MacDon M155, Installation Instructions Manual

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: ...cation 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 th...

Page 3: ...s provided in 2 Parts List page 5 Installation time It will take approximately 1 hour to install this kit Conventions The following conventions are followed in this document Right and left are determi...

Page 4: ...ront cover Added copyright and disclaimer statements Tech Pubs 1 1 Signal Words page 1 Added explanations of IMPORTANT and NOTE Tech Pubs 2 Parts List page 5 Replaced decal MD 167637 with decal MD 167...

Page 5: ...ords 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 16 3 3 Insta...

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Page 7: ...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 agai...

Page 8: ...glasses or goggles Heavy gloves Wet weather gear Respirator or filter mask 1000005 Figure 1 2 Safety Equipment Be aware that exposure to loud noises can cause hearing impairment or loss Wear suitable...

Page 9: ...r machine function and or safety It may also shorten machine s life To avoid injury or death from unexpected startup of machine ALWAYS stop the engine and remove the key from the ignition before leavi...

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Page 11: ...147762 5 Revision C Chapter 2 Parts List The following parts are included in this kit...

Page 12: ...147762 6 Revision C Figure 2 1 Auxiliary Lighting Harness Repair Kit Parts 1029865 A B 1 2 3 4 5 6 7 8 PARTS LIST...

Page 13: ...05 RUSSIAN 1 5 183567 DECAL FUSE BLK M155E4 ENGLISH 1 6 21763 FASTENER CABLE TIE BLACK 160 MM LONG 4 7 30753 FASTENER CABLE TIE BLACK 305 MM LONG 2 8 167635 TUBE HEAT SHRINK 3 8 X 1 1 4 1 9 183558 HAR...

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Page 15: ...indrower operator s manual or technical manual 1014016 A Figure 3 1 Battery Main Disconnect Switch 3 Turn the battery main disconnect switch A to POWER OFF 3 1 Installing Auxiliary Lighting Roof Harne...

Page 16: ...wiring connections out of the way to make it easier to feed the new auxiliary lighting roof harness through the cab post 1013919 A B Figure 3 5 Headliner Switch Panels A Left Switch Panel B Right Swit...

Page 17: ...gure 3 7 Harness and Fish Tape 6 Below the right rear corner post attach the female spade terminal labelled AUX LTS TO AUXILIARY LTS RELAY 30 from the new auxiliary lights roof harness to the fish tap...

Page 18: ...UXILLARY LTS Relay and Socket 10 In the left headliner switch panel remove the AUXILLARY LTS relay A from its socket B 1014080 A B Figure 3 11 Relay Socket 11 Remove terminal lock A from the relay soc...

Page 19: ...Socket 14 Push the repair harness wire A into terminal 30 on the relay socket B 1014083 A Figure 3 13 Relay and Socket 15 Reinstall the terminal lock A 1014084 A Figure 3 14 Relay and Socket 16 Press...

Page 20: ...3 16 Windrower Frame Directly below the Right Rear Cab Post 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 1013958...

Page 21: ...A from the connector 1013956 A Figure 3 19 P2C Connector 21 Remove plug A from position 4 on the connector 1018684 A Figure 3 20 Deutsch Pin and P2C Connector 22 In place of the plug insert Deutsch p...

Page 22: ...mount the fuse holder A of the auxiliary lighting chassis harness MD 183558 in an existing hole inside the right frame rail in between the hole leading to the battery and the battery main disconnect...

Page 23: ...age 14 C3B remove terminal lock A 1013952 A Figure 3 25 C3B Connector 7 Remove the plug from position 4 A on the connector 1013951 Figure 3 26 Deutsch Socket and C3B Connector 8 In place of the plug i...

Page 24: ...or with Terminal Lock in Place 9 Reinstall the terminal lock A 1013949 Figure 3 28 Harness Connected to C3B 10 Couple the connector 1013917 A Figure 3 29 Air Filter Pan and Filter 11 Replace the fresh...

Page 25: ...147762 19 Revision C 1013916 Figure 3 30 Bottom of Right Rear Cab Post 12 Reinsert the corner post seal into the bottom of the right rear cab post INSTALLATION INSTRUCTIONS...

Page 26: ...134762 in slot F4 1013967 Figure 3 33 M155 M205 English Fuse Box Decal MD 183562 5 The kit includes three fuse box decals Select the one that is appropriate for this machine decals have a model number...

Page 27: ...e box cover b Place the new decal in position Slowly peel off the backing paper smoothing the decal as it is applied c Prick small air pockets with a pin and smooth out 7 Reinstall the fuse box cover...

Page 28: ...column c Turn steering wheel counterclockwise to pivot operator s station clockwise 180 until pin engages latch to secure operator s station in new position 1000583 Figure 3 37 Field Light Switch in C...

Page 29: ...result when swiveling operator s station b Pull up on knob B and hold to release latch C at base of steering column c Turn steering wheel clockwise to pivot operator s station counterclockwise 180 un...

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Page 32: ...16 891 7313 f 816 891 7323 LLC MacDon Russia Ltd 123317 Moscow Russia 10 Presnenskaya nab Block C Floor 5 Office No 534 Regus Business Centre t 7 495 775 6971 f 7 495 967 7600 MacDon Australia Pty Ltd...

Page 33: ...The harvesting specialists M155E4 Self Propelled Windrower Update Kit MD 167728 Installation Instructions 167730 Revision B Original Instruction...

Page 34: ...M155E4 Self Propelled Windrower Published in March 2016...

Page 35: ...n this document Right hand RH and left hand LH are determined from the operator s position facing forward with the windrower in cab forward position Unless otherwise noted use the standard torque valu...

Page 36: ...List of Revisions Revision A was never published 167730 ii Revision B...

Page 37: ...or 9 3 2 Installing Traction Drive Test Fittings 12 3 3 Installing Fuse Decal 14 3 4 Replacing Pre cleaner Support 16 3 5 Replacing Fuel and Diesel Exhaust Fluid DEF Display Module 17 3 6 Replacing Di...

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Page 39: ...mminently 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: ...er mask Figure 1 1 Safety Equipment Be aware that exposure to loud noises can cause hearing impairment or loss Wear suitable hearing protection devices such as ear muffs or ear plugs to help protect a...

Page 41: ...ten the machine s life To avoid bodily injury or death from unexpected startup of machine always shut down the engine and remove the key from ignition before leaving operator s seat for any reason Fig...

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Page 43: ...2 Parts List The following parts are included in this kit 167730 5 Revision B...

Page 44: ...PARTS LIST Figure 2 1 M155E4 Update Kit MD 167728 167730 6 Revision B...

Page 45: ...HYD M16X2 4 7 183518 KIT OIL COOLER BYPASS 1 8 167693 KIT HARNESS AUX LTS M155 205 1 1 9 167589 KIT SCREEN CLEANER MOTOR 2 10 167522 KIT CAB SPNSN LIMIT STRAP 1 11 167513 KIT CAB SUSPENSION REAR BUMP...

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Page 47: ...off aspirator assembly C Figure 3 1 Aspirator Duct and Charge Air Cooler CAC Connectors 4 Using an impact gun or air ratchet with 1 2 in socket remove four bolts A and plate B securing aspirator assem...

Page 48: ...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 Figure 3 4 Aspirator Clearance 8 Reinst...

Page 49: ...the way into connector b Position clamp C snug against bead on CAC tube Insert a 018 in 46 mm feeler gauge into middle coils of clamp and tighten bolt on clamp until coils are snug on gauge Figure 3...

Page 50: ...the traction drive pump assembly B Figure 3 8 Location of Three Plugs Figure 3 9 Location of One Plug 2 Using a 3 4 in wrench remove one ORB plug A from the traction drive pump assembly NOTE It may be...

Page 51: ...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 and 3 page 13 until all four plugs have been replaced Figure 3 11 Traction Drive Pump Ass...

Page 52: ...latform 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 Ins...

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 15 Revision B...

Page 54: ...and washers A securing pre cleaner support B to the hood Retain hardware for reinstallation later 5 Remove pre cleaner support B 6 Install the new pre cleaner support included with the kit using the f...

Page 55: ...sole by sliding backwards out of console Be careful not to pull on the electrical connector A protruding from the rear of the DEF display module 3 Unplug the electrical connection A on the rear of the...

Page 56: ...el 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 con...

Page 57: ...ed by non combustible absorbent material like sand and then shovelled to a suitable container for disposal If spilled on tank or any surface of the vehicle rinse thoroughly with water as DEF is corros...

Page 58: ...nk Assembly 9 Pinch shut with clamp or similar means the black and red coolant lines A coming to the DEF head B approximately 6 in 152 mm from head in order to keep engine coolant from draining when h...

Page 59: ...13 Repeat Step 10 page 20 to Step 12 page 21 for the second coolant line D Figure 3 28 Hoses on DEF Head 14 Loosen the gear clamp A on the blue DEF vent hose B 15 Pull the vent hose B away from DEF h...

Page 60: ...F head B Figure 3 31 Hoses on DEF Head 19 Disconnect the wiring harness A going to the DEF head B Cover the exposed connectors on the harness with tape to protect from spills NOTE Part of tank made tr...

Page 61: ...move the tape used to seal the coolant ports and drain the coolant from the DEF head IMPORTANT Take note of the volume of the coolant for refill later Figure 3 34 DEF Assembly 24 Place the new DEF hea...

Page 62: ...ct 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 Figure 3 38 DEF Head 28 Reinstall the blue ve...

Page 63: ...emove the cap B from coolant recovery tank A NOTE For coolant specifications refer to the windrower technical manual 33 Add the same volume of coolant that was drained in Step 23 page 23 34 Close the...

Page 64: ...tion 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...

Page 65: ...should be two wires labeled AUXILIARY LTS an orange wire and a red wire The red auxiliary wire is the updated wiring harness 3 If there is no red wire labeled AUXILIARY LTS on the relay then install...

Page 66: ...S 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 8 Seal the AUXILIARY LTS orange wire C with heat shrink material i...

Page 67: ...he 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...

Page 68: ...MD 167693 Auxiliary Light Harness Kit2 MD 167589 Screen Cleaner Motor Kit MD 167522 Cab SPNSN Limit Strap Kit MD 167513 Cab Suspension Rear Bumper Kit 2 Some model year 2015 units may have this kit al...

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Page 70: ...04 885 5590 f 204 832 7749 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 1...