MacDon M155 Installation Instructions Manual
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MacDon M155 Installation Instructions Manual

Self-propelled windrowers, auxiliary lighting harness repair kit
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M155, M155E4, and M205
Self-Propelled Windrowers
Auxiliary Lighting Harness Repair Kit (MD #167693)
Installation Instructions
147762 Revision C
Original Instruction
The harvesting specialists.

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Summary of Contents for MacDon M155

  • Page 1 M155, M155E4, and M205 Self-Propelled Windrowers Auxiliary Lighting Harness Repair Kit (MD #167693) Installation Instructions 147762 Revision C Original Instruction The harvesting specialists.
  • Page 2 © 2019 MacDon Industries, Ltd. The information in this publication is based on the information available and in effect at the time of printing. MacDon Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the...
  • Page 3 • Unless otherwise noted, use the standard torque values provided in the windrower operator’s manual and technical manual. NOTE: Keep your MacDon publications up-to-date. The most current version of this instruction can be downloaded from our Dealer-only site (https://portal.macdon.com) (login required). NOTE: This document is currently available in English only.
  • Page 4 Summary of Changes At MacDon, we’re continuously making improvements, and occasionally these improvements affect product documentation. The following list provides an account of major changes from the previous version of this document. Section Summary of Change Internal Use Only Inside front cover Added copyright and disclaimer statements.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction ..............................i Summary of Changes............................ ii Chapter 1: Safety ............................1 1.1 Signal Words ............................1 1.2 General Safety ............................2 Chapter 2: Parts List............................ 5 Chapter 3: Installation Instructions ......................9 3.1 Installing Auxiliary Lighting Roof Harness ....................9 3.2 Installing Auxiliary Lighting Chassis Harness....................

  • Page 7: Chapter 1: Safety

    Chapter 1: Safety 1.1 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words, IMPORTANT and NOTE, identify non-safety related information. Signal words are selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

  • Page 8: General Safety

    SAFETY 1.2 General Safety CAUTION The following general farm safety precautions 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.
  • Page 9 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. •...

  • Page 11: Chapter 2: Parts List

    Chapter 2: Parts List The following parts are included in this kit: 147762 Revision C...
  • Page 12 PARTS LIST Figure 2.1: Auxiliary Lighting Harness Repair Kit Parts 147762 Revision C...
  • Page 13 Description Quantity BREAKER – MAXI TYPE 1 25 AMPS 134762 DECAL – M INLINE FUSES 167969 DECAL – FUSE M155/M205 ENGLISH 183562 DECAL – FUSE M155/M205 RUSSIAN 183563 DECAL – FUSE BLK, M155E4, ENGLISH 183567 FASTENER – CABLE TIE BLACK, 160 MM LONG 21763 FASTENER –...

  • Page 15: Chapter 3: Installation Instructions

    Chapter 3: Installation Instructions To install the Auxiliary Lighting Harness Repair kit, follow these steps: WARNING To avoid bodily injury or death from the unexpected startup of the machine, always stop the engine and remove the key from the ignition before leaving the operator’s seat for any reason. 1.
  • Page 16 INSTALLATION INSTRUCTIONS 2. Remove the fresh air filter pan (A) and filter to reveal an opening to the cab post. Retain for reinstallation. Figure 3.3: Air Filter Pan and Filter 3. Move wiring connections out of the way to make it easier to feed the new auxiliary lighting roof harness through the cab post.
  • Page 17 INSTALLATION INSTRUCTIONS 5. Feed a fish tape/draw wire through the right headliner switch panel, alongside the looms that run down into the right rear corner post of the cab. NOTE: The fish tape should follow the path shown in the illustration at right, from the right switch panel opening to the base of the right rear cab post.
  • Page 18 INSTALLATION INSTRUCTIONS 9. Attach the harness to the fish tape and pull it around to the left switch panel opening. Figure 3.9: Fish Tape and Harness on Left Switch Panel Opening 10. In the left headliner switch panel, remove the AUXILLARY LTS relay (A) from its socket (B).
  • Page 19 INSTALLATION INSTRUCTIONS 14. Push the repair harness wire (A) into terminal 30 on the relay socket (B). Figure 3.12: Relay Socket 15. Reinstall the terminal lock (A). Figure 3.13: Relay and Socket 16. Press the relay (A) into place. Figure 3.14: Relay and Socket 147762 Revision C...
  • Page 20 INSTALLATION INSTRUCTIONS 17. Reinstall the left and right headliner switch panels. Figure 3.15: Headliner Switch Panels A - Left Switch Panel B - Right Switch Panel 18. Below the right rear cab post, feed the loose end of the new auxiliary lights roof harness through port (A) on the windrower frame.
  • Page 21 INSTALLATION INSTRUCTIONS 20. Using a small screwdriver, remove terminal lock (A) from the connector. Figure 3.18: P2C Connector 21. Remove plug (A) from position 4 on the connector. 1013956 Figure 3.19: P2C Connector 22. In place of the plug, insert Deutsch pin (A) of the auxiliary lights roof repair harness.

  • Page 22: Installing Auxiliary Lighting Chassis Harness

    INSTALLATION INSTRUCTIONS 3.2 Installing Auxiliary Lighting Chassis Harness To install the auxiliary lighting chassis harness (MD #183558) provided in the kit, follow these steps: NOTE: You may need to remove and replace some of the existing cable ties. New cable ties in two lengths have been provided in the kit for this purpose.
  • Page 23 INSTALLATION INSTRUCTIONS 6. On the other end of the connector that was disconnected in Step 19, page 14, C3B, remove terminal lock (A). Figure 3.24: C3B Connector 7. Remove the plug from position 4 (A) on the connector. Figure 3.25: C3B Connector 8.
  • Page 24 INSTALLATION INSTRUCTIONS 9. Reinstall the terminal lock (A). Figure 3.27: C3B Connector with Terminal Lock in Place 10. Couple the connector. Figure 3.28: Harness Connected to C3B 11. Replace the fresh air filter pan (A) and filter. Figure 3.29: Air Filter Pan and Filter 147762 Revision C...
  • Page 25 INSTALLATION INSTRUCTIONS 12. Reinsert the corner post seal into the bottom of the right rear cab post. Figure 3.30: Bottom of Right Rear Cab Post 147762 Revision C...

  • Page 26: Installing Fuse Box Decals And Breaker

    Place the new decal in position. Slowly peel off the backing paper, smoothing the decal as it is applied. d. Prick small air pockets with a pin, and smooth out. 1013967 Figure 3.33: M155/M205 English Fuse Box Decal (MD #183562) 147762 Revision C...
  • Page 27 INSTALLATION INSTRUCTIONS 6. Install inline fuse decal (MD #167969) in the bottom of the F21 - 10A fuse box cover as follows: Clean and dry the installation area on the inside of the fuse box cover. b. Place the new decal in position. Slowly peel off the backing paper, smoothing the decal as it is applied.

  • Page 28: Checking Operation Of Lights

    INSTALLATION INSTRUCTIONS 3.4 Checking Operation of Lights Once all parts have been installed, check to make sure the high intensity discharge (HID) auxiliary lights are operating properly. Follow these steps: 1. If the windrower is in engine-forward mode (operator’s seat faces the engine), follow these steps to put the windrower in cab-forward mode: Place ground speed lever (GSL) (A) in N-DETENT.
  • Page 29 INSTALLATION INSTRUCTIONS 4. Follow these steps to put the windrower in engine- forward mode: Place ground speed lever (GSL) (A) in N-DETENT. Engine can be running. IMPORTANT: If GSL is NOT in N-DETENT, damage to the GSL cable may result when swiveling operator’s station. b.
  • Page 32 MacDon Industries Ltd. MacDon Brasil Agribusiness Ltda. 680 Moray Street Rua Grã Nicco, 113, sala 404, B. 04 Winnipeg, Manitoba Mossunguê, Curitiba, Paraná Canada R3J 3S3 CEP 81200-200 Brasil t. (204) 885-5590 f. (204) 832-7749 t. +55 (41) 2101-1713 f. +55 (41) 2101-1699 MacDon, Inc.
  • Page 33 M155E4 Self-Propelled Windrower Update Kit (MD #167728) Installation Instructions 167730 Revision B Original Instruction The harvesting specialists.
  • Page 34 M155E4 Self-Propelled Windrower Published in March 2016...
  • Page 35 • Unless otherwise noted, use the standard torque values provided in the windrower operator’s manual and technical manual. NOTE: Keep your MacDon publications up-to-date. The most current version of this instruction can be downloaded from our Dealer-only site (https://portal.macdon.com) (login required). NOTE: This document is not currently available in any language except English.
  • Page 36 List of Revisions Revision A was never published. 167730 Revision B...
  • Page 37 TABLE OF CONTENTS Introduction ............................i List of Revisions ..........................ii Safety ..............................1 Signal Words........................... 1 General Safety ..........................2 Parts List ............................... 5 Installation Instructions ........................9 Replacing Aspirator ......................... 9 Installing Traction Drive Test Fittings ....................12 Installing Fuse Decal........................14 Replacing Pre-cleaner Support .......................

  • Page 39: Safety

    1 Safety 1.1 Signal Words Three signal words, DANGER, WARNING, and CAUTION, are used to alert you to hazardous situations. The appropriate signal word for each situation has been selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

  • Page 40: General Safety

    SAFETY 1.2 General Safety CAUTION The following are general farm safety precautions that should be part of your operating procedure for all types of machinery. Protect yourself. • When assembling, operating, and servicing machinery, wear all the protective clothing and personal safety devices that could be necessary for the job at hand.
  • Page 41 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 the shaft and can telescope freely. •...

  • Page 43: Parts List

    2 Parts List The following parts are included in this kit: 167730 Revision B...
  • Page 44 PARTS LIST Figure 2.1: M155E4 Update Kit (MD #167728) 167730 Revision B...
  • Page 45 167522 KIT – CAB SPNSN LIMIT STRAP 167513 KIT – CAB SUSPENSION REAR BUMPERS M155, M205, W150 1. Some model year 2015 units may have this kit already installed from the factory. Refer to 3.7 Checking High-Intensity Discharge (HID) Auxiliary Light Wiring, page 27 before working on this kit.

  • Page 47: Installation Instructions

    3 Installation Instructions 3.1 Replacing Aspirator CAUTION 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. 1. Park windrower on level ground. Stop engine and remove key from ignition.
  • Page 48 INSTALLATION INSTRUCTIONS 5. With bolts and plate removed, slide aspirator assembly (A) out of fan shroud (B). 6. Install the new aspirator assembly. Figure 3.3: Aspirator Assembly 7. Adjust new aspirator assembly (A) within the shroud to achieve minimum 13/32 in. (10 mm) clearance (B) between the aspirator (A) and the engine cooling fan (C).
  • Page 49 INSTALLATION INSTRUCTIONS 9. Reattach CAC tube (A) to connector (B), if it was removed. Follow these steps: a. Replace CAC tube (A) into CAC connector (B), ensuring that CAC tube is inserted all the way into connector. b. Position clamp (C) snug against bead on CAC tube.

  • Page 50: Installing Traction Drive Test Fittings

    INSTALLATION INSTRUCTIONS 3.2 Installing Traction Drive Test Fittings The test fittings are installed to aid in any future neutral adjustments that may be required. 1. Locate the four plugs (A) that will be replaced with fittings on the traction drive pump assembly (B). Figure 3.8: Location of Three Plugs Figure 3.9: Location of One Plug 2.
  • Page 51 INSTALLATION INSTRUCTIONS 3. Thread fitting (A) into open port. Finger tighten, then torque to 19–21 ft·lbf (26–29 N·m). 4. Repeat Steps 2, page 12 3, page 13 until all four plugs have been replaced. Figure 3.11: Traction Drive Pump Assembly 167730 Revision B...

  • Page 52: Installing Fuse Decal

    INSTALLATION INSTRUCTIONS 3.3 Installing Fuse Decal 1. Move right cab-forward side platform rearward. For instructions, refer to windrower operator’s manual or technical manual. 2. Undo clips (A) on both sides of the fuse and breaker box. 3. Remove fuse box cover (B). Figure 3.12: Fuse Box 4.
  • Page 53 INSTALLATION INSTRUCTIONS 5. Replace fuse cover (B) on the fuse and breaker box, and secure with the clips (A). 6. Close hood. Figure 3.14: Fuse Box 167730 Revision B...

  • Page 54: Replacing Pre-Cleaner Support

    INSTALLATION INSTRUCTIONS 3.4 Replacing Pre-cleaner Support The new pre-cleaner support will prevent water build-up in the pre-cleaner tube. 1. Loosen clamp (A) and remove pre-cleaner (B). 2. Slide clamp (A) out of pre‑cleaner support (C). Figure 3.15: Pre-cleaner 3. Open hood to the highest position. 4.

  • Page 55: Replacing Fuel And Diesel Exhaust Fluid (Def) Display Module

    INSTALLATION INSTRUCTIONS 3.5 Replacing Fuel and Diesel Exhaust Fluid (DEF) Display Module The new display module has improved reliability. Refer to your MacDon Dealer if software update is needed. 1. Using a Phillips head screwdriver, remove four screws (A) securing DEF panel (B) and display module (C) to windrower console.
  • Page 56 INSTALLATION INSTRUCTIONS 5. Position the new DEF display module (A) into the display panel (B). Maintain correct orientation of DEF module by noting the position of the electrical connector on the rear. Figure 3.21: DEF Module 6. Position the DEF display module (C) and panel (B) into windrower console and secure with four screws (A).

  • Page 57: Replacing Diesel Exhaust Fluid (Def) Tank Head Assembly

    INSTALLATION INSTRUCTIONS 3.6 Replacing Diesel Exhaust Fluid (DEF) Tank Head Assembly The new DEF tank head offers improved reliability. 1. Open the maintenance platform on right cab-forward side. For instructions, refer to the windrower operator’s manual or technical manual. 2. Place a drain pan under the DEF tank. NOTE: Drain pan must be made of DEF compatible material such as HDPE.
  • Page 58 INSTALLATION INSTRUCTIONS 7. Using an M16 socket, remove the two bolts (A) holding the DEF tank cover (B) to the DEF tank assembly (C). Retain bolts for use later. 8. Remove the DEF tank cover (B) and set aside. Figure 3.25: DEF Tank Assembly 9.
  • Page 59 INSTALLATION INSTRUCTIONS 11. Pull the black (return) coolant line (A) away from DEF head (B) to remove it. Retain the clamp (C) for use later. 12. Seal the port in the DEF head (B) with tape to prevent coolant leakage into DEF tank. 13.
  • Page 60 INSTALLATION INSTRUCTIONS 17. Mark the position of the two black corrugated DEF lines (A) attached to the DEF head (B). NOTE: Connection points are identical on the new DEF head. 18. Press the black strip on the side of the quick-connect fitting (A), and disconnect fitting from pilot on DEF head (B).
  • Page 61 INSTALLATION INSTRUCTIONS 21. Pull up DEF head (A) to remove it from the tank (B). NOTE: You may need to use a step ladder to be high enough to remove the head completely from the tank. Take care as DEF head will be heavy if it is full of coolant.
  • Page 62 INSTALLATION INSTRUCTIONS 26. Reconnect the two DEF lines (A) to the DEF head (B), by pushing the quick-connect fitting onto the correct port on the DEF head (B). Figure 3.37: DEF Head 27. Reinstall interface hose (A) by pushing it on the vent port of the new DEF head (B).
  • Page 63 INSTALLATION INSTRUCTIONS 29. Reinstall the red and black coolant lines (A) into their previous positions, and secure with the constant tension clamps (B). 30. Remove the clamps used to pinch the coolant lines (A) shut. Figure 3.40: DEF Head 31. Re-open the manual coolant shutoff valve (A) to the full open position.
  • Page 64 INSTALLATION INSTRUCTIONS 37. Position DEF tank cover (B) on the DEF tank (C). 38. Apply anti-seize compound on bolts (A). 39. Secure DEF tank cover (B) with bolts (A) and torque to 11–13 ft·lbf (15–18 N·m). 40. Close the maintenance platform. Figure 3.43: DEF Tank 167730 Revision B...

  • Page 65: Checking High-Intensity Discharge (Hid) Auxiliary Light Wiring

    INSTALLATION INSTRUCTIONS 3.7 Checking High-Intensity Discharge (HID) Auxiliary Light Wiring Some M155E4 Self-Propelled Windrowers from model year 2015 were updated in the factory with the Auxiliary Lighting Harness kit. However, It may have been installed incorrectly. Before installing the Auxiliary Lighting Harness Repair Kit (MD #167693), check first if it’s already installed in the machine and if it was installed correctly.
  • Page 66 INSTALLATION INSTRUCTIONS 5. Remove the auxiliary lights relay (A) from its socket (B). Figure 3.46: Auxiliary Lights Relay and Socket 6. Remove the terminal lock (A) from the relay socket (B). 7. Remove the existing AUXILIARY LTS (orange) wire (C) from port 30 of the relay socket (B) with a wire extractor tool such as Delphi pin removal tool MD #134159 or equivalent.
  • Page 67 INSTALLATION INSTRUCTIONS 10. Reinstall the terminal lock (A). Figure 3.49: Auxiliary Lights Relay and Socket 11. Press the relay (A) in place. 12. Reinstall the left headliner switch panel. 13. Verify lighting works correctly. Refer to Checking Operation of Lights in Instruction MD #147762, Auxiliary Lighting Harness Repair kit or windrower operator’s manual for instructions.

  • Page 68: Installing Remaining Updates

    INSTALLATION INSTRUCTIONS 3.8 Installing Remaining Updates Install the following kits using the instructions included in each kit: • MD #183518 Oil Cooler Bypass Kit • MD #167693 Auxiliary Light Harness Kit • MD #167589 Screen Cleaner Motor Kit • MD #167522 Cab SPNSN Limit Strap Kit •...
  • Page 70 10708 N. Pomona Avenue Kansas City, Missouri United States 64153-1924 t. (816) 891-7313 f. (816) 891-7323 MacDon Australia Pty. Ltd. A.C.N. 079 393 721 P.O. Box 243, Suite 3, 143 Main Street Greensborough, Victoria, Australia 3088 t. 03 9432 9982 f.

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M155e4M205Md 167693

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