MacDon M155 User manual

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

M155 Self-Propelled Windrower
1000141
Published in June 2019
© 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
information in this publication. MacDon Industries, Ltd. reserves the right to make changes at any time without notice.

Introduction
1005500
A
Figure 1: HID Auxiliary Lighting
Some M155, M155E4, and M205 Self-Propelled Windrowers
from model year 2015 or earlier that are configured with the
high intensity discharge (HID) auxiliary lighting option (A)
experience flickering of lights and overheating of the fuse block.
The Auxiliary Lighting Harness Repair kit (MD #167693) can be
used to correct these issues.
This document explains how to install the kit. A list of parts
included in the kit is 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 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 currently available in English only.
147762 iRevision C

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. 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 #167969 in illustration
and parts list.
ECN 58263
3.3 Installing Fuse Box Decals and
Breaker, page 20
Replaced decal MD #167637 with decal MD #167969. ECN 58263
3.4 Checking Operation of Lights,
page 22
Added further detail to instruction to check voltage. Current
Products
147762 ii Revision C

147762 iii Revision C
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............................................................................................... 16
3.3 Installing Fuse Box Decals and Breaker ..................................................................................................... 20
3.4 Checking Operation of Lights .................................................................................................................. 22
TABLE OF CONTENTS

147762 1Revision C
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.
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.
IMPORTANT:
Indicates a situation that, if not avoided, could result in a malfunction or damage to the machine.
NOTE:
Provides additional information or advice.

147762 2Revision C
1.2 General Safety
1000004
Figure 1.1: Safety Equipment
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. Do NOT 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
1000005
Figure 1.2: Safety Equipment
•Be aware that exposure to loud noises can cause hearing
impairment or loss. Wear suitable hearing protection devices
such as earmuffs or earplugs to help protect against loud
noises.
1010391
Figure 1.3: Safety Equipment
•Provide a first aid kit in case of emergencies.
•Keep a properly maintained fire extinguisher on the machine.
Be familiar with its proper use.
•Keep young children away from machinery at all times.
•Be aware that accidents often happen when the operator is
tired or in a hurry. Take time to consider safest way. NEVER
ignore warning signs of fatigue.
SAFETY

147762 3Revision C
1000007
Figure 1.4: Safety around Equipment
•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.
•Use only service and repair parts made or approved by
equipment manufacturer. Substituted parts may not meet
strength, design, or safety requirements.
1000008
Figure 1.5: Safety around Equipment
•Keep hands, feet, clothing, and hair away from moving parts.
NEVER attempt to clear obstructions or objects from a
machine while engine is running.
•Do NOT modify machine. Unauthorized modifications may
impair 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 leaving the operator’s seat for any reason.
1000009
Figure 1.6: Safety around Equipment
•Keep 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.
SAFETY

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

147762 6Revision C
Figure 2.1: Auxiliary Lighting Harness Repair Kit Parts
1029865
AB
1
2
3
4
5
6
7
8
PARTS LIST

147762 7Revision C
Ref
Part
Number Description Quantity
1 134762 BREAKER –MAXI TYPE 1 25 AMPS 1
2 167969 DECAL –M INLINE FUSES 1
3 183562 DECAL –FUSE M155/M205 ENGLISH 1
4 183563 DECAL –FUSE M155/M205 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
8167635 TUBE –HEAT SHRINK 3/8 X 1-1/4 1
9 183558 HARNESS –AUX LIGHTS CHASSIS (not illustrated) 1
10 183559 HARNESS –AUX LIGHTS ROOF (not illustrated) 1
A18577 SCREW –MACH PHILIPS PAN HD #10 NC X 3/4 1
B21492 NUT –FLG (SERR FACE) #10 NC GR 5 ZP 1
PARTS LIST

147762 9Revision C
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. Stop the engine and remove the key.
2. Open the right platform. For instructions, refer to the windrower 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 Harness
To install the auxiliary lighting roof harness (MD #183559) 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. Use them as needed.
1013916
Figure 3.2: Bottom of Right Rear Cab Post
1. Remove the corner post seal from the bottom of the right
rear cab post. Retain for reinstallation.

147762 10 Revision C
1013917
A
Figure 3.3: Air Filter Pan and Filter
2. Remove the fresh air filter pan (A) and filter to reveal an
opening to the cab post. Retain for reinstallation.
1013918
Figure 3.4: Opening in Right Cab Post
3. Move 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 Switch Panel
4. Remove the screws attaching the left and right headliner
switch panels to the headliner. Plug connections can remain
intact and the switch panels can be left hanging. Retain
screws for reassembly.
INSTALLATION INSTRUCTIONS

147762 11 Revision C
1013921
Figure 3.6: Fish Tape Routing
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.
1013924
Figure 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 tape
using electrical tape.
7. Pull the fish tape and harness up through the cab post to
the right headliner switch panel opening. Disconnect the
harness from the fish tape.
1029949
A
B
Figure 3.8: Fish Tape Routing
A - Fish Tape B - Auxiliary Lights roof Harness
8. Run fish tape (A) from the left headliner switch panel
opening over to the right opening.
INSTALLATION INSTRUCTIONS

147762 12 Revision C
1013927
Figure 3.9: Fish Tape and Harness on Left Switch Panel
Opening
9. Attach the harness to the fish tape and pull it around to the
left switch panel opening.
1014079
A
B
Figure 3.10: AUXILLARY 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 socket.
12. Remove the existing AUX LTS wire (B) from terminal 30 of
the relay socket with a small flat screwdriver.
13. Seal the AUX LTS wire (B) with heat shrink material
(included with kit).
INSTALLATION INSTRUCTIONS

147762 13 Revision C
1014081
A
B
Figure 3.12: Relay 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 the relay (A) into place.
INSTALLATION INSTRUCTIONS

147762 14 Revision C
1013919
A
B
Figure 3.15: Headliner Switch Panels
A - Left Switch Panel B - Right Switch Panel
17. Reinstall the left and right headliner switch panels.
1013925
A
Figure 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
A
Figure 3.17: Connectors P2C and C3B
19. Locate connector P2C (A) on the inside of the frame at the
bottom of the right rear cab post. Disconnect this
connector.
INSTALLATION INSTRUCTIONS