MacDon M155 Unloading And Assembly Instructions
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MacDon M155 Unloading And Assembly Instructions

Self-propelled windrower
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M155 and M205
Self-Propelled Windrower
UNLOADING AND ASSEMBLY
INSTRUCTIONS
for
NORTH AMERICAN SHIPMENTS
Published: September, 2011
Form 169540
Revision B

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  • Page 1 M155 and M205 Self-Propelled Windrower UNLOADING AND ASSEMBLY INSTRUCTIONS NORTH AMERICAN SHIPMENTS Published: September, 2011 Form 169540 Revision B...

  • Page 2: Introduction

    INTRODUCTION This instructional manual describes the unloading, set-up and pre-delivery requirements for the MacDon M155 and M205 Self-Propelled Windrowers. Use the Table of Contents to guide you to specific areas. Retain this instruction for future reference. CAREFULLY READ ALL THE MATERIAL PROVIDED BEFORE ATTEMPTING TO UNLOAD, ASSEMBLE, OR USE THE MACHINE.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section/Title Page   INTRODUCTION ................................ 2   GENERAL SAFETY ..............................4   RECOMMENDED TORQUES ........................... 6     GENERAL ............................6     SAE BOLTS ............................6     METRIC BOLTS ..........................6     FLARE TYPE HYDRAULIC FITTINGS ....................7  ...

  • Page 4: General Safety

    SAFETY GENERAL SAFETY CAUTION The following are general farm safety precautions that should be part of your operating procedure for all types of machinery.  Provide a first-aid kit for use in case of  Protect yourself. emergencies.   When assembling, operating and servicing Keep a fire extinguisher on the machine.
  • Page 5 SAFETY  Stop engine, and remove key from ignition before leaving Operator's seat for any reason. A child or even a pet could engage an idling machine.  Keep the area used for servicing machinery clean and dry. Wet or oily floors are slippery. Wet spots can be dangerous when working with electrical equipment.

  • Page 6: Recommended Torques

    GENERAL RECOMMENDED TORQUES C. METRIC BOLTS STD COARSE BOLT TORQUE* A. GENERAL BOLT  10.9 Tighten all bolts to the torques specified in DIA. "A" chart (unless otherwise noted throughout this lbf·ft N·m lbf·ft N·m manual).  Check tightness of bolts periodically, using bolt torque chart as a guide.

  • Page 7: Flare Type Hydraulic Fittings

    GENERAL D. FLARE TYPE HYDRAULIC FITTINGS E. O-RING BOSS (ORB) HYDRAULIC FITTINGS FITTING FLARE LOCKNUT WASHER O-RING GROOVE BODY FLARESEAT SEAT a. Check flare and flare seat for defects that might cause leakage. b. Align tube with fitting before tightening. c.

  • Page 8: O-Ring Face Seal (Orfs) Hydraulic Fittings

    GENERAL F. O-RING FACE SEAL (ORFS) HYDRAULIC FITTINGS a. Check components to ensure that the sealing surfaces and fitting threads are free of burrs, nicks, and scratches, or any foreign material. b. Apply lubricant (typically Petroleum Jelly) to O-ring and threads. If O-ring is not already installed, install O-ring.

  • Page 9: Conversion Chart

    GENERAL CONVERSION CHART INCH-POUND UNITS SI UNITS (METRIC) QUANTITY FACTOR UNIT NAME ABBR. UNIT NAME ABBR. Area acres acres x 0.4047 = hectares gallons per minute (US) gpm (US) x 3.7854 = Flow liters per minute L/min gallons per minute (Imp) x 4.5460 = pounds force x 4.4482 =...

  • Page 10: Definitions

    GENERAL DEFINITIONS TERM DEFINITION American Petroleum Institute ASTM American Society of Testing And Materials Cab-Forward Windrower operation with the Operator and cab facing in the direction of travel. Cab Display Module Double Windrow Attachment Engine-Forward Windrower operation with the Operator and engine facing in the direction of travel. Intermediate Speed Control N-DETENT The slot opposite the NEUTRAL position on Operator’s console.

  • Page 11: Step 1. Unload Windrower

    UNLOADING AND ASSEMBLY STEP 1. UNLOAD WINDROWER CAUTION To avoid injury to bystanders from being struck by machinery, do not allow persons to stand in unloading area. A. TWO FORKLIFT METHOD CAUTION Equipment used for unloading must meet or exceed the requirements specified below. Using inadequate equipment may result in chain breakage, vehicle tipping or machine c.

  • Page 12: Single Forklift Methods

    UNLOADING AND ASSEMBLY e. Install chains from forklift mast to jacking brackets B. SINGLE FORKLIFT METHODS on both front legs of windrower. Chains must be the same length. There are two methods that can be used. CAUTION METHOD 1 CAUTION The front legs rest on the trailer bed on skid shoes.
  • Page 13 UNLOADING AND ASSEMBLY c. Position forklift on left or right side of trailer, and position forks under windrower frame. NOTE Windrower center gravity approximately 55 inches (1397 mm) rearward of drive wheel center. WARNING Ensure forks project beyond far side of frame. d.

  • Page 14: Step 2. Re-Position Rh Leg

    UNLOADING AND ASSEMBLY STEP 2. RE-POSITION RH LEG Only right cab-forward requires re-positioning from shipping to field configuration. d. Adjust jack height while observing pin position in bore. When pin is loosest, tap out pin with hammer or use tool (shown at the bottom of the previous column) to extract pin.

  • Page 15: Step 3. Install Front Wheels

    UNLOADING AND ASSEMBLY STEP 3. INSTALL FRONT STEP 4. RE-POSITION CASTER WHEELS WHEELS LIFT HERE a. Raise rear of windrower slightly so that most of the weight is off the casters, using a jack or other lifting device under the frame where shown. NOTE Lifting device should have a lifting capacity of at least 5000 lb (2270 kg).

  • Page 16: Step 5. Install Steps

    UNLOADING AND ASSEMBLY STEP 5. INSTALL STEPS WIDEST TREAD WIDTH SHOWN a. Remove two bolts securing steps to platform, and remove steps. IMPORTANT b. Remove the one existing upper bolt. Caster wheels must be equi-distant from center of windrower. c. Re-install one bolt in lower hole in platform. Do not thread in fully.

  • Page 17: Step 6. Install Batteries

    UNLOADING AND ASSEMBLY STEP 6. INSTALL BATTERIES IMPORTANT a. Batteries should meet the following specification: BATTERY IS NEGATIVE GROUNDED. Always connect starter cable to the positive RATING GROUP CCA VOLT MAX. DIMENSION (+) terminal of battery and battery ground cable to negative (-) terminal of battery. Heavy Reversed polarity in battery or alternator Duty,...

  • Page 18: Step 7. Install Am/Fm Radio

    UNLOADING AND ASSEMBLY STEP 7. INSTALL AM/FM RADIO Provision has been made for installation of AM/FM d. Remove the cut-out by cutting the tabs (B) in the radio. The mounting is designed to fit a DIN E panel. Remove sharp edges on panel. style radio with a depth of ‘X’...

  • Page 19: Step 8. Install Slow Moving Vehicle (Smv) Sign

    UNLOADING AND ASSEMBLY STEP 8. INSTALL SLOW h. Attach two additional wires in the wiring harness to the radio: MOVING VEHICLE 1. Circuit 503: Red with 1/4 in. female blade (SMV) SIGN terminal. This is a live wire provided for powering a radio clock/memory (if these exist on your radio).

  • Page 20: Step 9. Attach Header

    STEP 9. ATTACH HEADER A. HEADER ATTACHMENT: D SERIES CONFIGURE HYDRAULICS M205 and M155 windrowers must be fitted with a draper drive basic kit and a completion kit to operate the D-Series draper headers. DRAPER HEADER REEL HYDRAULICS Windrowers equipped with D-Series hydraulics have four header drive hoses on the LH side, and up to five reel drive hoses on the RH side.
  • Page 21 UNLOADING AND ASSEMBLY II. ATTACH HEADER BOOTS IMPORTANT b. Locate boot (D) on lift linkage (E), and re-install To prevent damage to the lift system when pin (C). Pin may be installed from either side of lowering header lift linkages without a boot.
  • Page 22 UNLOADING AND ASSEMBLY III. ATTACH HEADER 1. If the optional center link self-alignment kit is a. Remove hairpin on pins (F), and remove pins from installed, activate the REEL UP switch on the header legs. GSL to raise the center link (G). CAUTION Check to be sure all bystanders have cleared the area.
  • Page 23 4. Proceed to step f. on next page. HYDRAULIC LINK WITHOUT SELF-ALIGNMENT KIT (M205 STANDARD, M155 OPTIONAL) 1. Activate HEADER TILT cylinder switches on GSL to extend or retract center-link cylinder (G) so that the hook lines-up with the header attachment pin.
  • Page 24 UNLOADING AND ASSEMBLY MECHANICAL LINK (M155 OPTIONAL) g. If engine is not running, start engine, and press HEADER UP switch to raise header to maximum height. WARNING NOTE Stop windrower engine, and remove key If one end of the header does not raise fully, before making adjustments to machine.
  • Page 25 UNLOADING AND ASSEMBLY WARNING Stop windrower engine, and remove key before making adjustments to machine. A child or even a pet could engage the drive. h. Install pin (F) through header leg, (engaging U-bracket in lift linkage) on both sides, and secure with hairpin.

  • Page 26: Header Attachment: A Series

    MacDon Dealer, and install it in accordance with (continued next page) the instructions supplied with the kits. KIT DESCRIPTION KIT NUMBER Basic Drive B5491 Completion/Reverser B5492 The M155 is factory-equipped to run the A-Series auger headers. Form 169540 Revision B...
  • Page 27 UNLOADING AND ASSEMBLY CAUTION Check to be sure all bystanders have cleared the area. REEL DOWN REEL UP HEADER UP HEADER TILT UP 2. Without the self-alignment kit, re-locate the pin HEADER (G) at the frame linkage as required to raise TILT DOWN the center link (E).
  • Page 28 4. Proceed to step f. on next page. HYDRAULIC LINK WITHOUT SELF-ALIGNMENT KIT (M205 STANDARD, M155 OPTIONAL) 1. Activate HEADER TILT cylinder switches on GSL to extend or retract center-link cylinder (E) so that the hook lines-up with the header attachment pin.
  • Page 29 UNLOADING AND ASSEMBLY MECHANICAL LINK (M155 OPTIONAL) WARNING 1. Stop engine, and remove key from ignition. Stop windrower engine, and remove key before making adjustments to machine. A child or even a pet could engage the drive. DANGER To avoid bodily injury from fall of raised...
  • Page 30 UNLOADING AND ASSEMBLY h. Install pin (N) through each boot and foot, and m. Remove pin (Q) from “storage position” in linkage, secure with hairpin. and insert in hole (R) to engage float springs. Secure with lynch pin. IMPORTANT Ensure pin (N) is fully inserted, and hairpin is installed behind bracket.
  • Page 31 UNLOADING AND ASSEMBLY WARNING Stop windrower engine, and remove key before making adjustments to machine. A child or even a pet could engage the drive. q. Stop engine, and remove key. Connect header drive hydraulics (S) and electrical harness (T) to header. Refer to Auger Header Operator’s Manual.

  • Page 32: Header Attachment: R Series

    (D). (continued next page) KIT B5510 The M155 windrower operates only the R85 and R80 13 FT headers, and these headers need to be equipped with Kit B5510 (motor and hoses). To operate these headers, the M155 windrower requires the installation of hydraulic valve Kit B4657.
  • Page 33 UNLOADING AND ASSEMBLY CAUTION Check to be sure all bystanders have cleared the area. REEL DOWN REEL UP HEADER UP HEADER TILT UP 2. Without the self-alignment kit, re-locate the pin HEADER (G) at the frame linkage as required to raise TILT DOWN the center link (E).
  • Page 34 UNLOADING AND ASSEMBLY Connect center-link: HYDRAULIC LINK WITHOUT SELF-ALIGNMENT KIT (M205 STANDARD, M155 OPTIONAL) HYDRAULIC LINK WITH OPTIONAL 1. Activate HEADER TILT cylinder switches on SELF-ALIGNMENT KIT GSL to extend or retract center-link cylinder (E) so that the hook lines-up with the header attachment pin.
  • Page 35 UNLOADING AND ASSEMBLY MECHANICAL LINK (M155 OPTIONAL) CAUTION WARNING Check to be sure all bystanders have cleared the area. Stop windrower engine, and remove key before making adjustments to machine. A child or even a pet could engage the drive.
  • Page 36 UNLOADING AND ASSEMBLY DANGER To avoid bodily injury from fall of raised header, always engage header lift cylinder stops when working on or around raised header, and before going under header for any reason. h. Cylinder stops are located on both header lift cylinders on the windrower.

  • Page 37: Step 10. Lubricate Machine

    UNLOADING AND ASSEMBLY CAUTION STEP 10. LUBRICATE MACHINE Check to be sure all bystanders have cleared Recommended Lubricant: the area. SPEC DESCRIPTION High Temperature Extreme Pressure (EP2) HEADER UP As Required Performance With Unless 1% Max Molybdenum Multi- Otherwise Purpose Disulphide Specified.
  • Page 38 UNLOADING AND ASSEMBLY Lubrication Points (cont’d) High Temperature Extreme Pressure (EP2) Performance With 1% Max Molybdenum Disulphide (NLGI Grade 2). Lithium Base. TOP LINK - TWO FITTINGS (BOTH SIDES) WALKING BEAM PIVOT) FORMED CASTER WHEEL BEARING 1 PLACE (BOTH WHEELS) CASTER PIVOT (BOTH SIDES) FORKED CASTER SPINDLE BEARINGS...

  • Page 39: Step 11. Program Cab Display Module (Cdm)

    Displays Menu Item and Selection Displays Software Revision Status Upper Line - Menu Item Upper Line - C### (CDM) Lower Line - Selection Lower Line - M### (WCM) for M155 OR X### for M205. SELECT SWITCH Places Monitor into Program Mode with PROGRAM Switch Press to Accept Menu Item and Advance to Next Item.
  • Page 40 DETAILED PROGRAMMING INSTRUCTIONS IMPORTANT: ENGINE MUST BE RUNNING TO CALIBRATE SENSORS For M155 with 4 cylinder Cummins, second line software version code displays as Mxxx. For M205 with 6 cylinder Cummins, second line software version code displays as Xxxx. Programming Menu Flow Chart If "NO"...
  • Page 41 UNLOADING AND ASSEMBLY C x x x || P R E S S H A Z A R D S E T This is used to set the Intermediate Speed M x x x || I S C R P M O F F Control function for the engine.
  • Page 42 UNLOADING AND ASSEMBLY LOCKOUTS? menu selection. C x x x || K N I F E S P E E D M x x x || 5 7 5 . 1 H R S E N A B L E D M x x x || 6 4 8 .
  • Page 43 UNLOADING AND ASSEMBLY C x x x || H D R T I L T S E N S O R C A L The display will indicate the sensor being calibrated. The M x x x || E X T E N D operator will be prompted to extend the header tilt and HOLD T L T S T A R T...
  • Page 44 T E M P S E N S O R with the Sensata oil temp. sensor. M155 model with the Sensata oil temp. sensor. M x x x || E N A B L E / D I S A B L E C x x x || E X I T If "NO"...
  • Page 45 UNLOADING AND ASSEMBLY C x x x || A C T I V A T E F U N C T I O N S ? If "NO" then jump to: M x x x || N O / Y E S F O R C E H E A D E R T Y P E ?

  • Page 46: Step 12. Perform Pre-Delivery Checks

    PRE-DELIVERY CHECKS C. TIRE PRESSURE AND BALLAST STEP 12. PERFORM PRE- DELIVERY CHECKS TIRE PRESSURES Measure tire pressure with a gauge. WARNING TIRE TYPE SIZE PRESSURE Stop windrower engine, and remove key 18.4 - 26 32 psi (221 kPa) before making adjustments to machine. A child or even a pet could engage the drive.

  • Page 47: Engine Coolant

    PRE-DELIVERY CHECKS RECOMMENDED BALLAST HEADER DESCRIPTION LEVEL GROUND HILLS RECOMMENDED BOTH BOTH PER TIRE PER TIRE TIRE SIZE TIRES TIRES TYPE SIZE U.S. Gal. U.S. Gal. lb (kg) * lb (kg) * (Liters) (Liters) A Series 7.5 X 16 R Series 25 FT and Down 10 X 16 30 FT Single or Split Reel...

  • Page 48: Air Cleaner

    PRE-DELIVERY CHECKS b. Check spring clamps (A) on charge air cooling duct connections (at turbocharger outlet, engine E. AIR CLEANER intake, and inside cooling box). a. Check that air cleaner cap is firmly attached, and that all clamps are secure. 0.157 +/-.02 in.

  • Page 49: Fuel Separator

    PRE-DELIVERY CHECKS H. GEAR BOX LUBRICANT LEVEL G. FUEL SEPARATOR a. Remove plug (D). Lubricant should be visible A fuel water separator is incorporated into the through the hole, or slightly running out. primary fuel filter (A). The separator is equipped with a sensor (B) (that detects water in the fuel, b.

  • Page 50: Perform Safety System Checks

    PRE-DELIVERY CHECKS 2. Pry the steering interlock away from pintle J. PERFORM SAFETY SYSTEM arms by inserting a wedge or pry bar between one of the interlock channels and pintle arm. CHECKS 3. Insert a wood block approximately 3/4 inch Ensure battery main disconnect switch is switched (19 mm) thick between the other channel and to POWER ON position.

  • Page 51: Operational Checks

    PRE-DELIVERY CHECKS K. OPERATIONAL CHECKS A battery main disconnect switch is located on the (cab-forward) frame rail, behind e. Push HEADER DRIVE switch (C) to OFF. maintenance platform, and can be accessed by Normal Start: engine temperature above 60°F moving the platform. Ensure switch is switched to (16°C): POWER ON position.
  • Page 52 1. Follow procedure for Normal Start (on locked. Ensure lock is engaged. previous page). Neutral interlock Contact MacDon Dealer. 2. Engine will cycle through a period where it misadjusted. appears to labor until engine warms up. Fill empty fuel tank.
  • Page 53 With windrower moving at more than 5 mph WINDROWER IDLE MAX RPM (No Load) (8 km/h): 1. Stand up out of the seat. M155 2320 - 2350 2. The CDM beeps once, and displays “NO 1075 - 1150 M205 2250 - 2340 OPERATOR”...
  • Page 54 PRE-DELIVERY CHECKS VII. EXTERIOR LIGHTS c. Switch ROAD lights ON, and check that all lights a. Ensure Operator’s seat is locked in cab-forward are functioning as shown below. mode. b. Switch FIELD lights ON, and check that all lights are functioning as shown below. FIELD LIGHTS HIGH / LOW - ROAD TURN SIGNALS / HAZARDS - AMBER...
  • Page 55 PRE-DELIVERY CHECKS g. Rotate Operator’s seat to engine-forward mode. VIII. BEACON (If Installed) h. Switch ROAD lights ON, and check that all lights are functioning as shown below. TURN SIGNALS / HAZARDS - AMBER BEACON LIGHTS - AMBER TAIL / BRAKE LIGHTS - RED a.

  • Page 56: Manuals

    Cab Air Is Recirculated  Parts Catalog: See below.  Operator’s Manual: See below.  Windrower Quick Card: M155 - Form 169565 AIR CONDITIONING SWITCH M205 - Form 169475 Controls A/C System  OFF - A/C Does Not Operate. Warranty Documents.
  • Page 57 NOTES Form 169540 Revision B...
  • Page 58 MacDon Inc. 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.
  • Page 59 M155 and M205 Self-Propelled Windrower Pre-Delivery Checklist Perform these checks and adjustments prior to delivery to your Customer. The completed Checklist should be retained either by the Operator or the Dealer. CAUTION: Carefully follow the instructions given. Be alert for safety related messages which bring your attention to hazards and unsafe practices.

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