MacDon M205 User manual

The harvesting specialists.
M205
Self-Propelled Windrower
Oil Cooler Bypass Kit (MD #183519) Installation Instructions
147611 Revision B
Original Instruction

Published: July 2016

Introduction
The Oil Cooler Bypass kit (MD #183519) is used to replace the cooler bypass manifold and the hardware on the
wheel motor servo on an M205 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)andleft-hand(LH)are determinedfromtheoperator’sposition,facingforwardwiththe 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.
147611 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
Added hose routing information. 3.1.3 Replacing Cooler Bypass Manifold, page 12
Added topic.3.1.5 Testing Cooler Bypass Pressure, page 14
147611 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
Removing Lift Filter......................................................................................................... 10
Installing Lift Filter............................................................................................................11
3.1.3 Replacing Cooler Bypass Manifold.......................................................................................... 12
3.1.4 Refilling Hydraulic Reservoir ................................................................................................... 13
3.1.5 Testing Cooler Bypass Pressure.............................................................................................. 14
3.2 Wheel Drive Motor Servo Hardware (2014 and Prior Only)............................................................... 15
3.2.1 Removing Drive Wheels ......................................................................................................... 15
3.2.2 Replacing Servo Hardware .....................................................................................................16
3.2.3 Reinstalling Drive Wheels....................................................................................................... 20
147611 iiiRevision 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
Indicatesapo
tentially hazardous situation that, if not avoided, could result in death or serious injury. It
mayalsobeuse
d 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.
147611 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. 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
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
•Provideafirst aid kit for use in case of emergencies.
•Keepafire 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
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SAFETY
•Wearclose-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
147611 3Revision B

2PartsList
The following parts are included in this kit.
147611 5Revision B

PARTS LIST
Figure 2.1: Parts Included in Oil Cooler Bypass Kit (MD #183519)
147611 6Revision B

PARTS LIST
Ref Part Number Description Quantity
1 183494 MANIFOLD – COOLER BYPASS 1
2 21031 FITTING – ADAPTER HYDRAULIC 1
3183493 HOSE 1
4134437 FITTING – COUPLING HYDRAULIC TEST PORT 2
530970 FITTING – ELBOW 90° HYDRAULIC 1
A 136652 SCREW – HEX SOC HD M6 X 1.00 X 20-12.9-A2L 16
147611 7Revision B

3 Installation Instructions
To install the Oil Cooler Bypass kit (MD #183519), follow these procedures in order.
IMPORTANT:
DO NOT attempt to install the Oil Cooler Bypass kit in the field. Install the kit in a clean environment; 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:
147611 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 75 liters [20 US
gallons]) under drain at the bottom of the hydraulic
reservoir to collect the oil.
5. Remove drain plug (A) and allow oil to drain.
6. Change the liftfilter. Refer toRemoving Lift Filter, page
10.
7. 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.
8. Install drain plug (A), torque to 80 N·m (59 ft·lbf).
Figure 3.2: Hydraulic Oil Drain Plug
Removing Lift Filter
Change the lift filter at the same time that the hydraulic oil is changed (1500 hours or every two years).
1. Stop engine and remove key.
2. Open the hood.
3. Locate the lift filter (A) below the hydraulic oil reservoir.
4. Place a container underneath the filter to catch any oil
that may leak.
NOTE:
If replacing the filter between oil changes, apply
a vacuum to the supply tank to prevent the oil
from running out of the filter head when the filter
is removed.
5. Clean around head of the filter to prevent
contamination.
6. Unscrew the filter (A) with a filter wrench.
Figure 3.3: Hydraulic System
147611 10 Revision B

INSTALLATION INSTRUCTIONS
7. Remove gasket (C) from groove (B) in filter head (A).
Figure 3.4: Lift Filter
Installing Lift Filter
1. Clean the gasket groove (B) in the filter head (A).
2. Apply a thin film of clean oil to the filter gasket (C).
3. Install new gasket into the groove (B) in the filter
head (A).
4. Screw the new filter (D) onto the filter head until the
gasket contacts the filter.
Figure 3.5: Lift Filter
5. Tightenfilter an additional 3/4 turn by hand.
IMPORTANT:
Do NOT use a filter wrench to install oil filter.
Overtightening can damage gasket and filter.
Figure 3.6: Lift Filter Installed on Hydraulic
Reservoir
147611 11 Revision B

INSTALLATION INSTRUCTIONS
3.1.3 Replacing Cooler Bypass Manifold
To replace the cooler bypass manifold, follow these steps:
1. Remove plug and install new elbow fitting(MD #30970)
(A) in bottom of traction drive pump (B).
2. Attach hose (MD #183493) (C), provided in kit, to the
open end of elbow fitting (A).
Figure 3.7: Hose Connection at Traction Drive
Pump (View from Beneath Windrower)
3. On the left side of the windrower, inside the frame,
attachacabletie(notprovidedinkit)tohose(A)or
mark the hose to ensure that you remember where to
reattach it later.
4. Disconnect the hoses (A) and (D) attached to the
existing cooler bypass manifold (B).
5. Disconnect the existing cooler bypass manifold (B)
from the filter (C) next to it.
6. 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 3.9:
Hydraulic Ports on New Cooler Bypass Manifold, page
12. Discard the old manifold.
7. Install the new manifold in place of the old. Port F on
the new manifold connects to the filter head.
Figure 3.8: Inside LH Frame (View from Below)
8. Connect the five hoses disconnected in Step 4., page
12 to the new manifold as follows:
• Port CR – the 3/4 in. I.D. cooler return hose
• PortCP– the3/4in.I.D.hose withfromthe oilcooler
marked in Step 3., page 12
• Port A – the 1/2 in. I.D. hose from the triple
gear pump
• Port B – the 1/2 in. I.D. hose from the triple
gear pump
• Port P2 – the 1/4 in. I.D. hose from the lift manifold
9. Attach the new hose from Step 2., page 12 to the
adapter fitting in Port DR of the new manifold. Figure 3.9: Hydraulic Ports on New Cooler
Bypass Manifold
147611 12 Revision B

INSTALLATION INSTRUCTIONS
10. Rotate hose (B), leaving 1–2 mm of clearance between
thehoseandthefilter (A). There should also be
1–2 mm of clearance between hose (C) and hose (B).
Figure 3.10: Cooler Bypass Manifold Hoses
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 remove dipstick.
Figure 3.11: Windrower Hood
3. Add oil to maintain a level between the LOW andFULL
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: 66 liters (17.5 U.S. gallons)
4. Reinstall filler cap/dipstick, and turn clockwise to
tighten/lock.
5. Close thehood. For instructions, referto the windrower
operator’s manual or technical manual.
Figure 3.12: Hydraulic Oil Level
147611 13 Revision B

INSTALLATION INSTRUCTIONS
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.
1. To measure CR pressure, attach a 7000 kPa (1000 psi)
pressure gauge to the test fitting at port CRG (A).
2. To measure CP pressure, do one of the following:
• Attach a 7000 kPa (1000 psi) pressure gauge to the
test fitting at port CPG (B); OR
•Attachaflow meter capable of reading flow as high
as 106 lpm (30 gpm) and a 7000 kPa (1000 psi)
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 57–63°C
(135–145°F ). If using a flow meter, the reading should
be between 83–98 lpm (22–26 gpm).
4. Record CP and CR pressures. CP pressure should be
between 3447–4171 kPa (500–605 psi).
5. If CP pressure is not between 3447–4171 kPa
(500–605 psi), 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
552–1380 kPa (80–200 psi). A differential pressure
lower than 552 kPa (80 psi) indicates a possible
defective hydraulic cooler.
Figure 3.13: Hydraulic Ports on New Cooler
Bypass Manifold
147611 14 Revision B