MacDon M205 Installation Instructions Manual
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MacDon M205 Installation Instructions Manual

Self-propelled windrower, oil cooler bypass kit
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M205
Self-Propelled Windrower
Oil Cooler Bypass Kit (MD #183519) Installation Instructions
147611 Revision B
Original Instruction
The harvesting specialists.

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  • Page 1 M205 Self-Propelled Windrower Oil Cooler Bypass Kit (MD #183519) Installation Instructions 147611 Revision B Original Instruction The harvesting specialists.
  • Page 2 Published: July 2016...
  • Page 3 The Oil Cooler Bypass kit (MD #183519) is used to replace the cooler bypass manifold and the hardware on the wheel motor servo on an M205 Self-Propelled Windrower. This document explains how to install the kit. Refer to the parts list to ensure you have all required items before installing this kit.
  • Page 4 List of Revisions 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. Summary of Change Location Added hose routing information.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction ............................i List of Revisions ..........................ii Safety ..............................1 Signal Words........................... 1 General Safety ..........................2 Parts List ............................... 5 Installation Instructions ........................9 Cooler Bypass Manifold ........................9 3.1.1 Preparing Kit Components for Installation .................. 9 3.1.2 Changing the Hydraulic Oil .......................

  • Page 7: 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 8: 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 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 the shaft and can telescope freely. •...

  • Page 11: Parts List

    2 Parts List The following parts are included in this kit. 147611 Revision B...
  • Page 12 PARTS LIST Figure 2.1: Parts Included in Oil Cooler Bypass Kit (MD #183519) 147611 Revision B...
  • Page 13 PARTS LIST Part Number Description Quantity 183494 MANIFOLD – COOLER BYPASS 21031 FITTING – ADAPTER HYDRAULIC 183493 HOSE 134437 FITTING – COUPLING HYDRAULIC TEST PORT 30970 FITTING – ELBOW 90° HYDRAULIC 136652 SCREW – HEX SOC HD M6 X 1.00 X 20-12.9-A2L 147611 Revision B...

  • Page 15: Installation Instructions

    3 Installation Instructions To install the Oil Cooler Bypass kit (MD #183519), follow these procedures in order. IMPORTANT: DO NOT attempt to install the Oil Cooler Bypass kit in the field. Install the kit in a clean environment; the hydraulic hose and fittings must be kept clean during installation to avoid hydraulic system damage.

  • Page 16: Removing Lift Filter

    INSTALLATION INSTRUCTIONS 1. Park the windrower on level ground, and lower the header and reel so that the lift cylinders are fully retracted. 2. Stop the engine and remove the key. 3. Open the hood. For instructions, refer to the windrower operator’s manual or technical manual.

  • Page 17: Installing Lift Filter

    INSTALLATION INSTRUCTIONS 7. Remove gasket (C) from groove (B) in filter head (A). Figure 3.4: Lift Filter Installing Lift Filter 1. Clean the gasket groove (B) in the filter head (A). 2. Apply a thin film of clean oil to the filter gasket (C). 3.

  • Page 18: Replacing Cooler Bypass Manifold

    INSTALLATION INSTRUCTIONS 3.1.3 Replacing Cooler Bypass Manifold To replace the cooler bypass manifold, follow these steps: 1. Remove plug and install new elbow fitting (MD #30970) (A) in bottom of traction drive pump (B). 2. Attach hose (MD #183493) (C), provided in kit, to the open end of elbow fitting (A).

  • Page 19: Refilling Hydraulic Reservoir

    INSTALLATION INSTRUCTIONS 10. Rotate hose (B), leaving 1–2 mm of clearance between the hose and the filter (A). There should also be 1–2 mm of clearance between hose (C) and hose (B). Figure 3.10: Cooler Bypass Manifold Hoses 3.1.4 Refilling Hydraulic Reservoir To refill the hydraulic reservoir, follow these steps: 1.

  • Page 20: Testing Cooler Bypass Pressure

    INSTALLATION INSTRUCTIONS 3.1.5 Testing Cooler Bypass Pressure IMPORTANT: Make sure you check CP and CR pressure after installing the new Oil Bypass Cooler kit, and adjust as necessary. 1. To measure CR pressure, attach a 7000 kPa (1000 psi) pressure gauge to the test fitting at port CRG (A). 2.

  • Page 21: Wheel Drive Motor Servo Hardware (2014 And Prior Only)

    INSTALLATION INSTRUCTIONS 3.2 Wheel Drive Motor Servo Hardware (2014 and Prior Only) Along with the parts required to replace the cooler bypass manifold, the kit also includes 16 hex socket head screws. These are needed to replace the hardware on both wheel drive motor servos on windrowers from model years 2014 and earlier.

  • Page 22: Replacing Servo Hardware

    INSTALLATION INSTRUCTIONS CAUTION Use a suitable lifting device capable of supporting a minimum of 907 kg (2000 lb.) to lift the wheel assembly away from the windrower. 4. Remove the wheel nuts (B). 5. Use a suitable lifting device to remove the drive wheel (A).
  • Page 23 INSTALLATION INSTRUCTIONS 3. To disengage drive wheel and allow wheel to rotate: a. Remove the two hex bolts (A) at the center of the drive wheel. b. Remove cap (B), and flip over so that the dished side faces in. c.
  • Page 24 INSTALLATION INSTRUCTIONS 6. To access the wheel drive motor servo, remove upper plug (A) on both sides of windrower leg. Figure 3.22: Plugs in Windrower Leg 7. Through one of the access holes, remove one of the existing servo bolts (A) with a 5 mm hex wrench and replace it with one of the hex socket head screws (MD #136652) provided in the kit.
  • Page 25 INSTALLATION INSTRUCTIONS 13. To access the remaining bolts on the servo: a. Pull out the wheel drive assembly approx. 38 mm (1-1/2 in.). b. Rotate the wheel motor with wrench on lock nut (A) to align servo bolts on both sides. Wedge a 2 x 4 (B) in top or bottom as necessary.

  • Page 26: Reinstalling Drive Wheels

    INSTALLATION INSTRUCTIONS 19. Install bolt and nut removed at (B), just securing nut to engage threads. 20. Reinstall the lower six bolts (A) that hold the wheel ® drive to the windrower leg. Use Loctite 243 on the threads. Loosen tension on chain (D) or vary tension as necessary to align holes for bolt installation.
  • Page 27 INSTALLATION INSTRUCTIONS 1. Position drive wheel (A) against wheel drive hub (B) such that air valve (C) is on the outside and tire tread (D) points forward when windrower is in cab forward position. For turf tires (diamond tread), be sure arrow on sidewall points in forward rotation when windrower is in cab-forward.
  • Page 28 INSTALLATION INSTRUCTIONS CAUTION Jack stand must be capable of supporting a minimum of 2268 kg (5000 lb.). 6. Place a jack under the leg jack point (A) and raise the drive wheel slightly off the jack stand. 7. Remove the jack stand from under the cylinder lift mount (B) and lower the drive wheel to the ground.
  • Page 30 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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Md 183519

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