MacDon M155 User manual

The harvesting specialists.
M155
Self-Propelled Windrower
Oil Cooler Bypass Kit (MD #183518) Installation Instructions
147595 Revision B
Original Instruction

Published: January 2016

Introduction
The Oil Cooler Bypass kit (MD #183518) is used to replace the cooler bypass manifold and the hardware on the
wheel motor servo on an M155 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.
Installation Time
Installation time for this kit is approximately six hours.
Conventions
The following conventions are followed in 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 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.
147595 iRevision B

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
Created topic. 3.1.5 Testing Cooler Bypass Pressure, page 12
147595 ii Revision B

TABLE OF CONTENTS
Introduction...................................................................................................................................... i
List of Revisions ...............................................................................................................................ii
1 Safety.................................................................................................................................................... 1
1.1 Signal Words................................................................................................................................... 1
1.2 General Safety ................................................................................................................................ 2
2 Parts List............................................................................................................................................... 5
3 Installation Instructions ........................................................................................................................ 9
3.1 Cooler Bypass Manifold ................................................................................................................... 9
3.1.1 Preparing Kit Components for Installation .................................................................................. 9
3.1.2 Changing the Hydraulic Oil ....................................................................................................... 9
3.1.3 Replacing Cooler Bypass Manifold.......................................................................................... 10
3.1.4 Refilling Hydraulic Reservoir ................................................................................................... 12
3.1.5 Testing Cooler Bypass Pressure.............................................................................................. 12
3.2 Wheel Drive Motor Servo Hardware (2014 and Prior Only)............................................................... 14
3.2.1 Removing Drive Wheel........................................................................................................... 14
3.2.2 Replacing Servo Hardware.....................................................................................................15
3.2.3 Reinstalling Drive Wheel......................................................................................................... 19
147595 iii Revision B

1Safety
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. 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.
147595 1Revision B

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.
Don’t 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
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 against objectionable or loud noises.
Figure 1.2: Safety Equipment
• Provideafirstaidkitforuseincaseofemergencies.
• Keep a fire extinguisher on the machine. Be sure the
fire extinguisher is properly maintained. Be familiar with
its proper use.
• Keep young children away from the machinery at
all times.
• Be aware that accidents often happen when the
Operator is tired or in a hurry. Take the time to
consider the safest way. Never ignore the warning
signs of fatigue.
Figure 1.3: Safety Equipment
147595 2Revision B

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.
• Use only service and repair parts made or approved by
the equipment manufacturer. Substituted parts may not
meet strength, design, or safety requirements.
Figure 1.4: Safety around Equipment
• Keep hands, feet, clothing, and hair away from moving
parts. Never attempt to clear obstructions or objects
from a machine while the engine is running.
•DoNOT modify the machine. Non-authorized
modifications may impair machine function and/or
safety. It may also shorten the machine’s life.
• To avoid bodily injury or death from unexpected startup
of machine, always stop the engine and remove the
key from ignition before leaving operator’s seat for
any reason.
Figure 1.5: Safety around Equipment
• Keep the 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. Figure 1.6: Safety around Equipment
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2PartsList
The following parts are included in this kit.
147595 5Revision B

PARTS LIST
Figure 2.1: Parts Included in Oil Cooler Bypass Kit (MD #183518)
147595 6Revision B

PARTS LIST
Ref Part Number Description Quantity
1 183494 MANIFOLD – COOLER BYPASS 1
2 21031 FITTING – ADAPTER HYDRAULIC 1
3 183493 HOSE 1
4 134437 FITTING – COUPLING HYDRAULIC TEST PORT 2
5 50086 FITTING – HYDRAULIC TEE 1
A 136652 SCREW – HEX SOC HD M6 X 1.00 X 20-12.9-A2L 16
147595 7Revision B

3 Installation Instructions
To install the Oil Cooler Bypass kit (MD #183518), follow these procedures in order.
IMPORTANT:
Do NOT attempt to install the Oil Cooler Bypass kit in the field. The hydraulic hose and fittings must be kept clean
during installation to avoid hydraulic system damage.
IMPORTANT:
Protect the ends of hoses, fittings, and ports from contamination with clean, lint-free towels or clean plastic bags.
3.1 Cooler Bypass Manifold
3.1.1 Preparing Kit Components for Installation
To prepare the cooler bypass manifold components for installation, follow these steps:
1. As shown in the illustration at right, attach the two test
port fittings (MD #134437) (A) to ports CRG and CPG
on the new cooler bypass manifold (MD #183494) (B).
All parts are provided in the kit.
2. Attach the adapter fitting (MD #21031) (C) provided in
the kit to port DR on the manifold.
Figure 3.1: New Cooler Bypass Manifold with
Fittings
3.1.2 Changing the Hydraulic Oil
DANGER
To avoid bodily injury or death from 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.
To drain hydraulic oil, follow these steps:
147595 9Revision B

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.
4. Place a clean container (at least 20 US gallons
[75 liters]) under drain at the bottom of the hydraulic
reservoir to collect the oil.
5. Remove drain plug (A) and allow oil to drain.
6. Inspect particles and clean off any metal debris that
may have accumulated on magnetic plug. Wipe plug
with a clean cloth. Check O-ring condition. Look for
cracking, breakage, or deformation that may impede
sealing ability and replace as required.
7. Install drain plug (A), torque to 59 ft·lbf (80 N·m).
Figure 3.2: Hydraulic Oil Drain Plug
3.1.3 Replacing Cooler Bypass Manifold
To replace the cooler bypass manifold, follow these steps:
1. At the bottom of the hydraulic reservoir, detach
hose (A) from elbow fitting (B).
2. Remove elbow fitting (B) and replace with hydraulic tee
fitting (MD #50086) from the kit. Discard elbow fitting.
Figure 3.3: Bottom LH End of Hydraulic
Reservoir
147595 10 Revision B

INSTALLATION INSTRUCTIONS
3. Reattach hose (A) from the reel and conveyor pump to
the middle of the new tee fitting (B).
4. Attach hose (MD #183493) (C), provided in kit, to the
open end of tee fitting (B).
Figure 3.4: Bottom LH End of Hydraulic
Reservoir
5. On the left side of the windrower, inside the frame,
attach a cable tie (not provided in kit) to hose (A) or
mark the hose to ensure that you remember where to
reattach it later.
6. Disconnect hoses and lines (A) and (D)attached to the
existing cooler bypass manifold (B).
7. Disconnect the existing cooler bypass manifold (B)
from the filter (C) next to it.
8. One at a time, transfer fittings from the old manifold (B)
to the new manifold (MD #183494) provided in the kit.
Fittings should be positioned as shown in Figure 3.6:
Hydraulic Ports on New Cooler Bypass Manifold, page
11. Discard the old manifold.
9. Install the new manifold in place of the old. Port F on
the new manifold connects to the filter head.
Figure 3.5: Inside LH Frame (View from Below)
10. Connect the hoses and lines disconnected in Step 6.,
page 11 to the new manifold as follows:
• Port CR – the cooler return hose
• Port CP – the hose from the oil cooler marked in
Step 5., page 11
• Port A – the steel line from Port T2 on the
multifunction control block
• Port B –the5/8in. hosefrom the inboardgear pump
• Port P2 – the 1/4 in. hose from the lift manifold block
11. Attach the new hose from Step 4., page 11 to the
adapter fitting in Port DR of the new manifold. Figure 3.6: Hydraulic Ports on New Cooler
Bypass Manifold
147595 11 Revision B

INSTALLATION INSTRUCTIONS
3.1.4 Refilling Hydraulic Reservoir
To refill the hydraulic reservoir, follow these steps:
1. Stand on left-hand platform to access the filler pipe.
2. Turn filler cap (A) counterclockwise to unlock cap and
remove dipstick.
Figure 3.7: Windrower Hood
3. Add oil to maintain a level between the LOW and FULL
marks, and make sure that no debris falls into the
reservoir.
•Oil type: SAE 15W-40 compliant with SAE specs
for API Class SJ and CH-R engine oil
•Reservoir capacity: 17.2 U.S. gallons (66 liters)
4. Reinstall dipstick and filler cap, and turn clockwise to
tighten/lock.
5. Close the hood. Forinstructions, refer tothe windrower
operator’s manual or technical manual.
Figure 3.8: Hydraulic Oil Level
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.
147595 12 Revision B

INSTALLATION INSTRUCTIONS
1. To measure CR pressure, attach a 1000 psi (7000 kPa)
pressure gauge to the test fitting at port CRG (A).
2. To measure CP pressure, do one of the following:
• Attach a 1000 psi (7000 kPa) pressure gauge to the
test fitting at port CPG (B); OR
• Attach a flow meter capable of reading flow as high
as 28 gpm (106 lpm) and a 1000 psi (7000 kPa)
pressure gauge between port CP and cooler. The
test equipment must attach to the #12 JIC fitting at
port CP on the cooler bypass manifold.
3. Start engine and run at high idle (wide open throttle)
until hydraulic oil temperature is between 135–145°F
(57–63°C). If using a flow meter, the reading should be
between 20–24 gpm (76–91 lpm).
4. Record CP and CR pressures. CP pressure should be
between 500–605 psi (3447–4171 kPa).
5. If CP pressure is not between 500–605 psi
(3447–4171 kPa), adjust pressure by removing cap (C)
and increasing or decreasing cooler bypass setting by
turning adjustment screw.
NOTE:
CR pressure is not adjustable.
6. When CP pressure is in the correct range, subtract the
CR pressure reading from the CP pressure reading.
The differential pressure should range between
80–200 psi (552–1380 kPa). A differential pressure
lower than 80 psi (552 kPa) indicates a possible
defective hydraulic cooler.
Figure 3.9: Hydraulic Ports on New Cooler
Bypass Manifold
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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. Follow the remaining procedures twice: once for the right-hand wheel drive and once for
the left-hand wheel drive.
NOTE:
These procedures are NOT required for 2015 windrowers. The motors on these windrowers already have
the required hardware.
3.2.1 Removing Drive Wheel
To remove the drive wheel, follow these steps:
CAUTION
To avoid bodily injury or death from unexpected
startup of machine, always stop engine and remove
key from ignition before leaving operator’s seat for
any reason.
1. Place ground speed lever (GSL) in N-DETENT (A),
shut down engine, and remove key.
Figure 3.10: Ground Speed Lever
CAUTION
Jack stand must be capable of supporting a minimum
of5000lb.(2268kg).
2. Place a jack under the leg jack point (A), and raise the
drive wheel until it is slightly off ground. Place a jack
stand beneath the lift cylinder mount (B).
NOTE:
Do NOT place jack stand under the cylinder. Use a
small metal plate on top of the jack stand.
3. Lower the windrower onto the jack stand.
Figure 3.11: Drive Wheel Jack Point
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