MacDon M205 Operator's Manual

2018 Model Year Original Instruction The harvesting specialists.

1000141 Published March, 2018 California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals, and related accessories contain lead and lead components. Wash hands after handling. Whole Body and Hand-Arm Vibration Levels The weighted root mean square acceleration, to which the whole body is subjected, ranges from 0.57 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/s2 when 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.

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 M205 Windrower features Dual Direction®, meaning that the windrower can be driven in cab-forward or engine-forward mode. 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. When setting up the machine or making adjustments, review and follow the recommended machine settings in all relevant MacDon publications. Failure to do so may compromise the machine function and machine life and may result in a hazardous situation. If you follow the instructions given here, your M205 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. MacDon provides warranty for Customers who operate and maintain their equipment as described in this manual. A copy of the MacDon Industries Limited Warranty Policy, which explains this warranty, should have been provided to you by your Dealer. Damage resulting from any of the following conditions will void the warranty: • Accident • Misuse • Abuse • Improper maintenance or neglect • Abnormal or extraordinary use of the machine • Failure to use the machine, equipment, component, or part in accordance with the manufacturer’s instructions 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). 214603 i Revision A

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 Changed the publication part number from 147955 to 214603. — Added Declaration of Conformity. Declaration of Conformity, page 3 Added D1 SP header compatibility. Throughout. Updated illustrations to show beacons and engine air precleaner. 2.4 Component Location, page 37 Added swath compressor information to the CDM display tables. 3.19.3 Operating Screens, page 78 • Updated illustrations of front wiper switch. • Added illustrations of beacon/clearance switch for Russian-configured windrower. 3.7 Exterior Lighting, page 49 Revised note to say that the two front corner field lights remain on when the auto road light feature is activated. • 3.7.1 Field Light: Cab-Forward, page 50 • Driving on the Road, page 179 Changed swath roller to swath compressor. Double Windrow Attachment (DWA) / Swath Compressor Switch (if installed), page 75 Added topic. 3.19.12 Calibrating the Swath Compressor Sensor, page 131 Added topic. Converting from Transport Mode to Field Operation, page 189 Added illustration showing DWA crop delivery. 4.4.10 Using the Double Windrowing Attachment, page 213 Added swath compressor section. 4.4.11 Swath Compressor (Option), page 215 • Added reference to union fittings required to hard plumb R85 16-ft. header to M205. • Added reference to Hydraulic Coupler kit (MD #B5497). 4.8 Operating with an R Series Header, page 281 Updated engine interlock information. Checking Engine Interlock, page 296 Updated air intake illustration and description. 5.8.4 Air Intake System, page 317 Changed H2O level from 2.5 in. to 25 in. Air Filter Restriction Indicator, page 317 214603 ii Revision A

Removed swath roller topic. — Added replacement bulb part number and description. • Replacing Headlight Bulb, page 358 • Replacing Field Light Bulb, page 363 • Replacing Bulb in Cab-Forward Flood Light, page 363 • Replacing Bulb in Rear Flood Light, page 369 Updated fuse box decal to MD #167962. Fuse Box Decal, page 381 Changed wheel drive lubricant from 80W-140 to 75W-90. 8.2 Recommended Fuel, Fluids, and Lubricants, page 460 Added swath compressor to options and attachments chapter. 7.3.11 Swath Compressor, page 447 Added Recommended Fluids and Lubricants to the inside back cover. — Removed Pre-cleaner and Sweeps kit (B6422) from Options and Attachments chapter; the kit is not applicable to 2018 M205 Windrowers. — 214603 iii Revision A

Record the model number, model year, and serial number of the windrower and engine on the lines below. 1013874 A Machine Serial Number Location 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 1005633 A Engine 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 214603 iv Revision A

Serial Numbers ........................................................................................................................................ iv Chapter 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 Precautions ............................................................................................................................9 1.9 Engine Safety ....................................................................................................................................10 1.9.1 High Pressure Rail ....................................................................................................................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 Chapter 2: Product Overview ............................................................................................................27 2.1 Definitions .........................................................................................................................................27 2.2 Specifications ....................................................................................................................................30 2.3 Windrower Dimensions.......................................................................................................................34 2.4 Component Location ..........................................................................................................................37 Chapter 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 Adjusting Fore-Aft Position.........................................................................................................42 3.3.2 Adjusting Seat Suspension and Height .......................................................................................42 3.3.3 Adjusting Vertical Dampener ......................................................................................................43 3.3.4 Adjusting the Armrest ................................................................................................................43 3.3.5 Adjusting Fore-Aft Isolator Lock..................................................................................................44 3.3.6 Adjusting Seat Tilt .....................................................................................................................44 3.3.7 Adjusting Armrest Angle ............................................................................................................45 3.3.8 Adjusting Lumbar Support..........................................................................................................45 TABLE OF CONTENTS

3.5 Using Seat Belts ................................................................................................................................47 3.6 Adjusting Steering Column .................................................................................................................48 3.7 Exterior Lighting.................................................................................................................................49 3.7.1 Field Light: Cab-Forward ...........................................................................................................50 3.7.2 Road Light: Engine-Forward ......................................................................................................51 3.7.3 Road Light: Cab-Forward...........................................................................................................52 3.7.4 Hazard Light .............................................................................................................................53 3.7.5 Beacon Light (Optional) .............................................................................................................53 3.7.6 Auto Road Light ........................................................................................................................54 3.7.7 HID Auxiliary Lighting (Optional).................................................................................................54 3.8 Windshield Wipers .............................................................................................................................56 3.9 Rear View Mirrors ..............................................................................................................................57 3.10 Cab Temperature .............................................................................................................................58 3.10.1 Heater Shut-Off.......................................................................................................................58 3.10.2 Air Distribution ........................................................................................................................58 3.10.3 Climate Controls......................................................................................................................59 Refrigerant Oil..........................................................................................................................59 3.11 Interior Lights...................................................................................................................................60 3.12 Emergency Exit................................................................................................................................61 3.13 Operator Amenities ..........................................................................................................................62 3.14 Radio ..............................................................................................................................................64 3.14.1 AM/FM Radio..........................................................................................................................64 3.14.2 Mounting the Antenna..............................................................................................................64 3.15 Horn................................................................................................................................................66 3.16 Engine Controls and Gauges ............................................................................................................67 3.17 Windrower Controls..........................................................................................................................68 3.18 Header Controls...............................................................................................................................70 3.18.1 Header Drive Switch................................................................................................................70 3.18.2 Header Drive Reverse Button...................................................................................................70 3.18.3 Ground Speed Lever (GSL) Header Switches............................................................................71 Display Selector Switch.............................................................................................................72 Reel Position Switches..............................................................................................................72 Header Position Switches .........................................................................................................73 Reel and Disc Speed Switches ..................................................................................................73 3.18.4 Console Header Switches........................................................................................................74 Deck Shift / Float Preset Switch .................................................................................................74 Double Windrow Attachment (DWA) / Swath Compressor Switch (if installed) ...............................75 3.19 Cab Display Module (CDM)...............................................................................................................76 3.19.1 Engine and Windrower Functions .............................................................................................76 3.19.2 Header Functions....................................................................................................................77 3.19.3 Operating Screens ..................................................................................................................78 Ignition ON, Engine Not Running ...............................................................................................78 TABLE OF CONTENTS

Engine-Forward, Engine Running ..............................................................................................79 Cab-Forward, Engine Running, Header Disengaged ...................................................................79 Cab-Forward, Engine Running, Header Engaged, Auger Header Index Switch OFF......................80 Cab-Forward, Engine Running, Header Engaged, Auger Header Index Switch ON........................81 Cab-Forward, Engine Running, Header Engaged, Draper Header, Index Switch OFF....................82 Cab-Forward, Engine Running, Header Engaged, Draper Header Index Switch ON ......................83 Cab-Forward, Engine Running, Header Engaged, Rotary Header Installed...................................84 Miscellaneous Operational Information.......................................................................................85 3.19.4 Cab Display Module (CDM) Warning and Alarms .......................................................................86 Engine Warning Lights..............................................................................................................86 Display Warnings and Alarms....................................................................................................87 3.19.5 Configuration Guidelines..........................................................................................................89 3.19.6 Cab Display Module (CDM) Configuration .................................................................................90 3.19.7 Configuring the Windrower.......................................................................................................91 Setting the Header Knife Speed.................................................................................................91 Setting the Knife Overload Speed ..............................................................................................93 Setting the Rotary Disc Overload Speed.....................................................................................94 Setting the Hydraulic Overload Pressure ....................................................................................95 Setting the Header Index Mode .................................................................................................96 Setting the Return to Cut Mode..................................................................................................97 Setting the Auto Raise Height....................................................................................................98 Activating the Double Windrow Attachment (DWA)......................................................................98 Setting the Header Cut Width ..................................................................................................101 Activating the Swath Compressor ............................................................................................102 Displaying Reel Speed............................................................................................................104 Setting the Windrower’s Tire Size ............................................................................................105 Setting the Engine Intermediate Speed Control (ISC) RPM........................................................106 Clearing Sub-Acres ................................................................................................................107 3.19.8 Activating Cab Display Lockouts.............................................................................................107 Activating the Header Tilt Control Lockout ................................................................................108 Activating the Header Float Control Lockout .............................................................................109 Activating the Reel Fore-Aft Control Lockout............................................................................. 110 Activating the Draper Speed Control Lockout............................................................................ 112 Activating the Auger Speed Control Lockout ............................................................................. 113 Activating Knife Speed Control Lockout.................................................................................... 114 Activating Rotary Disc Speed Control Lockout .......................................................................... 116 Activating the Reel Speed Control Lockout ............................................................................... 117 3.19.9 Displaying Activated Cab Display Lockouts ............................................................................. 118 3.19.10 Cab Display Options ............................................................................................................ 119 Setting the Cab Display Language ...........................................................................................120 Changing the Windrower Display Units.....................................................................................121 Adjusting the Cab Display Buzzer Volume ................................................................................122 Adjusting the Cab Display Backlighting.....................................................................................123 Adjusting the Cab Display Contrast..........................................................................................124 3.19.11 Calibrating the Header Sensors ............................................................................................125 Calibrating the Header Height Sensor ......................................................................................125 Calibrating the Header Tilt Sensor............................................................................................127 Calibrating the Header Float Sensors.......................................................................................129 3.19.12 Calibrating the Swath Compressor Sensor ............................................................................131 3.19.13 Troubleshooting Windrower Problems...................................................................................133 TABLE OF CONTENTS

Switching the Installed Header Sensors ON or OFF ..................................................................134 Displaying Header Sensor Input Signals...................................................................................136 Forcing a Header ID................................................................................................................137 3.19.14 Troubleshooting Header Problems........................................................................................139 Testing the Header Up/Down Activate Function Using the Cab Display Module (CDM).................139 Testing the Reel Up/Down Activate Function Using the Cab Display Module (CDM).....................140 Testing the Header Tilt Activate Function 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) .............145 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)................................................................................................150 Testing the Reel Fore-Aft Activate Function Using the Cab Display Module (CDM) ......................152 Activating the Hydraulic Purge Using the Cab Display Module (CDM).........................................154 3.19.15 Engine Error Codes .............................................................................................................156 3.19.16 Cab Display Module (CDM) and Windrower Control Module (WCM) Fault Codes .....................156 Chapter 4: Operation .........................................................................................................................157 4.1 Owner/Operator Responsibilities.......................................................................................................157 4.2 Symbol Definitions ...........................................................................................................................158 4.2.1 Engine Functions ....................................................................................................................158 4.2.2 Windrower Operating Symbols.................................................................................................159 4.2.3 Header Functions....................................................................................................................160 4.3 Operating the Windrower..................................................................................................................161 4.3.1 Operational Safety ..................................................................................................................161 4.3.2 Break-In Period.......................................................................................................................162 4.3.3 Preseason Checks / Annual Service .........................................................................................162 Air Conditioning (A/C) Compressor Coolant Cycling ..................................................................163 4.3.4 Daily Checks and Maintenance ................................................................................................163 4.3.5 Engine Operation ....................................................................................................................164 Starting the Engine .................................................................................................................164 Engine Warm-Up....................................................................................................................166 Engine Intermediate Speed Control (ISC).................................................................................166 Shutting down the Engine........................................................................................................166 Filling the Fuel Tank................................................................................................................167 Engine Temperature ...............................................................................................................168 Engine Oil Pressure................................................................................................................168 Cab Display Module (CDM) Voltage Display .............................................................................169 Engine Warning Lights............................................................................................................169 4.3.6 Driving the Windrower .............................................................................................................169 Entering and Exiting the Windrower .........................................................................................171 Driving Forward in Cab-Forward Mode.....................................................................................172 Driving Reverse in Cab-Forward Mode.....................................................................................173 Driving Forward in Engine-Forward Mode.................................................................................174 Driving in Reverse in Engine-Forward Mode .............................................................................175 Spin Turning...........................................................................................................................176 TABLE OF CONTENTS

4.3.8 Transporting ...........................................................................................................................179 Driving on the Road ................................................................................................................179 Towing Header with Windrower................................................................................................181 Towing the Windrower (Emergency).........................................................................................192 Disengaging Final Drives ........................................................................................................192 4.3.9 Storing the Windrower .............................................................................................................193 4.4 Operating with a Header...................................................................................................................194 4.4.1 Engaging and Disengaging Header Safety Props: M Series Self-Propelled Windrower .................194 4.4.2 Using Header Float .................................................................................................................196 Float Operating Guidelines......................................................................................................196 Checking Float .......................................................................................................................197 Float Options..........................................................................................................................199 4.4.3 Levelling the Header................................................................................................................201 4.4.4 Header Drive ..........................................................................................................................204 Engaging and Disengaging the Header ....................................................................................204 Reversing the Header .............................................................................................................205 4.4.5 Adjusting Header Angle ...........................................................................................................205 Checking Self-Locking Center-Link Hook .................................................................................206 4.4.6 Controlling Cutting Height ........................................................................................................208 4.4.7 Return to Cut .........................................................................................................................208 Programming the Return to Cut Feature...................................................................................209 Using the Return to Cut Feature ..............................................................................................210 4.4.8 Auto Raise Height ................................................................................................................... 211 Programming the Auto Raise Height Feature............................................................................ 211 Using the Auto Raise Height Feature .......................................................................................212 4.4.9 Header Drop Rate ...................................................................................................................212 4.4.10 Using the Double Windrowing Attachment...............................................................................213 Engaging and Disengaging the Double Windrow Attachment (DWA) ..........................................214 Adjusting Double Windrow Attachment (DWA) Draper Speed ....................................................214 4.4.11 Swath Compressor (Option) ...................................................................................................215 Using the Swath Compressor ..................................................................................................215 4.5 Attaching and Detaching Headers .....................................................................................................217 4.5.1 Attaching Header Boots...........................................................................................................217 4.5.2 Attaching a D Series or D1 SP Series Header............................................................................218 Attaching a D Series or D1 SP Series Header: Hydraulic Center-Link with Optional Self- Alignment ..................................................................................................................218 Attaching a D Series or D1 SP Series Header: Hydraulic Center-Link without Self- Alignment ..................................................................................................................223 4.5.3 Detaching a D Series or D1 SP Series Header ..........................................................................229 Detaching a D Series or D1 SP Series Header: Hydraulic Center-Link ........................................229 4.5.4 Attaching an A Series Header ..................................................................................................232 Attaching an A Series Header: Hydraulic Center-Link with Optional Self-Alignment .....................233 Attaching an A Series Header: Hydraulic Center-Link without Self-Alignment ..............................238 4.5.5 Detaching an A Series Header .................................................................................................244 Detaching an A Series Header: Hydraulic Center-Link...............................................................244 4.5.6 Attaching an R Series Header ..................................................................................................248 TABLE OF CONTENTS

Attaching an R Series Header: Hydraulic Center-Link without Optional Self-Alignment.................254 4.5.7 Detaching an R Series Header .................................................................................................259 Detaching an R Series Header: Hydraulic Center-Link...............................................................259 4.6 Operating with a D Series or D1 SP Series Header.............................................................................263 4.6.1 Header Position ......................................................................................................................264 4.6.2 Adjusting the Reel Fore-Aft Position .........................................................................................264 4.6.3 Adjusting the Reel Height.........................................................................................................264 4.6.4 Reel Speed.............................................................................................................................264 Setting Reel to Ground Speed .................................................................................................264 Setting the Reel Only Speed....................................................................................................267 4.6.5 Draper Speed .........................................................................................................................268 Setting Draper to Ground Speed..............................................................................................268 Setting Minimum Draper Speed ...............................................................................................268 Setting Draper Index...............................................................................................................269 Setting Draper Speed Independent of Ground Speed................................................................270 4.6.6 Knife Speed............................................................................................................................271 4.6.7 Deck Shift Control ...................................................................................................................272 Deck Shift ..............................................................................................................................272 Setting Float Options with Deck Shift........................................................................................273 4.7 Operating with an A Series Header....................................................................................................275 4.7.1 Auger Speed...........................................................................................................................276 Auger Speed on A30D Headers...............................................................................................276 Setting the Auger Speed on A40D Headers ..............................................................................276 4.7.2 Reel Speed.............................................................................................................................277 Reel Speed on A30D Headers.................................................................................................277 Reel Speed on A40D Headers.................................................................................................277 4.7.3 Knife Speed............................................................................................................................280 4.8 Operating with an R Series Header ...................................................................................................281 4.8.1 Disc Speed.............................................................................................................................282 Setting Disc Speed .................................................................................................................282 Chapter 5: Maintenance and Servicing.........................................................................................283 5.1 Preparation for Servicing ..................................................................................................................283 5.2 Engine Compartment Hood ..............................................................................................................284 5.2.1 Opening Hood (Lower Position)................................................................................................284 5.2.2 Closing Hood (Lower Position) .................................................................................................285 5.2.3 Opening Hood (Highest Position) .............................................................................................286 5.2.4 Closing Hood (Highest Position)...............................................................................................287 5.3 Maintenance Platforms.....................................................................................................................288 5.3.1 Opening Platforms (Standard Position) .....................................................................................288 5.3.2 Closing Platforms (Standard Position).......................................................................................289 5.3.3 Opening Platforms (Major Service Position) ..............................................................................290 5.3.4 Closing Platforms (Major Service Position)................................................................................292 5.4 Windrower Lubrication......................................................................................................................293 TABLE OF CONTENTS

5.4.2 Lubrication Points....................................................................................................................294 5.5 Operator’s Station............................................................................................................................295 5.5.1 Seat Belts...............................................................................................................................295 5.5.2 Safety Systems.......................................................................................................................295 Checking Operator Presence System ......................................................................................295 Checking Engine Interlock.......................................................................................................296 5.5.3 Ground Speed Lever (GSL) Adjustments ..................................................................................296 Adjusting Ground Speed Lever (GSL) Lateral Movement...........................................................296 Adjusting Ground Speed Lever (GSL) Fore-Aft Movement.........................................................298 5.5.4 Steering Adjustments ..............................................................................................................298 Checking Steering Link Pivots .................................................................................................298 Checking and Adjusting Steering Chain Tension .......................................................................301 5.6 Cab Suspension Limit Straps ............................................................................................................302 5.7 Heating, Ventilating, and Air Conditioning (HVAC) System ..................................................................303 5.7.1 Fresh Air Intake Filter ..............................................................................................................303 Removing Fresh Air Filter........................................................................................................303 Inspecting and Cleaning Fresh Air Filter Element ......................................................................304 Installing Fresh Air Filter..........................................................................................................304 5.7.2 Servicing the Return Air Cleaner/Filter ......................................................................................305 Cleaning Return Air Cleaner/Filter............................................................................................306 5.7.3 Air Conditioning Condenser .....................................................................................................307 5.7.4 Air Conditioning (A/C) Evaporator Core.....................................................................................307 Removing Air Conditioning (A/C) Cover....................................................................................307 Cleaning Air Conditioning (A/C) Evaporator Core......................................................................308 Installing Air Conditioning (A/C) Cover .....................................................................................309 5.7.5 Air Conditioning (A/C) Compressor...........................................................................................310 Servicing the Air Conditioning Compressor...............................................................................310 5.8 Engine ............................................................................................................................................ 311 5.8.1 General Engine Inspection....................................................................................................... 311 5.8.2 Turning the Engine Manually.................................................................................................... 311 5.8.3 Engine Oil...............................................................................................................................313 Checking Engine Oil Level ......................................................................................................313 Changing Engine Oil...............................................................................................................315 Draining Engine Oil.................................................................................................................315 Replacing Engine Oil Filter ......................................................................................................316 Adding Engine Oil...................................................................................................................316 5.8.4 Air Intake System....................................................................................................................317 Air Filter Restriction Indicator...................................................................................................317 Removing Primary Air Filter.....................................................................................................318 Installing Primary Air Filter.......................................................................................................320 Cleaning Engine Air Filter Primary Element ..............................................................................321 Removing and Installing Secondary Air Filter............................................................................322 Air Precleaner ........................................................................................................................323 5.8.5 Fuel System ...........................................................................................................................323 Replacing Fuel Tank Vent Filter ...............................................................................................323 Maintaining Fuel Filters...........................................................................................................324 Removing Primary Fuel Filter ..................................................................................................325 TABLE OF CONTENTS

Removing Secondary Fuel Filter..............................................................................................326 Installing Secondary Fuel Filter................................................................................................327 Draining Fuel Tank..................................................................................................................328 Fuel/Water Separator..............................................................................................................329 Removing Water from Fuel System..........................................................................................329 System Priming ......................................................................................................................330 Priming Fuel System...............................................................................................................330 5.8.6 Engine Cooling System ...........................................................................................................331 Inspecting Radiator Cap..........................................................................................................331 Checking Engine Coolant Strength ..........................................................................................332 Checking Coolant Level ..........................................................................................................333 Changing Coolant...................................................................................................................333 Draining and Cleaning the Coolant Tank...................................................................................333 Adding Coolant.......................................................................................................................336 Maintaining Engine Cooling Box ..............................................................................................337 Opening Cooler Box Screen ....................................................................................................337 Charge Air Cooling .................................................................................................................338 Cleaning Screens and Coolers ................................................................................................338 Cleaning Cooler Box Components ...........................................................................................339 Adjusting Screen Cleaner Rotor to Screen Clearance................................................................341 Closing Cooler Box Screen......................................................................................................342 5.8.7 Gearbox .................................................................................................................................343 Checking Lubricant Level and Adding Lubricant........................................................................343 Changing Lubricant ................................................................................................................344 5.8.8 Exhaust System......................................................................................................................345 5.8.9 Belts ......................................................................................................................................345 Tensioning Alternator/Fan Belt.................................................................................................345 Replacing Fan Belt .................................................................................................................345 Tensioning Air Conditioner (A/C) Compressor Belt ....................................................................347 Replacing Air Conditioner (A/C) Compressor Belt .....................................................................347 5.8.10 Engine Speed .......................................................................................................................348 Throttle Adjustment ................................................................................................................348 5.9 Electrical System .............................................................................................................................349 5.9.1 Preventing Electrical System Damage ......................................................................................349 5.9.2 Battery ...................................................................................................................................349 Maintaining Batteries ..............................................................................................................349 Battery Main Disconnect Switch...............................................................................................350 Charging the Batteries ............................................................................................................350 Boosting the Batteries.............................................................................................................352 Adding Electrolyte to the Battery ..............................................................................................353 Removing Batteries ................................................................................................................354 Installing Batteries ..................................................................................................................356 Connecting Batteries ..............................................................................................................357 5.9.3 Headlights: Engine-Forward.....................................................................................................358 Replacing Headlight Bulb ........................................................................................................358 Aligning Headlights.................................................................................................................360 5.9.4 Field Lights: Cab-Forward........................................................................................................362 Adjusting Field Lights..............................................................................................................362 Replacing Field Light Bulb.......................................................................................................363 5.9.5 Floodlights: Forward................................................................................................................363 TABLE OF CONTENTS

Replacing Bulb in Cab-Forward Flood Light..............................................................................363 5.9.6 High-Intensity Discharge (HID) Auxiliary Lighting (Optional – MD #B5596) ..................................365 Adjusting High-Intensity Discharge (HID) Auxiliary Lights (if Installed).........................................365 Replacing High-Intensity Discharge (HID) Auxiliary Lights (if Installed) .......................................366 5.9.7 Floodlights: Rear.....................................................................................................................369 Adjusting Rear Floodlights.......................................................................................................369 Replacing Bulb in Rear Flood Light ..........................................................................................369 5.9.8 Replacing Bulbs in Red and Amber Lights.................................................................................371 5.9.9 Replacing Red Taillights ..........................................................................................................372 5.9.10 Replacing the Bulbs in Beacon Lights (If installed) ...................................................................372 5.9.11 Replacing a Console Gauge Light...........................................................................................376 5.9.12 Replacing the Cabin Dome Light ............................................................................................377 5.9.13 Replacing the Ambient Light Fixture........................................................................................378 5.9.14 Turn Signal Indicators............................................................................................................378 5.9.15 Circuit Breakers and Fuses ....................................................................................................378 Accessing Circuit Breakers and Fuses .....................................................................................378 Checking and Replacing Fuses ...............................................................................................379 Replacing Circuit Breakers and Relays.....................................................................................380 Fuse Box Decal......................................................................................................................381 Inspecting and Replacing 125A Main Fuses .............................................................................382 5.10 Hydraulic System ...........................................................................................................................384 5.10.1 Checking and Filling Hydraulic Oil...........................................................................................385 5.10.2 Hydraulic Oil Cooler...............................................................................................................386 5.10.3 Changing the Hydraulic Oil.....................................................................................................386 5.10.4 Changing Hydraulic Oil Filters ................................................................................................387 Charge Oil Filter .....................................................................................................................387 Removing Charge Oil Filter .....................................................................................................387 Installing Charge Oil Filter .......................................................................................................389 Return Oil Filter ......................................................................................................................389 Removing Return Oil Filter ......................................................................................................389 Installing Return Oil Filter ........................................................................................................391 Servicing the Lift Filter.............................................................................................................392 5.10.5 Header and Reel Hydraulics...................................................................................................394 Hoses and Lines.....................................................................................................................394 Relief Valve and Overload Settings ..........................................................................................394 Flow Control Blocks................................................................................................................395 Adjusting Header Drop Rate....................................................................................................396 Adjusting Reel Drop Rate........................................................................................................396 5.10.6 Traction Drive Hydraulics .......................................................................................................397 Checking Transmission Oil Pressure........................................................................................397 Checking Charge Pump Pressure............................................................................................398 5.11 Wheels and Tires ...........................................................................................................................399 5.11.1 Drive Wheels.........................................................................................................................399 Inflating Drive Wheel Tire ........................................................................................................399 Tightening Drive Wheel Nuts ...................................................................................................400 Lubricating Wheel Drive ..........................................................................................................400 Checking Wheel Drive Lubricant Level .....................................................................................400 Adding Wheel Drive Lubricant .................................................................................................401 TABLE OF CONTENTS

Servicing Drive Wheel.............................................................................................................403 Raising Drive Wheel ...............................................................................................................403 Removing Drive Wheel ...........................................................................................................404 Installing Drive Wheel .............................................................................................................405 Lowering Drive Wheel.............................................................................................................406 5.11.2 Caster Wheels.......................................................................................................................406 Inflating Caster Tire ................................................................................................................406 Tightening Caster Wheel Nuts .................................................................................................407 Servicing Caster Wheels.........................................................................................................408 Raising Caster Wheel (Formed and Forked) .............................................................................408 Lowering Caster Wheel (Formed and Forked)...........................................................................410 Removing Forked Caster Wheel ..............................................................................................410 Installing Forked Caster Wheel................................................................................................ 411 Removing Formed Caster Wheel.............................................................................................412 Installing Formed Caster Wheel...............................................................................................412 Tightening Caster Wheel Anti-Shimmy Dampeners ...................................................................413 Ballast Requirements..............................................................................................................413 5.12 Maintenance Schedule ...................................................................................................................415 5.12.1 Maintenance Schedule/Record...............................................................................................415 Chapter 6: Troubleshooting.............................................................................................................421 6.1 Engine Troubleshooting....................................................................................................................421 6.2 Electrical Troubleshooting.................................................................................................................427 6.3 Hydraulics Troubleshooting...............................................................................................................429 6.4 Header Drive Troubleshooting...........................................................................................................430 6.5 Traction Drive Troubleshooting..........................................................................................................431 6.6 Steering and Ground Speed Control Troubleshooting .........................................................................435 6.7 Cab Air Troubleshooting ...................................................................................................................436 6.8 Operator’s Station Troubleshooting ...................................................................................................441 Chapter 7: Options and Attachments............................................................................................443 7.1 Cab.................................................................................................................................................443 7.1.1 AM/FM Radio..........................................................................................................................443 7.1.2 Automated Steering Systems...................................................................................................443 7.1.3 High Intensity Discharge (HID) Auxiliary Lighting .......................................................................443 7.1.4 Lighting and Marking for Cab-Forward Road Travel ...................................................................443 7.1.5 Pressure Sensor Kit ................................................................................................................443 7.1.6 Warning Beacons....................................................................................................................444 7.1.7 Windshield Shades .................................................................................................................444 7.2 Engine ............................................................................................................................................445 7.2.1 Engine Block Heater................................................................................................................445 7.2.2 Engine Fan Air Baffle...............................................................................................................445 7.2.3 Reversible Fan........................................................................................................................445 7.3 Header Operation ............................................................................................................................446 TABLE OF CONTENTS

7.3.2 Spring with Internal Booster Spring...........................................................................................446 7.3.3 Completion Kit for Auger and Draper Header Drives ..................................................................446 7.3.4 Completion Kit for Auger Header Drive and Conditioner Reverser...............................................446 7.3.5 Completion Kit for Draper Header Reel Drive.............................................................................446 7.3.6 Double Windrow Attachment (DWA) .........................................................................................447 7.3.7 Hydraulic Union Kit..................................................................................................................447 7.3.8 Light Header Flotation .............................................................................................................447 7.3.9 Quick Coupler Kit ....................................................................................................................447 7.3.10 Self-Aligning Center-Link .......................................................................................................447 7.3.11 Swath Compressor ................................................................................................................447 7.4 Transport.........................................................................................................................................448 7.4.1 Towing Harness ......................................................................................................................448 7.4.2 Weight Box .............................................................................................................................448 Chapter 8: Reference.........................................................................................................................449 8.1 Recommended Torques ...................................................................................................................449 8.1.1 Torque Specifications ..............................................................................................................449 SAE Bolt Torque Specifications................................................................................................449 Metric Bolt Specifications ........................................................................................................451 Metric Bolt Specifications Bolting into Cast Aluminum................................................................453 Flare-Type Hydraulic Fittings...................................................................................................454 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable) ...................................................................455 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) ............................................................457 O-Ring Face Seal (ORFS) Hydraulic Fittings ............................................................................458 Tapered Pipe Thread Fittings...................................................................................................459 8.2 Recommended Fuel, Fluids, and Lubricants.......................................................................................460 8.2.1 Storing Lubricants and Fluids ...................................................................................................460 8.2.2 Fuel Specifications ..................................................................................................................460 8.2.3 Lubricants, Fluids, and System Capacities ................................................................................461 8.2.4 Filter Part Numbers .................................................................................................................462 8.3 Conversion Chart.............................................................................................................................463 8.4 Engine Error Codes..........................................................................................................................464 8.5 Cab Display Module (CDM) Error Codes............................................................................................478 Index.......................................................................................................................................................481 Lubricants, Fluids, and System Capacities ....................................................Inside Back Cover TABLE OF CONTENTS

1000915 Figure 1.1: Safety Symbol This safety alert symbol indicates important safety messages in this manual and on safety signs on the machine. This symbol means: • ATTENTION! • BECOME ALERT! • YOUR SAFETY IS INVOLVED! Carefully read and follow the safety message accompanying this symbol. Why is safety important to you? • Accidents disable and kill • Accidents cost • Accidents can be avoided

words are 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. SAFETY

CAUTION The following are general farm safety precautions that should be part of your operating procedure for all types of machinery. Protect yourself. • When assembling, operating, and servicing machinery, wear all protective clothing and personal safety devices that could be necessary for job at hand. Do NOT take chances. You may need the following: • Hard hat • Protective footwear with slip resistant soles • Protective glasses or goggles • Heavy gloves • Wet weather gear • Respirator or filter mask 1000005 Figure 1.3: Safety Equipment • Be aware that exposure to loud noises can cause hearing impairment or loss. Wear suitable hearing protection devices such as earmuffs or earplugs to help protect against loud noises. 1010391 Figure 1.4: Safety Equipment • Provide a first aid kit for use in case of emergencies. • Keep a fire extinguisher on the machine. Be sure fire extinguisher is properly maintained. Be familiar with its proper use. • Keep young children away from machinery at all times. • Be aware that accidents often happen when Operator is tired or in a hurry. Take time to consider safest way. Never ignore warning signs of fatigue. SAFETY

• Wear close-fitting clothing and cover long hair. Never wear dangling items such as scarves or bracelets. • Keep all shields in place. NEVER alter or remove safety equipment. Make sure driveline guards can rotate independently of shaft and can telescope freely. • Use only service and repair parts made or approved by equipment manufacturer. Substituted parts may not meet strength, design, or safety requirements. 1000008 Figure 1.6: Safety around Equipment • Keep hands, feet, clothing, and hair away from moving parts. NEVER attempt to clear obstructions or objects from a machine while engine is running. • Do NOT modify machine. Unauthorized modifications may impair machine function and/or safety. It may also shorten machine’s life. • To avoid bodily injury or death from unexpected startup of machine, ALWAYS stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1000009 Figure 1.7: Safety around Equipment • Keep service area clean and dry. Wet or oily floors are slippery. Wet spots can be dangerous when working with electrical equipment. Be sure all electrical outlets and tools are properly grounded. • Keep work area well lit. • Keep machinery clean. Straw and chaff on a hot engine is a fire hazard. Do NOT allow oil or grease to accumulate on service platforms, ladders, or controls. Clean machines before storage. • NEVER use gasoline, naphtha, or any volatile material for cleaning purposes. These materials may be toxic and/or flammable. • When storing machinery, cover sharp or extending components to prevent injury from accidental contact. SAFETY

To ensure your safety while maintaining machine: • Review operator’s manual and all safety items before operation and/or maintenance of machine. • Place all controls in Neutral, stop the engine, set the park brake, remove the ignition key, and wait for all moving parts to stop before servicing, adjusting, and/or repairing. • Follow good shop practices: – Keep service areas clean and dry – Be sure electrical outlets and tools are properly grounded – Keep work area well lit 1008958 Figure 1.9: Equipment NOT Safe for Children • Relieve pressure from hydraulic circuits before servicing and/or disconnecting machine. • Make sure all components are tight and that steel lines, hoses, and couplings are in good condition before applying pressure to hydraulic systems. • Keep hands, feet, clothing, and hair away from all moving and/or rotating parts. • Clear area of bystanders, especially children, when carrying out any maintenance, repairs, or adjustments. • Install transport lock or place safety stands under frame before working under machine. • If more than one person is servicing machine at same time, be aware that rotating a driveline or other mechanically-driven component by hand (for example, accessing a lube fitting) will cause drive components in other areas (belts, pulleys, and knives) to move. Stay clear of driven components at all times. 1000004 Figure 1.10: Safety Equipment • Wear protective gear when working on machine. • Wear heavy gloves when working on knife components. SAFETY

• Always place all hydraulic controls in Neutral before dismounting. • Make sure that all components in hydraulic system are kept clean and in good condition. • Replace any worn, cut, abraded, flattened, or crimped hoses and steel lines. • Do NOT attempt any makeshift repairs to hydraulic lines, fittings, or hoses by using tapes, clamps, cements, or welding. The hydraulic system operates under extremely high pressure. Makeshift repairs will fail suddenly and create hazardous and unsafe conditions. 1001207 Figure 1.12: Hydraulic Pressure Hazard • Wear proper hand and eye protection when searching for high-pressure hydraulic leaks. Use a piece of cardboard as a backstop instead of hands to isolate and identify a leak. • If injured by a concentrated high-pressure stream of hydraulic fluid, seek medical attention immediately. Serious infection or toxic reaction can develop from hydraulic fluid piercing the skin. 1000013 Figure 1.13: Safety around Equipment • Make sure all components are tight and steel lines, hoses, and couplings are in good condition before applying pressure to a hydraulic system. SAFETY

WARNING • Service tires safely. • A tire can explode during inflation which could cause serious injury or death. • Follow proper procedures when mounting a tire on a wheel or rim. Failure to do so can produce an explosion that may result in serious injury or death. 1000019 Figure 1.15: Safely Inflating Tire WARNING • Do NOT stand over tire. Use a clip-on chuck and extension hose. • Do NOT exceed maximum inflation pressure indicated on tire label. • Replace tires that have defects. • Replace wheel rims that are cracked, worn, or severely rusted. • Never weld a wheel rim. • Never use force on an inflated or partially inflated tire. • Make sure tire is correctly seated before inflating to operating pressure. • If tire is not correctly positioned on rim or is overinflated, tire bead can loosen on one side causing air to escape at high speed and with great force. An air leak of this nature can thrust tire in any direction endangering anyone in area. • Make sure all air is removed from tire before removing tire from rim. • Do NOT remove, install, or repair a tire on a rim unless you have proper equipment and experience to perform job. • Take tire and rim to a qualified tire repair shop. SAFETY

WARNING • Keep all sparks and flames away from batteries, as a gas given off by electrolyte is explosive. • Ventilate when charging in enclosed space. 1000016 Figure 1.17: Safety around Batteries WARNING • Wear safety glasses when working near batteries. • Do NOT tip batteries more than 45° to avoid electrolyte loss. • Battery electrolyte causes severe burns. Avoid contact with skin, eyes, or clothing. • Electrolyte splashed into eyes is extremely dangerous. Should this occur, force eye open, and flood with cool, clean water for 5 minutes. Call a doctor immediately. • If electrolyte is spilled or splashed on clothing or body, neutralize it immediately with a solution of baking soda and water, then rinse with clear water. 1000017 Figure 1.18: Safety around Batteries WARNING • To avoid injury from spark or short circuit, disconnect battery ground cable before servicing any part of electrical system. • Do NOT operate engine with alternator or battery disconnected. With battery cables disconnected and engine running, a high voltage can be built up if terminals touch frame. Anyone touching frame under these conditions would be severely shocked. • When working around storage batteries, remember that all of the exposed metal parts are live. Never lay a metal object across terminals because a spark or short circuit will result. • Keep batteries out of reach of children. SAFETY

welding on any part of windrower or an attached header, disconnect all electronic module harness connections as well as battery cables. Refer to your Dealer for proper procedures. SAFETY

CAUTION • On initial start-up of a new, serviced, or repaired engine, always be ready to stop the engine in order to stop an overspeed. This may be accomplished by shutting off the air and/or fuel supply to the engine. • Do NOT bypass or disable 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 your Dealer for repairs and adjustments. • Inspect the engine for potential hazards. • Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that people clear the area. • 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 parts carefully. • If a warning tag is attached to engine start switch or to controls, do NOT start engine or move controls. Consult with person who attached warning tag before engine is started. • Start engine from operator’s compartment. Always start engine according to procedure that is described in Starting Engine section of operator’s manual. Knowing correct procedure will help to prevent major damage to engine components and prevent personal injury. • To ensure that the jacket water heater (if equipped) and/or lube oil heater (if equipped) is working correctly, check the water temperature gauge and/or oil temperature gauge during 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. 1.9.1 High Pressure Rail CAUTION Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these instructions may cause personal injury or death. SAFETY

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 the electronic unit injectors. Do NOT come in contact with the harness connector for the electronic unit injectors while 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 engine operating conditions. If conditions exceed the allowable range, the ECM will initiate immediate action. The following actions are available for engine monitoring control: • Warning • Derate • Shut down The following monitored engine operating conditions have the ability to limit engine speed and/or 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, monitoring system and engine monitoring control will be similar for all engines. Together, two controls provide engine monitoring function for specific engine application. SAFETY

• Keep safety signs clean and legible at all times. • Replace safety signs that are missing or become illegible. • If original part on which a safety sign was installed is replaced, be sure repair part also bears current safety sign. • Replacement safety signs are available from your MacDon Dealer Parts Department. 1.10.1 Installing Safety Decals 1. Clean and dry installation area. 2. Decide on exact location before you remove decal backing paper. 3. Remove smaller portion of split backing paper. 4. Place decal in position and slowly peel back remaining paper, smoothing decal as it is applied. 5. Prick small air pockets with a pin and smooth out. SAFETY

Figure 1.20: Safety Sign Locations (Left Cab-Forward Side) 1011018 A C D E B F G H J K L M N P Q S T B U R A - Hazard Sign (MD #135378) B - Cab Door and Rim (MD #166454) C - Oil Reservoir under Hood (MD #166466) D - Exhaust Cover (MD #166450) E - Close to Radiator Cap (MD #166461) F - Fan Shroud (Top) (MD #166450) G - Fan Shroud (Middle) (MD #166451) H - Fan Shroud (Bottom) (MD #166452) J - Frame Opening (MD #166233) K - Platform (Left of Step) (MD #166425) L - Platform (Right of Step) (MD #166441) M - Frame at Multifunction Manifold (MD #166466) N - Lift Linkage (MD #166438) P - Inner Post (MD #166457) Q - Inner Post (MD #166234) R - Inner Post (MD #166463) S - Neutral Interlock (MD #166425) T - Frame (MD #166425) U - Trainer’s Seat (MD #167502) SAFETY

1011019 A B C D E F G H J K L M N P Q R T S U SAFETY

1011017 A B C D E F G H J K L M A - Hazard Sign on Seat (MD #115148) B - Lift Linkage (MD #166439) C - Frame (MD #166455) D - Frame (MD #166456) E - Cab Frame (MD #184372) F - Platform (MD #166425) G - Shroud (MD #166451) H - Shroud (MD #166452) J - Hydraulic Reservoir (MD #174436) K - Wiper Cover (MD #166465) L - Rim (MD #166454) M - Window (MD #167504) SAFETY

1011020 A B C D E F G H J K L M SAFETY

1000698 Figure 1.24: MD #166233 MD #166233 Run-over hazard DANGER • Do not start engine by shorting across starter or starter relay terminals. Machine will start with drive engaged and move if starting circuitry is bypassed. • Start engine only from operator’s seat. Do not try to start engine with someone under or near machine. 1000700 Figure 1.25: MD #166234 MD #166234 Run-over hazard WARNING • The training seat is provided for an experienced Operator of the machine when a new Operator is being trained. • The training seat is not intended as a passenger seat or for use by children. • Use the seat belt whenever operating the machine or riding as a trainer. • Keep all other riders off the machine. 1000685 Figure 1.26: MD #166425 MD #166425 Run-over hazard WARNING • Remove the key from the ignition. • Read the windrower and header manuals for inspection and maintenance instructions. SAFETY

MD #166438 Crushing hazard DANGER • Rest header on ground or engage safety props before going under unit. 1000691 Figure 1.28: MD #166439 MD #166439 Crushing hazard DANGER • Rest header on ground or engage safety props before going under unit. SAFETY

MD #166441 Loss of control hazard CAUTION • To prevent machine damage and/or loss of control, it is essential that the machine be equipped such that weights are within the specified limits. 1000688 Figure 1.30: MD #166450 MD #166450 Hot surface hazard WARNING • To avoid injury, keep a safe distance from hot surface. 1000696 Figure 1.31: MD #166451 MD #166451 Rotating fan hazard WARNING • To avoid injury, stop the engine and remove the key before opening engine hood. SAFETY

MD #166454 General hazard pertaining to machine operation and servicing CAUTION • Read the operator’s manual and follow all safety instructions. • Do not allow untrained persons to operate the machine. • Review safety instructions with all Operators every year. • Ensure that all safety signs are installed and legible. • Make certain everyone is clear of machine before starting engine and during operation. • Keep riders off the machine. • Keep all shields in place and stay clear of moving parts. • Disengage header drive, put transmission in Neutral, and wait for all movement to stop before leaving operator’s position. • Stop the engine and remove the key from the ignition before servicing, adjusting, lubricating, cleaning, or unplugging machine. • Engage locks to prevent lowering of header or reel before servicing in the raised position. • Use slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited by law. 1000692 Figure 1.33: MD #166455 MD #166455 Explosion hazard WARNING • Prevent serious bodily injury caused by explosive battery gases. • Keep sparks and flames away from the battery. • Refer to operator’s manual for battery boosting and charging procedures. SAFETY

MD #166456 Battery acid hazard WARNING • Corrosive and poisonous battery acid. Acid can severely burn your body and clothing. SAFETY

MD #166457 General hazard pertaining to machine operation and servicing CAUTION To avoid injury or death from improper or unsafe machine operation: • Read the operator’s manual and follow all safety instructions. If you do not have a manual, obtain one from your Dealer. • Do not allow untrained persons to operate the machine. • Review safety instructions with all Operators every year. • Ensure that all safety signs are installed and legible. • Make certain everyone is clear of machine before starting engine and during operation. • Keep riders off the machine. • Keep all shields in place and stay clear of moving parts. • Disengage header drive, put transmission in Neutral and wait for all movement to stop before leaving operator’s position. • Stop the engine and remove the key from the ignition before servicing, adjusting, lubricating, cleaning, or unplugging machine. • Engage locks to prevent lowering of header or reel before servicing in the raised position. • Use slow moving vehicle emblem and flashing warning lights when operating on roadways unless prohibited by law. Run-over hazard WARNING • Machine will move if steering wheel is turned while engine is running. • Steering response is opposite to what is normally expected when backing up. Turn bottom of steering wheel in direction you want to go. • Always move ground speed lever to slow end of range before shifting high-low speed control. • Stop the engine and remove the key from the ignition before servicing, adjusting, lubricating, cleaning, or unplugging the machine. SAFETY

MD #166461 Hot fluid under pressure hazard CAUTION • Coolant is under pressure and may be hot. Never remove radiator cap when engine is hot. 1000701 Figure 1.37: MD #166463 MD #166463 Collision hazard in transport WARNING • Collision between windrower and other vehicles may result in injury or death. When driving windrower on public roadways: • Obey all highway traffic regulations in your area. Use pilot vehicles front and rear of windrower if required by law. • Use slow moving vehicle emblem and flashing warning lights unless prohibited by law. • If width of attached header impedes other vehicle traffic, remove header and install MacDon approved weight box. Refer to operator’s manual for safe procedure to tow header. 1000702 Figure 1.38: MD #166465 MD #166465 Loss of control hazard WARNING To avoid serious injury or death from loss of control: • Do not make abrupt changes in steering direction. • Anticipate turns by slowing down well in advance. • Do not rapidly accelerate or decelerate while turning. • Limit speed to maximum 32 km/h (20 mph) when towing a header. To ensure steering control, refer to operator’s manual for adding weight to drive wheels. When travelling on steep slopes: • Reduce speed and lower header. • Move ground speed lever to slow end of range. SAFETY

With header removed, steering control is reduced if weight is not added to drive wheels. If you must drive the windrower without header or MacDon weight system: • Operate in low-speed range. • Avoid slopes. • Do not tow a header. If control of machine is lost, immediately pull ground speed lever to neutral. 1000706 Figure 1.39: MD #166466 MD #166466 High pressure oil hazard WARNING • Do not go near leaks. • High pressure oil easily punctures skin causing serious injury, gangrene, or death. • If injured, seek emergency medical help. Immediate surgery is required to remove oil. • Do not use finger or skin to check for leaks. • Lower load or relieve hydraulic pressure before loosening fittings. 1014916 Figure 1.40: MD #166843 MD #166843 Steering control WARNING To avoid serious injury or death from loss of control: • Do not make abrupt changes in steering direction. • Anticipate turns by slowing down well in advance. • Do not rapidly accelerate or decelerate while turning. • Limit speed to maximum 32 km/h (20 mph) when towing a header. To ensure steering control, refer to operator’s manual for adding weight to drive wheels. SAFETY

MD #167502 Pinch point hazard WARNING • To avoid injury, be cautious when opening/closing the training seat to avoid getting pinched. • Failure to comply could result in death or serious injury. 1011016 Figure 1.42: MD #167504 MD #167504 Emergency exit ATTENTION • To exit the machine via the secondary door, follow the arrow on the running man sign. 1000920 Figure 1.43: MD #174436 MD #174436 High pressure oil hazard WARNING • Do not go near leaks. • High pressure oil easily punctures skin causing serious injury, gangrene, or death. • If injured, seek emergency medical help. Immediate surgery is required to remove oil. • Do not use finger or skin to check for leaks. • Lower load or relieve hydraulic pressure before loosening fittings. SAFETY

MD #190546 Slippery surface WARNING • Do not use this area as a step or platform. • Failure to comply could result in serious injury or death. SAFETY

Term Definition A Series header MacDon A30D and A40D auger headers API American Petroleum Institute ASTM American Society of Testing and Materials Bolt A headed and externally threaded fastener that is designed to be paired with a nut Cab-forward Windrower operation with Operator and cab facing in direction of travel CDM Cab display module on a windrower Center-link A hydraulic cylinder link between header and machine used to change header angle CGVW Combined gross vehicle weight D Series header MacDon D50, D60, and D65 rigid draper headers D1 SP Series header MacDon D115, D120, D125, D130, D135, or D140 rigid draper headers for M Series Windrower DK Double knife DKD Double-knife drive DDD Double-draper drive DWA Double Windrow Attachment ECM Engine control module Engine-forward Windrower operation with Operator and engine facing in direction of travel FFFT Flats from finger tight Finger tight Finger tight is a reference position where sealing surfaces or components are making contact with each other, and fitting has been tightened to a point where fitting is no longer loose GSL Ground speed lever GSS Grass Seed GVW Gross vehicle weight Hard joint A joint made with use of a fastener where joining materials are highly incompressible Header A machine that cuts and lays crop into a windrow and is attached to a windrower Hex key A tool of hexagonal cross-section used to drive bolts and screws that have a hexagonal socket in head (internal-wrenching hexagon drive); also known as an Allen key and various other synonyms HDS Hydraulic deck shift hp Horsepower

JIC Joint Industrial Council: A standards body that developed standard sizing and shape for original 37° flared fitting Knife A cutting device which uses a reciprocating cutter (also called a sickle) MDS Mechanical deck shift n/a Not applicable N-DETENT The slot opposite the NEUTRAL position on operator’s console of M Series SP Windrowers NPT National Pipe Thread: A style of fitting used for low pressure port openings. Threads on NPT fittings are uniquely tapered for an interference fit Nut An internally threaded fastener that is designed to be paired with a bolt ORB O-ring boss: A style of fitting commonly used in port opening on manifolds, pumps, and motors ORFS O-ring face seal: A style of fitting commonly used for connecting hoses and tubes. This style of fitting is also commonly called ORS, which stands for O-ring seal R Series header MacDon R80 and R85 rotary disc headers RoHS (Reduction of Hazardous Substances) A directive by the European Union to restrict use of certain hazardous substances (such as hexavalent chromium used in some yellow zinc platings) rpm Revolutions per minute SAE Society of Automotive Engineers Screw A headed and externally threaded fastener that threads into preformed threads or forms its own thread into a mating part SDD Single-draper drive Self-Propelled (SP) Windrower Self-propelled machine consisting of a power unit with a header SK Single knife SKD Single-knife drive Soft joint A joint made with use of a fastener where joining materials are compressible or experience relaxation over a period of time spm Strokes per minute Tension Axial load placed on a bolt or screw, usually measured in Newtons (N) or pounds (lb.) TFFT Turns from finger tight Torque The product of a force X lever arm length, usually measured in Newton-meters (Nm) or foot-pounds (lbf∙ft) Torque angle A tightening procedure where fitting is assembled to a precondition (finger tight) and then nut is turned farther a number of degrees to achieve its final position Torque-tension The relationship between assembly torque applied to a piece of hardware and axial load it induces in bolt or screw PRODUCT OVERVIEW

ULSD Ultra low sulphur diesel Washer A thin cylinder with a hole or slot located in the center that is to be used as a spacer, load distribution element, or a locking mechanism WCM Windrower control module Windrower Power unit of a self-propelled header PRODUCT OVERVIEW

control module CM2250 Displacement 6.7 L (409 cu. in.) Power Rated 164 kW (220 hp) @ 2200 rpm Power Peak 172 kW (230 hp) @ 2000 rpm Bore 107 mm (4.21 in.) Stroke 124 mm (4.88 in.) Maximum rpm (no load) 2250–2340 Idle rpm 1075–1150 Electrical System Battery (2) 12 Volt, maximum dimension – 334 x 188 x 232 mm (13 x 6.81 x 9.43 in.). Group rating 29H or 31A, heavy duty/off road/vibration resistant Minimum CCA per battery (cold cranking amps) 750 Alternator 130 amp Egress lighting Standard Starter Wet type Working lights 11 Traction Drive Type Hydrostatic, 3-speed electric shift Speed Field (cab-forward) Low range 0–18 km/h (11 mph), mid range 0–26 km/h (16 mph) Speed Reverse (cab-forward) 9.6 km/h (6 mph) Speed Transport (engine-forward) High range 0–37 km/h (23 mph) Transmission Type 2 piston pumps – 1 per drive wheel Transmission Displacement 44 cc (2.65 cu. in.) Transmission Flow 167 L/min (40 US gpm) Final drive Type Planetary gearbox Final drive Ratio 30.06:1 PRODUCT OVERVIEW

Wheel motor displacement Mid-range 50 cc (3.01 cu. in.) Wheel motor displacement High-range 32 cc (1.93 cu. in.) System Capacities Fuel tank 367 L (97 US gallons) Cooling 30 L (7.9 US gallons) Hydraulic reservoir 65 L (17.2 US gallons ) Header Drive Type Hydraulic, electrical displacement control Displacement Piston pump A – 105.5 cc (6.44 cu. in.) Gear pumps C and D – 16.7 cc (1.02 cu .in.) Flow Piston pump A – 0–273 L/min (0–72 gpm) Gear pumps C and D – 45 L/min (12 gpm) Piston Pump (A) Gear Pump (C) Gear Pump (D) Maximum pressure1 Disc drive (no header) 41,369 kPa (6000 psi)2 — — Maximum pressure1 Knife drive (differential) 27,579–31,026 kPa (4000–4500 psi)2 — — Maximum pressure1 Reel (draper) drive (differential) 22,063–24,132 kPa (3200–3500 psi)2 — — Maximum pressure1 Double Windrow Attachment (DWA) drive — — 22,063–24,132 kPa (3200–3500 psi)2 Maximum pressure1 Conveyor (draper) Reel/Auger (A40) — 22,063–24,132 kPa (3200–3500 psi)2 — Maximum pressure1 Supercharge — 1655–2068 kPa (240–300 psi)3 Header Lift/Tilt Type Hydraulic double acting cylinders: tilt – hydraulic positioning Gear pump (B)1 Displacement 16.7 cc (1.02 cu. in.) Gear pump (B)1 Flow 45 L/min (12 US gpm) Gear pump (B)1 System pressure (relief/max) 17,237–19,305 kPa (2500–2800 psi) PRODUCT OVERVIEW 1. Refer to Figure 2.1, page 33 for pump reference. 2. Measured at 38°C (100°F) minimum. 3. Measured at 54°C (130°F) minimum.

One inner booster spring on left side Fine adjustment Hydraulic, in-cab switch Automatic Hydraulic, 3 programmable settings for all headers (deck shift compensation on draper headers) Cab Type Spring/shock suspension Dimensions Width 1600 mm (63 in.) Dimensions Depth 1735 mm (68.3 in.) (at top of window) Dimensions Height 1640 mm (64.6 in.) Dimensions Volume 3540 L (125 cu. ft.) Seat Driver Adjustable air-ride suspension, seat belt Seat Training Folding, cab mounted, seat belt Windshield wiper Front 800 mm (31.5 in.) blade Windshield wiper Rear 560 mm (22 in.) blade Heater 7038 W (24,000 Btu/h) Air conditioning 8288 W (28,280 Btu/h) Electrical outlets One live, two on ignition, one live/keyed Mirrors One inside (transport), two outside (field) Radio Two speakers and antenna factory installed: radio Dealer installed System Monitoring Speeds Ground (mph or km/h), engine (rpm), knife (spm), disc (rpm), reel (rpm or mph / km/h), conveyor (Ref. No.) Header Height, angle, float, header drive load gauge Tire Options Size Drive 18.4 – 26 bar, 18.4 – 26 turf, 600-65 R28 bar, 23.1 – 26 turf, 580/70R26 turf Size Rear 7.5 – 16SL single rib, 10 – 16 front steer tire 16.5L – 16.1 rib implement flotation, forked caster Pressure Drive Refer to Inflating Drive Wheel Tire, page 399 Pressure Rear Refer to Inflating Caster Tire, page 406 PRODUCT OVERVIEW

Dimensions Refer to 2.3 Windrower Dimensions, page 34 Frame to ground (crop clearance) 1160 mm (45.7 in.) Weight Base 4500 kg (9920 lb.) Weight Max GVW 9750 kg (2,1500 lb.) Weight Max CGVW 10480 kg (2,3100 lb.) Header compatibility A40D Auger D50 Harvest Header D60 Harvest Header/D65 Draper up to 12.2 m (40 ft.) D1 SP Draper Header up to 12.2 m (40 ft.) R80/R85 Rotary Disc NOTE: • Specifications and design are subject to change without notice or obligation to revise previously sold units. • Weights do not include options. Figure 2.1: Hydraulic Pumps (Orientation) 1020618 A B C D A - Piston Pump: Disc Drive, Knife Drive, Reel (Draper) Drive B - Gear Pump (Outboard): Lift, Tilt, and Reel Fore-Aft Circuits C - Gear Pump (Middle)4: Draper Control D Series / D1 Series, Reel/Auger Control A Series D - Gear Pump (Inboard)4 : DWA (Double Windrow Attachment) PRODUCT OVERVIEW 4. Pump (C) and (D) combine for supercharge.

1008767 A B C F G H J A - Drive Tire Tread B - Drive Tire Hubs C - Drive Tires F - 1160 mm (45-3/4 in.) G - 3378 mm (133 in.) H - 4022 mm (158-5/16 in.) J - 5280 mm (207-7/8 in.) Table 2.1 Drive Tires Tire Size Wheel Position Tread (A) mm (in.) Hubs (B) mm (in.) Tires (C) mm (in.) 18.4 x 26 bar and turf narrow track5 Inner/outer (shipping) 3144 (123-3/4) 3571 (140-9/16) 3644 (143-7/16) 18.4 x 26 bar and turf narrow track5 Outer/outer 3324 (130-7/8) 3751 (147-11/16) 3824 (150-5/8) 18.4 x 26 bar and turf narrow track5 Inner/inner 2964 (116-11/16) 3391 (133-1/2) 3464 (136-3/8) 18.4 x 26 bar and turf wide track5 Inner/outer (shipping) 3319 (130-11/16) 3571 (140-9/16) 3819 (150-3/8) 18.4 x 26 bar and turf wide track5 Outer/outer 3499 (137-3/4) 3751 (147-11/16) 3999 (157-7/16) PRODUCT OVERVIEW 5. Only 18.4 x 26 tires are compatible with the 13-foot R80 and R85.

Tire Size Wheel Position Tread (A) mm (in.) Hubs (B) mm (in.) Tires (C) mm (in.) 18.4 x 26 bar and turf wide track5 Inner/inner 3139 (123-9/16) 3391 (133-1/2) 3639 (143-1/4) 600/65R28 radial tire Inner/outer (shipping) 3139 (123-9/16) 3571 (140-9/16) 3758 (147-15/16) 600/65R28 radial tire Outer/outer 3319 (130-11/16) 3751 (147-11/16) 3938 (155-1/16) 600/65R28 radial tire Inner/inner 2959 (116-1/2) 3391 (133-1/2) 3578 (140-7/8) 23.1-26 and 580/70R26 turf tires Inner/outer (shipping) 3203 (126-1/8) 3571 (140-9/16) 3793 (149-5/16) 23.1-26 and 580/70R26 turf tires Outer/outer 3383 (133-3/16) 3751 (147-11/16) 3973 (156-7/16) 23.1-26 and 580/70R26 turf tires Inner/inner 3023 (119) 3391 (133-1/2) 3613 (142-1/4) PRODUCT OVERVIEW

1008783 D E K L D - Caster Tire Tread E - Caster Tire Casters K - 3064 mm (120-9/16 in.) L - 4747 mm (186-7/8 in.) Table 2.2 Caster Tires Tire Size Wheel Position Tread (D) mm (in.) Casters (E) mm (in.) 7.5-16SL Minimum 2448 (96-7/16) 3032 (118-15/16) 7.5-16SL Maximum 3448 (135-11/16) 4032 (158-3/4) 10-16 formed caster Minimum 2448 (96-7/16) 3032 (118-15/16) 10-16 formed caster Maximum 3448 (135-11/16) 4032 (158-3/4) 10-16 forked caster Minimum 2448 (96-7/16) 3014 (118-11/16) 10-16 forked caster Maximum 3448 (135-11/16) 4014 (158) 16.5 x 16.1 Minimum 2448 (96-7/16) 3014 (118-11/16) 16.5 x 16.1 Maximum 3448 (135-11/16) 4014 (158) PRODUCT OVERVIEW

1022542 A B C D E F G H F K L M N J J A - Header Lift Leg B - Header Float Springs C - Operator’s Station D - Windshield Wiper E - Turn Signal/Hazard Lights F - Taillight Engine-Forward G - Field/Road Lights H - Handholds J - Beacon K - Mirror L - Door M - Maintenance Platform N - Center-Link PRODUCT OVERVIEW

1022536 A B C D E F G H J K L M N P A - Caster Wheel B - Walking Beam C - Taillights - Cab-Forward (Option) D - Engine Compartment Hood E - Windshield Wiper F - Field Lights G - Horn H - Turn Signal/Hazard Lights J - Mirror K - Door L - Drive Wheel M - Maintenance Platform N - Engine Air Precleaner (Export) P - Headlights PRODUCT OVERVIEW

engine-forward mode (transport mode). The operator’s station—which includes the seat, console, and steering column—pivots 180° to provide access to controls and gauges regardless of the direction of travel. 3.1 Operator Console 1000570 A B C D C E Figure 3.1: Operator Console A - Ignition B - Cab Display Module (CDM) C - Header Controls D - Ground Speed Lever (GSL) E - Throttle The console contains controls to operate the windrower, as well as amenities for the Operator. The console position is adjustable to suit each Operator. 1000572 A Figure 3.2: Console Fore-Aft 1. Adjusting fore-aft and height: a. Pull lever (A) and slide console fore or aft to the desired position. b. Release lever to lock console.

2. Adjusting only fore-aft: a. Loosen nuts (A) under console. b. Move console as required. c. Tighten nuts (A). OPERATOR’S STATION

The operator presence system is a safety feature designed to deactivate or alert selected systems when the Operator is not seated at the operator’s station. These systems include: • Header drive • Engine and transmission 3.2.1 Header Drive • To engage the header drive, the Operator must be seated in the operator’s seat. • If the Operator leaves the seat, power to the header drive is maintained for 5 seconds, then the header shuts down automatically. • To restart the header after an automatic shut down, move the HEADER DRIVE switch to the OFF position and then to the ON position. 3.2.2 Engine and Transmission • If the HEADER DRIVE switch is engaged, the engine will not start. • If the windrower is moving 8 km/h (5 mph) or slower and the Operator leaves the seat, the CDM will flash NO OPERATOR on the upper line and ENGINE SHUT DOWN 5...4...3...2...1...0 on the lower line accompanied by a steady tone. When the countdown reaches 0, the engine shuts down. • If the windrower is moving 8 km/h (5 mph) or faster, and the Operator leaves the seat for more than 5 seconds, an alarm will sound and the lower display line will flash NO OPERATOR. • If the operator’s seat is in between cab-forward and engine-forward positions and the transmission is not locked in the NEUTRAL position, the engine shuts off. The lower display will flash LOCK SEAT BASE until the seat base is locked into position. OPERATOR’S STATION

The operator’s seat has several adjustments. Refer to the following for the location and description of each adjustment. 3.3.1 Adjusting Fore-Aft Position 1000573 A Figure 3.4: Fore-Aft Position 1. Pull lever (A) up to release. 2. Move seat forward or rearward. 3. Release lever (A). 3.3.2 Adjusting Seat Suspension and Height Controls suspension stiffness and seat height. 1000574 A B Figure 3.5: Seat Suspension and Height INCREASE: Press upper switch (A). DECREASE: Press lower switch (B). OPERATOR’S STATION

Controls suspension dampening. 1000579 A Figure 3.6: Vertical Dampener INCREASE: Turn knob (A) counterclockwise. DECREASE: Turn knob (A) clockwise. 3.3.4 Adjusting the Armrest 1000575 A Figure 3.7: Armrest Raise armrest (A) for easier access to seat. Lower armrest (A) after seat belt is buckled. OPERATOR’S STATION

Locks seat fore-aft isolator. 1000578 A Figure 3.8: Fore-Aft Isolator Lock LOCK: Push lever (A) down. UNLOCK: Pull lever (A) up. 3.3.6 Adjusting Seat Tilt 1000577 A Figure 3.9: Seat Tilt 1. Pull lever (A) up to release. 2. Position seat back as desired. 3. Release lever (A). OPERATOR’S STATION

1000576 A Figure 3.10: Armrest Angle INCREASE: Rotate knob (A) clockwise. DECREASE: Rotate knob (A) counterclockwise. 3.3.8 Adjusting Lumbar Support Adjusts the stiffness of seat back. 1007710 A Figure 3.11: Lumbar Support INCREASE: Rotate knob (A) upward. DECREASE: Rotate knob (A) downward. OPERATOR’S STATION

WARNING • The training seat is provided for use by an experienced machine Operator while training a new Operator. • The training seat is NOT intended as a passenger seat or for use by children. Use the seat belt whenever operating the machine or riding as a Trainer. • Keep all other riders off the machine. 1000581 A B Figure 3.12: Training Seat in Storage Position For storage, lift seat (B) and secure with latch (A). 1000580 A B Figure 3.13: Training Seat To lower seat, lift latch (A) and lower seat (B). OPERATOR’S STATION

The windrower is equipped with seat belts on the operator’s and trainer’s seats. WARNING The seat belts can help ensure your safety when properly used and maintained. • Before starting the engine, fasten your seat belt, and ensure that the training seat occupant’s seat belt is securely fastened. • Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members. To fasten seat belt: 1006291 A B C Figure 3.14: Seat Belt 1. Pull belt with metal eye (A) at right side completely across your body. 2. Push metal eye (A) into buckle (B) until it locks. 3. Adjust the position of the belt as low on your body as possible. To release seat belt: 4. Push red button (C) in the end of the buckle. 5. Separate buckle (B) and metal eye (A). OPERATOR’S STATION

The steering column can be adjusted to suit each particular Operator and to make it easier to get in and out of the seat. 1000582 A Figure 3.15: Steering Column 1. Hold onto the steering wheel, lift handle (A), and move the steering wheel up or down to desired position. 2. Release handle (A) to lock the steering wheel position. OPERATOR’S STATION

A - FIELD / OFF / ROAD B - HIGH / LOW C - BEACONS / OFF 1022563 A B C Figure 3.17: Headliner Console (Russia) A - FIELD / OFF / ROAD B - LOW / HIGH C - BEACON & CLEARANCE / OFF / CLEARANCE The field/road (A), high/low beam (B), and beacon light (C) switches are located on a panel in the cab headliner. The hazard/turn signal switch is located on the cab display module (CDM). The position of the operator’s station (cab-forward mode or engine-forward mode) automatically determines the lighting. IMPORTANT: Red and amber reflector tape is positioned so as to be visible in both engine-forward and cab-forward modes. OPERATOR’S STATION

1000583 Figure 3.18: Field Light Switch The following lights are ON when the light switch is in FIELD position with the windrower in cab-forward mode: • Field lights in cab roof (front and rear) • Swath lights in hood • HID lights (if installed) on mirror supports NOTE: If the auto-road light feature is activated (i.e., windrower is in engine- or cab-forward mode, out of park, high range switch position, and header off), only the two front corner field lights will turn on; the remaining field lights are disabled. 1000585 A Figure 3.19: Cab-Forward: Front View The two innermost lights in the field light group (A) at the front of the cab are adjustable. Refer to Adjusting Field Lights, page 362. 1000586 A B Figure 3.20: Cab-Forward: Rear View The two field lights (A) at the rear of the cab are adjustable. Refer to Adjusting Rear Floodlights, page 369. NOTE: When the engine is shut down, rear field lights (A) turn on for 60 seconds to illuminate the platform and stairs. The two swath lights (B) in the hood are adjustable, but because they are used as road lights in engine-forward mode and adjusted accordingly, they should NOT be adjusted for field operation. OPERATOR’S STATION

1010282 A Figure 3.21: Road Light Switch The following lights are ON when the light switch (A) is in ROAD position with the windrower in engine-forward mode: 1000588 A B Figure 3.22: Engine-Forward: Rear View • Red taillights (A) on the mirror supports • Amber turn signals and hazard lights (B) on mirror supports rear view 1000589 A B Figure 3.23: Engine-Forward: Front View • Amber turn signals and hazard lights (A) on mirror supports front view • Headlights (B) in hood with low/high switch The two headlights in the hood are adjustable. Refer to Aligning Headlights, page 360. OPERATOR’S STATION

1010282 A Figure 3.24: Road Light Switch If equipped, the following lights are functional with switch (A) in the ROAD position: 1000591 B A Figure 3.25: Cab-Forward: Front View • Four lights (A) in cab roof • Amber turn signals and hazard lights (B) on mirror supports visible from both front and rear 1009843 C Figure 3.26: Cab-Forward: Rear View • Red lights (C) in hood (optional) NOTE: The hazard lights must be activated with the switch on the cab display module (CDM) when driving on the road. IMPORTANT: Optional red tail lighting and marking kit must be installed so that road travel in the cab-forward mode complies with regulations. Refer to 7.1.4 Lighting and Marking for Cab- Forward Road Travel, page 443 or see your MacDon Dealer. NOTE: If the red tail lighting kit is not installed, travelling in cab- forward mode and activating the turn indicator will trigger a stop lamp error (E134 or E135). IMPORTANT: If red tail lighting kit is installed and stop lamp errors still occur, contact your MacDon Dealer. OPERATOR’S STATION

The hazard lights can be switched on or off manually by pressing the HAZARD switch (A) on the cab display module (CDM). These lights will also turn on automatically when the auto- road light feature is activated (i.e., engine running, header off, and transmission in either mid or high range), and can only be turned off by engaging the header drive. 3.7.5 Beacon Light (Optional) MD #B5582 1000593 A Figure 3.28: Cab-Forward: Front View 1010285 B Figure 3.29: Beacon Light Switch The beacon lights (A) are functional when the ignition and the beacon switch (B) are ON. The beacons MUST be used when driving on the road where required by law. The beacons will also turn on automatically when the auto- road light feature is activated (i.e., engine running, header off, and transmission in either mid or high range), and can only be turned off by engaging the header drive. OPERATOR’S STATION

The beacon and hazard lights are included in the auto road light feature. The beacon and hazard lights will turn on when this feature is activated, and can only be turned off by engaging the header drive. This feature will activate when: • Windrower is in cab- or engine-forward mode • Engine is running • Header is disengaged • Transmission is in either mid or high range Moving the ground speed lever (GSL) out of neutral (brake off) will switch the white lights from field/work lights to road lights, if the switch is in the field/road lights position. 3.7.7 HID Auxiliary Lighting (Optional) Two optional high intensity discharge (HID) lights (MD #B5596) provide additional lighting during field operation. 1005500 A Figure 3.30: HID Auxiliary Lights (Optional) If installed, HID auxiliary lighting is located on the mirror supports (A) and operates in cab-forward mode only. OPERATOR’S STATION

1022644 B Figure 3.32: Field Light Switch (Russia) Optional HID auxiliary lighting is activated with the light switch (B) in the FIELD position. OPERATOR’S STATION

A - Rear Wiper B - Front Wiper The windshield wiper controls are located in the cab headliner. The illustration shows the controls in cab-forward mode. OPERATOR’S STATION

1000595 A B Figure 3.34: Mirrors Two outside-mounted, adjustable mirrors (A) provide a rear view when the windrower is in cab-forward mode. A single interior-mounted mirror (B) provides a rear view in the engine-forward mode. The mirror/light assembly (A) is designed to fold back if accidentally struck. A detent-type lock keeps it in place. OPERATOR’S STATION

The heater/evaporator/blower assembly is located under the cab floor and is accessible from beneath the windrower. 3.10.1 Heater Shut-Off 1000596 A Figure 3.35: Heater Shut-Off Valve A shut-off valve (A) at the engine allows the cab heater to be isolated from the engine coolant. The valve must be OPEN to provide heat to the cab, but can be CLOSED for maximum cooling. 3.10.2 Air Distribution 1000598 A B C Figure 3.36: Adjustable Air Vents A - Vent B - Open/Close C - Direction Cab air distribution is controlled through adjustable air vents (A) located in the cab posts. The vents provide Operator ventilation. OPERATOR’S STATION

A – BLOWER Switch controls the blower speed • OFF / LOW / MEDIUM / HIGH B – Air Conditioning (A/C) Switch controls A/C system • OFF: A/C does not operate • ON: A/C operates with blower switch ON C – Outside Air Switch controls the air source • FRESH AIR: Starts booster fan and filtered outside air is drawn into cab • RECIRCULATE: Stops booster fan and cab air is recirculated D – TEMPERATURE Control Dial controls cab temperature • Turning the dial clockwise increases temperature • Turning the dial counterclockwise decreases temperature IMPORTANT: To distribute the refrigerant oil throughout the A/C system, perform the following steps when starting the windrower after more than one week of storage: 1. Ensure heater shut-off valve at engine is OPEN. Refer to 3.10.1 Heater Shut-Off, page 58. 2. Turn blower switch to the first position, turn temperature control switch to MAXIMUM heating, and A/C control to OFF. 3. Start the engine and operate at low idle until the engine is warm. 4. Click A/C switch from OFF to ON for 1 second, then back to OFF for 5 to 10 seconds. Repeat this step ten times. Refrigerant Oil Perform the following steps when starting the windrower after more than one week of storage to distribute the refrigerant oil throughout the A/C system: 1. Ensure heater shut-off valve at engine is OPEN. Refer to 3.10.1 Heater Shut-Off, page 58. 2. Turn blower switch to the first position, turn temperature control switch to MAXIMUM heating, and A/C control to OFF. 3. Start the engine and operate at low idle until the engine is warm. 4. Click A/C switch from OFF to ON for 1 second, then back to OFF for 5 to 10 seconds. Repeat this step ten times. OPERATOR’S STATION

Two interior lights are installed in the cab headliner. A low intensity LED light (A) is located directly overhead to provide ambient lighting if desired. It functions only when the key is in the RUN position. An ON/OFF switch is located on the light. The other interior light (B) is located on the headliner switch panel and the push-ON, push-OFF button is located on the light. It functions at any time. OPERATOR’S STATION

The emergency exit window (indicated by the emergency exit decal [A]) is located beside the operator’s station. To open the emergency exit window, follow these steps: 1011937 A B C Figure 3.40: Emergency Exit Window 1. Release the window latch (A). 2. Remove the latch pin (B). 3. Push window open (C). OPERATOR’S STATION

1000601 1000601 A B C D E Figure 3.41: Console Operator’s Console A - Auxiliary power outlet B - Utility tray (under armrest) C - Cigarette lighter D - Ashtray/cup holder E - Utility tray 1000602 A A Figure 3.42: Windshield Shades Windshield Shades (Optional) Retractable window shades (A) can be installed for the front and rear windows. Refer to 7.1.7 Windshield Shades, page 444 for ordering information. 1010329 A B C D E Figure 3.43: Auxiliary Power Outlets A - Auxiliary Power Outlet B - Auxiliary Power Outlet C - Battery Terminal D - Ground Terminal E - Switched Terminal Auxiliary Outlets Two auxiliary power outlets are located on either side of the wiper motor cover/storage tray behind the Operator (cab-forward mode). OPERATOR’S STATION

Manual Storage A manual storage case (A) is located under the training seat. 1000608 A Figure 3.45: Coat Hook Coat Hook A coat hook (A) is located above the training seat, left of the Operator. OPERATOR’S STATION

3.14.1 AM/FM Radio 1000603 A A B Figure 3.46: Speakers in Headliner A - Speakers B - Radio Mounting Location A space (B) is provided in the cab headliner to accommodate the installation of an AM/FM radio that is available as optional equipment from your Dealer. In order to retain radio settings and preset memory with the battery disconnect turned off, select a radio with non-volatile settings memory. Two pre-wired speakers (A) have been factory-installed in the headliner. For radio installation procedures, refer to the M155 and M205 Self-Propelled Windrower Unloading and Assembly Instructions: North American Shipments or M Series Self- Propelled Windrower Unloading and Assembly Instructions for Container Shipments. Operating instructions are supplied with the radio. 3.14.2 Mounting the Antenna An optional base for a magnetic roof-mounted antenna is available from your Dealer. IMPORTANT: Antenna base can only be installed on the left cab-forward and right rear cab roof bolts. Order antenna mount (MD #160288 [B]) or refer to 3.49, page 65 for part dimensions to make an improvised version. A knockout (C) for the antenna lead is provided on the cab post. 1000609 A B C Figure 3.47: Antenna Mount 1. Remove existing bolt (A). 2. Install antenna mount (B) and secure with bolt (A). OPERATOR’S STATION

The knockout (A) is located on the exterior right cab-forward rear corner post of the cab, under the roof, between the horn and the light. 1000611 Figure 3.49: Template for Antenna Mount To make your own mount, refer to dimensions template. Use 11 GA. or 3.0 mm steel sheet. OPERATOR’S STATION

The horn is activated by pushing button (A) located on the panel in the headliner. Sound the horn three times prior to starting the engine. 1000612 A Figure 3.51: Horn Location The horn (A) is located outside the cab on the rear right cab-forward corner of the cab, under the roof. OPERATOR’S STATION

1000614 A B C D Figure 3.52: Engine Controls and Gauges The following engine controls and gauges are conveniently located on the operator’s console. Ignition Switch (A) • ACC (Accessory): Fully counterclockwise • OFF: All electrical systems OFF • RUN: Clockwise • START: Fully clockwise to crank engine: Release and switch returns to RUN NOTE: Remove key when windrower is not in use; the key also locks doors. Engine Coolant Temperature Gauge (B) • Normal Running: 82°–104°C (180°–220°F) NOTE: For information about temperature warnings and alarms, refer to Display Warnings and Alarms, page 87. Fuel Gauge (C) • E: Empty • F: Full Throttle (D) controls engine speed • FULL: Push lever forward • OPERATING: Refer to Driving Forward in Cab-Forward Mode, page 172 • CLOSED: Pull lever back OPERATOR’S STATION

Console Controls: A – TURN SIGNALS activate turn signals on windrower and header • Push-ON/Push-OFF B – GROUND SPEED LEVER (GSL) controls speed and direction of movement • F: Forward • N: NEUTRAL • N-DETENT: Engages neutral interlock, and applies park brake when steering locked in center • R: Reverse C – HAZARD WARNING LIGHTS activate signals on windrower and header • Push-ON/Push-OFF D – GROUND SPEED RANGE SWITCH shifts transmission speed range • High range: 0–37 km/h (23 mph) ENGINE-FORWARD ONLY • Mid range: 0–25.7 km/h (16 mph) CAB-FORWARD ONLY • Low range: 0–17.7 km/h (11 mph) E – N-Detent 1009722 A Figure 3.54: GSL Autosteer Control: A – AUTOSTEER ENGAGEMENT SWITCH engages/disengages the automated steering system (if compatible system is installed) • ENGAGE: Click to engage • DISENGAGE: Turn steering wheel or click to disengage OPERATOR’S STATION

1014371 A Figure 3.55: Autosteer Harness SW1 GSL SW1 (A) is located in the cab, beneath the floor mat at the engine-end seat position switch. 1000881 A Figure 3.56: Autosteer Harness SW2 GSL SW2 (A) is located beneath the cab, between the fuel tank and evaporator box. OPERATOR’S STATION

handle. NOTE: Some controls are optional equipment and may not be present in your unit. Some controls may be installed but nonfunctional for certain headers. Refer to specific header sections in this manual for detailed operating procedures of all header controls. 3.18.1 Header Drive Switch 1000618 A B Figure 3.57: Header Drive Switch The HEADER DRIVE switch (A) engages and disengages the header drive. To engage the header drive, pull up on collar (B) and push down on switch (A). To disengage the header drive, push the switch down. IMPORTANT: Always move throttle lever back to IDLE before engaging header drive. Do NOT engage header with engine at full rpm. 3.18.2 Header Drive Reverse Button 1005292 A B Figure 3.58: Header Drive Switches NOTE: The hydraulic reversing kit must be installed on auger headers. Rotary disc headers are factory-equipped with the ability to reverse. • ENGAGE: Push and hold REVERSER button (B) and engage header with switch (A) • DISENGAGE: Release REVERSER Button (B) NOTE: To engage forward operation, push switch (A) down and then up again. OPERATOR’S STATION

1000620 A B Figure 3.59: GSL The switches on the GSL (A) control the most common header functions. NOTE: A decal (B) identifying switch functions is located on the cab post above the operator’s console. 1007606 A B C D E Figure 3.60: GSL Function Groups A - Reel Speed B - Reel Position C - Autosteer Engagement D - Display Selector E - Header Position OPERATOR’S STATION

1009342 A Figure 3.61: Ground Speed Lever Pressing the display selector switch (A) selects and displays the settings on the cab display module (CDM) top line read-out for each of the header controls. Press switch (A) to scroll through settings. Reel Position Switches 1009534 A B C D Figure 3.62: Ground Speed Selector A - Reel Down B - Reel Forward C - Reel Up D - Reel Aft The functions performed by the reel position switches depend on which header is attached and the cab display module (CDM) programming. • For functions related to double windrow attachment (DWA) position, refer to: – 4.4.10 Using the Double Windrowing Attachment, page 213 • For functions related to reel fore-aft position and height on draper headers, refer to: – 4.6.2 Adjusting the Reel Fore-Aft Position, page 264 – 4.6.3 Adjusting the Reel Height, page 264 • For the center-link assist cylinder, refer to the section appropriate for your header: – 4.5.4 Attaching an A Series Header, page 232 – 4.5.2 Attaching a D Series or D1 SP Series Header, page 218 – 4.5.6 Attaching an R Series Header, page 248 NOTE: For detailed switch operating modes, refer to the section in this manual, specific to your header. OPERATOR’S STATION

Use the header position switches on the ground speed lever (GSL) to adjust the position of the header relative to the ground. 1009604 A B C D Figure 3.63: Ground Speed Lever • To lower the header, press switch (A) • To raise the header, press switch (C) • To tilt the header down, press switch (B) • To tilt the header up, press switch (D) Release switch at desired position. NOTE: Refer to the section in this manual that is specific to your header for detailed switch operating modes. Reel and Disc Speed Switches 1009518 A B Figure 3.64: Ground Speed Lever Press and hold switch (A) to increase the reel or disc speed. Press and hold switch (B) to decrease the reel or disc speed. Release switch at desired speed. Auger Header • A30 header: Not applicable • A40 header: Auger speed is automatically maintained when reel speed is changed IMPORTANT: Reel speed on auger header MUST NOT EXCEED 85 rpm. Auger speed MUST NOT EXCEED 320 rpm. Draper Header • Reel speed is limited in INDEX HEADER SPEED mode Rotary Disc Header • Conditioner speed automatically adjusts when DISC SPEED is changed OPERATOR’S STATION

The operator’s console contains switches for the following header functions: Deck Shift / Float Preset Switch 1000626 A B C D Figure 3.65: Header Switches A - Deck Shift / Float Preset Switch B - Left-Side Delivery C - Center Delivery D - Right-Side Delivery Draper Header with Deck Shift Option Controls deck shifting and float settings for double windrowing options with a draper header. 1000626 A B C D Figure 3.66: Header Switches A - Deck Shift / Float Preset Switch B - Float Preset 1 C - Float Preset 2 D - Float Preset 3 Draper Header with Fixed Decks / Auger Header / Rotary Header Selects preprogrammed header float settings. Refer to Float Options, page 199 to learn how to preset the float. NOTE: Refer to the section in this manual that is specific to your header for detailed switch operating modes. OPERATOR’S STATION

The functions performed by the DWA/swath compressor switch depend on how the windrower is equipped. 1018379 A B C D Figure 3.67: Console Switches If the windrower is equipped with a double windrow attachment: • The DWA deck is raised with switch (A) in position (C) • The DWA deck is lowered with switch (A) in position (B) The cab display module (CDM) must be programmed for this configuration. Refer to Activating the Double Windrow Attachment (DWA), page 98. Switch (A) may be used instead of the DWA switches on the ground speed lever (GSL). The DWA draper speed is controlled with the rotary switch (D) next to the rocker switch on the operator’s console. For more information on the DWA attachment and controls, refer to 4.4.10 Using the Double Windrowing Attachment, page 213. If the windrower is equipped with a swath roller attachment: • The swath compressor is raised by pressing switch (A) to position (C) • The swath compressor is lowered by pressing switch (A) to position (B) OPERATOR’S STATION

3.19.1 Engine and Windrower Functions Figure 3.68: Cab Display Module (CDM) Engine and Windrower Functions 1000644 A B C D E F G H • (A) ENGINE RPM • (B) GROUND SPEED – mph or km/h • (C) DISPLAY – Engine/windrower functions • (D) HAZARD WARNING LIGHTS SWITCH – Activates hazard warning lights, cancels turn signal • (E) SELECT SWITCH – Allows Operator to select display item on lower line. Push to SELECT • (F) TURN SIGNAL SWITCHES – Activates turn signals on windrower and header. Push-ON/Push-OFF • (G) IGNITION SWITCH POSITIONS – Accessory / Stop / Run / Start • (H) ENGINE WARNING LIGHTS – Engine Pre-Heat / Water In Fuel / CAUTION / Stop Engine OPERATOR’S STATION

1000645 A B C D E F G • (A) DISPLAY – Header functions. • (B) SELECT SWITCH – Allows Operator to select display item on lower line. Push to SELECT. • (C) FLOAT SWITCH – Header Right Side: Changes header float. The system remembers setting with deck shift option if activated with float setting switch. Push + to Increase. Push – to Decrease. • (D) FLOAT SWITCH – Header Left Side: Changes header float. The system remembers setting with deck shift option if activated with float setting switch. Push + to Increase. Push – to Decrease. • (E) AUGER/DRAPER SPEED ADJUST: Changes auger/draper speed INDEX with INDEX SWITCH ON. Changes auger/draper SPEED with INDEX SWITCH OFF. Push upper switch to increase. Push lower switch to decrease. • (F) HEADER INDEX SWITCH: Links reel and conveyor speed to ground speed. Push-ON/Push-OFF. NOTE: Illuminates in ON position. (Header must be engaged) • (G) RETURN TO CUT HEIGHT SWITCH: Allows cutting height preset. Push-ON/Push-OFF. NOTE: Illuminates in ON position (Header must be engaged). OPERATOR’S STATION

for the engine, header, and windrower. The information displayed in various operating modes is described in the following sections. Figure 3.70: CDM Operating Screen 1000647 A B C D E A - Display Selector for Upper Line B - Display C - CDM Upper Line D - CDM Lower Line E - Display Selector for Lower Line Ignition ON, Engine Not Running Display (Upper Line) (2–3 Seconds) Description HEADER DISENGAGED Indicates HEADER DRIVE switch is OFF IN PARK Indicates ground speed lever (GSL) is in N-DETENT Engine Running – At Initial Start Up Display (Upper Line) (2–3 seconds) Description HEADER TYPE AND SIZE Ignition start, engine running. IN PARK Indicates ground speed lever (GSL) in N-DETENT. On startup. OPERATOR’S STATION

Display Description ROAD GEAR (upper line) low-speed range in HIGH range #####.# ENGINE HRS (upper or lower line) Total engine operating time #####.# UNIT HRS (upper or lower line) Total windrower operating time #####.# HEADER HRS (upper or lower line) Total header operating time ###### TOTAL ACRES (upper or lower line) ###### TOTAL HECT (if metric) Total area cut by machine ##.# HEADER HEIGHT (upper or lower line) Distance setting (00.0–10.0) between cutterbar and ground ##.# HEADER ANGLE (upper or lower line) Angle setting (00.0–10.0) header relative to ground ### °C or F HYD OIL TEMP Hydraulic oil temperature ##.# VOLTS (upper or lower line) Engine electrical system operating voltage ##.# SWATH COMPR HT Swath compressor height (00.0–10.0); fully raised is 0. SCROLL (lower line) Displays above items after 2 to 3 seconds; press SELECT to cancel Cab-Forward, Engine Running, Header Disengaged Scroll through display with cab display module (CDM) switch or ground speed lever (GSL) switch. Display (Lower or Upper Line) Description #####.# ENGINE HRS Total engine operating time #####.# UNIT HRS Total windrower operating time #####.# HEADER HRS Total header operating time ###.# SUB ACRES ###.# SUB HECTARES (if metric) Area cut since last reset. To reset, display SUB ACRES on lower line, and hold down PROGRAM switch until display resets (five to seven seconds) ###### TOTAL ACRES ###### TOTAL HECT (if metric) Total area cut by machine ##.# HEADER HEIGHT Distance setting (00.0–10.0) between cutterbar and ground ##.# HEADER ANGLE Angle setting (00.0–10.0) header relative to ground ##.# L FLOAT R ##.# Float setting (0.0–10.0) ### °C or F HYD OIL TEMP Hydraulic oil temperature ##.# VOLTS Engine electrical system operating voltage ##.# SWATH COMPR HT Swath compressor height (00.0–10.0); fully raised is 0. SCROLL (lower line) Displays above items after two to three seconds; press SELECT to cancel OPERATOR’S STATION

Scroll through display with cab display module (CDM) switch or ground speed lever (GSL) switch. Display (Lower or Upper Line) Description #####.# ENGINE HRS Total engine operating time #####.# UNIT HRS Total windrower operating time #####.# HEADER HRS Total header operating time ##.# ACRES/HOUR ##.# HECTARES/HOUR (if Metric) Actual cutting rate in acres (hectares)/hour ###.# SUB ACRES ###.# SUB HECTARES (if Metric) Area cut since last reset; to reset, display SUB ACRES on lower line, and hold down PROGRAM switch until display resets (5 to 7 seconds) ###### TOTAL ACRES ###### TOTAL HECT (if Metric) Total area cut by machine ##.## REEL RPM ##.## REEL SENSOR Reel rotational speed Sensor disabled. RPM and SENSOR alternate at 1 second intervals ##.# AUGER SPEED Auger rotational speed (4.7–9.9) #### KNIFE SPEED #### KNIFE SENSOR Knife speed in strokes per minute Sensor disabled. SPEED and SENSOR alternate at 1 second intervals ##.# HEADER HEIGHT ##.# HEADER SENSOR Distance setting (00.0–10.0) between cutterbar and ground Sensor disabled. HEIGHTand SENSOR alternate at 1 second intervals. ##.# HEADER ANGLE ##.# HEADER SENSOR Angle setting (00.0–10.0) header relative to ground Sensor disabled. ANGLE and SENSOR alternate at 1 second intervals ##.# L FLOAT R ##.# FLOAT SENS DISABLED Left and right float setting (0.0–10.0) Sensor disabled LOAD|■■■■| | #### Bar graph representing hydraulic operating pressure. Full scale is preprogrammed overload pressure (2500– 5000 psi). If sensor disabled, LOAD does not display6 ### °C or F HYD OIL TEMP ### °C or F HYD TEMP Hydraulic oil temperature Sensor disabled. TEMP and SENSOR alternate at 1 second intervals ##.# VOLTS Engine electrical system operating voltage OPERATOR’S STATION 6. The LOAD sensor to monitor knife/conditioner circuit pressure is optional. To monitor reel/auger circuit pressure, relocate sensor as per kit instruction MD #169031, which is available through your Dealer.