MacDon M155E4 User manual

M155E4
Self-Propelled Windrower
DEF Head Service Kit (MD #183997) Installation Instructions
215233 Revision B
Original Instruction
The Harvesting Specialists.

M155E4 Self-Propelled Windrower, featuring Dual Direction®and Ultra Glide®suspension.
1011662
Published May 2020
© 2020 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
The DEF Head Service kit (MD #183997) is for 2018 and prior M155E4 Self-Propelled Windrowers that require DEF head
replacement.
This document explains how to install the kit. A list of parts included in the kit is provided in Chapter 2 Parts List, page 5.
NOTE:
A complete list of serviceable parts is included in 2.1 Serviceable Parts, page 6. Please provide these pages to the end user
to ensure they have the correct list of serviceable parts for this DEF head and tank.
Installation time
The approximate installation time for this kit is 2 hours.
Conventions
The following conventions are used 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.
215233 iRevision B

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
3.1 Removing DEF Head and Tank
Assembly, page 9
Revised instructions for releasing clips on DEF hoses. Product Support
3.2 Installing DEF Head and Tank
Assembly, page 14
Updated illustration of DEF hose (MD #207770) and deleted the
associated note.
Tech Pubs
3.2 Installing DEF Head and Tank
Assembly, page 14
Corrected electrical connector numbers (P172 and P173 were
reversed).
Product Support
215233 ii Revision B

215233 iii Revision B
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
2.1 Serviceable Parts ....................................................................................................................................6
Chapter 3: Installation Instructions ........................................................................................................... 9
3.1 Removing DEF Head and Tank Assembly.....................................................................................................9
3.2 Installing DEF Head and Tank Assembly .................................................................................................... 14
TABLE OF CONTENTS

215233 1Revision B
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.

215233 2Revision B
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 the 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
In addition, take the following precautions:
•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

215233 3Revision B
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 the engine is running.
•Do NOT modify the machine. Unauthorized modifications
may impair machine function and/or safety. It may also
shorten the machine’s life.
•To avoid 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.
1000009
Figure 1.6: Safety around Equipment
•Keep service area clean and dry. Wet and/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 are
fire hazards. 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

215233 5Revision B
Chapter 2: Parts List
The following parts are included in this kit:
NOTE:
For a complete list of serviceable parts, refer to 2.1 Serviceable Parts, page 6.
1026983
1
2
3
4
5
6
Figure 2.1: Parts Included in Kit
Ref Part Number Description Quantity
1183993 HOSE –HEATER 1
2 183994 HOSE –HEATER 1
3 183995 HOSE –HEATER, SILICONE 1
4207769 HOSE –DEF, BACKFLOW 1
5207770 HOSE –DEF, SUCTION 1
6 NSS1ASSEMBLY –DEF TANK SSI W/ HEAD 1
1. Not sold separately.

215233 6Revision B
2.1 Serviceable Parts
NOTE:
Please provide these pages to the end user to ensure they have the correct list of serviceable parts for this DEF head
and tank.
Below is the complete list of serviceable parts included in kit MD #183997.
1027057
1
2
3
4
5
6
7
8
9
10
11 12
13
14
15
16
17
18
A
B
Figure 2.2: Serviceable Parts
PARTS LIST

215233 7Revision B
Ref Part Number Description Quantity
12074452ASSEMBLY –DEF HEAD, SSI 1
2 291158 GASKET –DEF HEAD 1
3 291159 VALVE –AIR VENT VALVE S/A 1
4291160 FLANGE –SAE 6 HOLE TANK FLANGE 1
5291161 GROMMET –LARGE, DEF HEAD 1
6 291162 HOUSING –LIQUID FILTER, S/A 1
7208917 TANK –DEF SSI 1
8 204101 ASSEMBLY –SCREEN, FILL NECK 1
9 204094 FILL NECK, LESS CAP 1
10 204098 PLUG –DRAIN CW GASKET 1
11 204097 CAP –DEF TANK 1
12 207536 O-RING –DEF TANK FILL NECK 1
13 207534 RETAINER –DEF CAP TETHER 2
14 183993 HOSE –HEATER 1
15 183994 HOSE –HEATER 1
16 183995 HOSE –HEATER, SILICONE 1
17 207769 HOSE –DEF, BACKFLOW 1
18 207770 HOSE –DEF, SUCTION 1
A252203 SCREW –PAN HD ISO 7045 M5 X 0.8 X 20-SS-PLN 4
B136252 SCREW –PAN HD M6 X 1X25-4.8-H-SS 6
PARTS LIST
2. Includes items #2–6.

215233 9Revision B
Chapter 3: Installation Instructions
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.
WARNING
Diesel Exhaust Fluid (DEF) contains urea. Do NOT get the substance in your eyes. In case of contact, immediately flush
eyes with water for a minimum of 15 minutes. Do NOT swallow. In the event the DEF is ingested, contact doctor
immediately.
To install the DEF Head Service kit (MD #183997), follow these steps:
1. Shut down the engine, and remove the key from the ignition.
NOTE:
Wait approximately 1 minute after shutting down the windrower for the DEF supply module to complete the purge
cycle before disconnecting hoses from the DEF tank head.
2. Open the right platform to the standard service position. For instructions, refer to the windrower operator’s manual or
technical manual.
3. Drain the remaining fluid from the DEF tank. For instructions, refer to the windrower operator’s manual or technical
manual.
IMPORTANT:
Any spilled DEF must be contained and absorbed by non-combustible absorbent material like sand, and then shovelled
into a suitable container for disposal. DEF is corrosive. If spilled on tank or any surface of the vehicle, rinse thoroughly
with water.
3.1 Removing DEF Head and Tank Assembly
To remove the existing DEF head and tank assembly, follow these steps:
1012581
A
B
Figure 3.1: DEF Tank
1. Remove two bolts (A) and top cover (B) from the DEF tank.
Retain cover and bolts for the new tank.

215233 10 Revision B
1033099
A
B
C
Figure 3.2: Solenoid Valve Harness
2. Disconnect harness (A) from solenoid valve (B) near the DEF
supply module (C).
1027038
A
B
Figure 3.3: Solenoid Valve
3. Clamp hoses (A) and (B) at the solenoid valve to prevent
coolant loss when replacing hose (B).
1027040
A
B
C
Figure 3.4: Coolant Hoses
4. Clamp hoses (A), (B), and (C) at the fuel injector module tee
to prevent coolant loss when replacing hose (C).
INSTALLATION INSTRUCTIONS

215233 11 Revision B
1012587
A
CB
D
Figure 3.5: DEF Tank Head
5. Disconnect electrical harness (A).
6. Clamp off hoses (B) and (C).
WARNING
The coolant lines are likely full of fluid. Use caution when
disconnecting them from the DEF head.
7. Disconnect coolant hoses (B) and (C) from DEF head (D).
Retain clamps for installing the new hoses.
1023650
A
C
B
D
E
Figure 3.6: DEF Tank Head –Top View
8. The DEF hoses are held on with a plastic retaining clip.
Press the black portion of each clip to expand it, and then
lift DEF backflow hose (A) and DEF suction (inlet) hose (B)
off DEF head (C).
NOTE:
Refer to the illustration below for a closer view of the
plastic retaining clip.
9. Remove lined clamp (D) securing vent hose (E), and
disconnect the vent hose from the DEF head.
1033078
A
Figure 3.7: DEF Hose Connector
NOTE:
The illustration at right is intended to clearly show the
plastic retaining clip (A). The hoses are not exactly
as shown.
INSTALLATION INSTRUCTIONS

215233 12 Revision B
1012589
A
B
Figure 3.8: DEF Tank –Bottom View
10. Remove and retain four bolts (A) from under the DEF tank.
11. Remove the DEF tank from bracket (B).
1026986
CC
B
A
Figure 3.9: DEF Supply Module Connections
12. Disconnect the electrical harnesses on DEF hoses (A)
and (B) from the aftertreatment harness.
13. The DEF hose connectors lock onto the DEF supply module
with plastic retaining clips. Press the clips at locations (C) to
expand them, then lift suction (inlet) hose (A) and backflow
hose (B) from the DEF supply module, and discard
the hoses.
1026998
A
B
Figure 3.10: Solenoid Valve Coolant Hose
14. Remove coolant hose (A) from solenoid valve. Retain
clamp (B) and discard hose.
INSTALLATION INSTRUCTIONS

215233 13 Revision B
C
1027000
A
B
Figure 3.11: Fuel Filter
15. Remove vent hose (A) from filter (B). Retain clamp (C) and
discard hose.
1027002
A
B
C
D
Figure 3.12: Coolant Hoses
16. Cut the cable ties that secure coolant hoses (A) and (B)
together along the inside of the frame and to the battery
cable sleeve.
17. Remove coolant hose (A) (previously disconnected from the
DEF head) from DEF injector module tee (C). Retain
clamp (D) and discard hose.
INSTALLATION INSTRUCTIONS

215233 14 Revision B
3.2 Installing DEF Head and Tank Assembly
To install the new DEF head and tank assembly provided in the kit, follow these steps:
1012589
A
B
Figure 3.13: DEF Tank –Bottom View
1. Position new DEF tank assembly on bracket (B) and install
the four retained bolts (A) from below the tank.
1026987
A
B
C
D
D
Figure 3.14: Vent Hose Installed
2. Install vent hose (A) (MD #183995) from air vent valve (B)
to fuel filter (C), and secure with retained clamps (D).
1027008
A
B
B
Figure 3.15: Coolant Hose (MD #183993) Installed
3. Install coolant IN hose (A) (MD #183993) onto DEF head
and solenoid valve, and secure with retained clamps (B).
INSTALLATION INSTRUCTIONS