9.1 Hi
gh Pressure Rails
CAUTION
Contact with high pressure fuel may cause fluid p e netration and burn hazards. High pressure fuel spray
may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may
cause personal injury or death.
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1.9.2 Engine Electronics
WARNING
Tampering with the electronic system installation or the original equipment manufacturer (OEM) wiring
installation can be dangerous and could result in personal injury or death and/or engine damage.
WARNING
Electrical Shock Hazard. The electronic unit injectors use DC voltage. The engine control module (ECM)
sends this voltage to theelectronic unit injectors. Do NOT come in contact with theharness connector for
the electronic unit injectors while the engine is operating. Failure to follow this instruction could result in
personal injury or death.
This engine has a comprehensive, programmable engine monitoring system. The ECM has the ability to monitor
the engine operating conditions. If any of the engine parameters extend outside an allowable range, the ECM will
initiate an immediate action.
The following actions are available for engine monitoring control:
• Warning
• Derate
• Shutdown
The following mo nitored engine o pe rating conditions have the ability to limit engine speed and/or the engine power:
• Engine Coolant Temperature
• Engine Oil Pressure
• Engine Speed
• Intake Manifold Air Temperature
The engine monitoring package can vary for different engine models and different engine applications. However,
the monitoring system and the engine monitoring control will be similar for all engines. Together, the two controls
will provide the engine monitoring function for the specific engine application.
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1.10 Safety Signs
• Keep safety signs clean and legible at all times.
• Replace safety signs that are missing or
become illegible.
• If original parts on which a safety sign was installed are
replaced, be sure the repair part also bears the current
safety sign.
• Safety signs are available from your Dealer
Parts Department.
1.10.1 Installing Safety Decals
Figure 1.19: Operator ’s Manual Decal
To i ns t al
1. Be sure th
2. Decide on
3. Remove t
4. Place th
5. Small ai
l a safety decal, follow these steps:
e sign in p osition and slowly peel back the remaining paper, smoothing the sign as it is applied.
r pockets can be smoothed out or pricked with a pin.
e installation area is clean and dry.
the exact location before you remove the decal backing paper.
he smaller portion of the split backing paper.
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1.11 Safety Sign Locations
SAFETY
Figure 1
A - Hazard Sign (MD #135378) B - Cab Door and Rim (MD #166454) C - Oil Reservoir under Hood (MD #174436)
D - Exhaust Cover (MD #166450) E - Close to Radiator Cap (MD #166461) F - Fan Shroud (Top) (MD #166450)
G-FanSh
K - Platform (L of Step) (MD #166425) L - Platform (R of Step) (MD #166441) M - Frame at Valve Block (MD #166466)
N - Lift Linkage (MD #166438) O - Inner Post (MD #166457) P - Inner Post (MD #166234)
Q - Inne
.20: Safety Sign Locations (LH Side)
roud (Middle) (MD #166451)
r Post (MD #166463)
H-FanSh
R-Neut
roud (Bottom) (MD #166452)
ral Interlock (MD #166425)
J-Frame
S-Fram
Opening (MD #166233)
e (MD #166425)
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Figure 1.21: Safety Signs (LH Side)
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