MacDon M155E4 2016 User manual

The harvesting specialists.
M155E4
Self-Propelled Windrower
Unloading and Assembly Instructions (North America)
147764 Revision A
2016 Model Year
Original Instruction

Featuring the Dual Direction®and Ultra Glide®suspension on the M155E4.
Published in October, 2015

Introduction
This instruction manual describes the unloading, setup, and predelivery requirements for the MacDon M155E4
Self-Propelled Windrowers.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
Retain this instruction for future reference.
Conventions
The following conventions are used in this document: Right- and left-hand are determined from the operator’s
position. The front of the windrower is the side that faces the crop.
NOTE:
Keep your MacDon publications up-to-date. The most current version can be downloaded from our website
(www.macdon.com) or from our Dealer-only site (https://portal.macdon.com) (login required).
147764 iRevision A

List of Revisions
The following list provides an account of major changes from the previous version of this document.
Summary of Change Location
Updated inside front cover illustration to match those
used in other M155E4 manuals and catalogs. Inside Front Cover
Addednotet
o keep MacDon publications up-to-date. Introduction, page i
Revised walking beam bolt torque sequence. 3.3 Repositioning Caster Wheels, page 13
Added note to ensure that there is enough diesel
exhaust fluid (DEF) to avoid DEF level warnings. 3.7 Starting Engine, page 18
Added fuel shut off valve check to starting engine
troubleshooting table. Table 3.1 Troubleshooting, page 19
Added paragraph to recommend selecting a radio with
non-volatile memory in order to retain radio settings
and preset memory.
3.8 Installing AM/FM Radio, page 21
Updated lift cylinder safety prop illustrations to show
red plastic handle. Throughout 3.10 Attaching Headers, page 26
Updated lubrication points illustration to show M155E4
Windrower. 3.11.2 Lubrication Points, page 62
Replaced “Gauges” with “Display Module” in chapter
title. 3.12 Fuel and Diesel Exhaust Fluid (DEF) Display Module, page 63
Corrected pressure sensor part number from
“MD #5574” to “MD #B5574” in footnote. 4.7.2 Switching the Installed Header Sensors On or Off, page 108
Added procedure to locate windrower and engine serial
numbers, and updated illustrations. 5.1 Recording Serial Numbers, page 131
Addedsteptocleanfiller cap and surrounding area. 5.5 Checking Hydraulic Oil, page 137
Added description of auto road light feature. 5.11.7 Checking Exterior Lights, page 149
Moved torque specification topics, conversion chart,
and definitions to a new Reference chapter. 6 Reference, page 157
Added and revised terms and acronyms. 6.3 Definitions, page 170
Revisedhazardstatementstobeconsistentwith
current MacDon manuals. Throughout
Revised figure titles. Throughout
147764 ii Revision A

TABLE OF CONTENTS
Introduction...................................................................................................................................... i
List of Revisions ...............................................................................................................................ii
1 Safety.................................................................................................................................................... 1
1.1 Signal Words................................................................................................................................... 1
1.2 General Safety ................................................................................................................................ 2
1.3 Safety Signs.................................................................................................................................... 4
2 Unloading the Windrower...................................................................................................................... 5
2.1 Using Two Forklifts to Unload Windrower .......................................................................................... 5
2.2 Using One Forklift to Unload Windrower............................................................................................7
2.2.1 Method 1: Pulling from Trailer Deck........................................................................................... 7
2.2.2 Method 2: Lifting from Trailer Deck............................................................................................ 8
3 Assembling the Windrower................................................................................................................... 9
3.1 Repositioning Right Leg................................................................................................................... 9
3.2 Installing Drive Wheel .....................................................................................................................11
3.3 Repositioning Caster Wheels.......................................................................................................... 13
3.4 Unpacking Ignition Keys................................................................................................................. 15
3.5 Installing Steps.............................................................................................................................. 16
3.6 Connecting Batteries...................................................................................................................... 17
3.7 Starting Engine.............................................................................................................................. 18
3.8 Installing AM/FM Radio.................................................................................................................. 21
3.9 Installing the Slow Moving Vehicle (SMV) Sign ................................................................................ 25
3.10 Attaching Headers......................................................................................................................... 26
3.10.1 Attaching a D-Series Header................................................................................................... 26
Attaching Header Boots .................................................................................................. 26
Attaching a D-Series Header: Hydraulic Center-Link with Optional Self-Alignment.............. 27
Attaching a D-Series Header: Hydraulic Center-Link without Self-Alignment....................... 32
3.10.2 Attaching an A-Series Header.................................................................................................38
Attaching an A-Series Header: Hydraulic Center-Link with Optional Self-Alignment............. 39
Attaching an A-Series Header: Hydraulic Center-Link without Self-Alignment..................... 44
3.10.3 Attaching an R-Series Header.................................................................................................50
Attaching an R-Series Header: Hydraulic Center-Link with Optional Self-Alignment ............ 50
Attaching an R-Series Header: Hydraulic Center-Link without Self-Alignment..................... 55
3.11 Lubricating the Windrower.............................................................................................................. 61
3.11.1 Lubrication Procedure ............................................................................................................ 61
3.11.2 Lubrication Points................................................................................................................... 62
3.12 Fuel and Diesel Exhaust Fluid (DEF) Display Module....................................................................... 63
4 Cab Display Module (CDM).................................................................................................................. 67
4.1 Cab Display Module (CDM) Programming....................................................................................... 67
4.2 Cab Display Options...................................................................................................................... 69
4.2.1 Setting the Cab Display Language........................................................................................... 69
4.2.2 Changing the Windrower Display Units.................................................................................... 70
4.2.3 Adjusting the Cab Display Buzzer Volume................................................................................ 71
4.2.4 Adjusting the Cab Display Backlighting.................................................................................... 72
4.2.5 Adjusting the Cab Display Contrast ......................................................................................... 73
4.3 Calibrating the Header Sensors...................................................................................................... 75
4.3.1 Calibrating the Header Height Sensor...................................................................................... 75
4.3.2 Calibrating the Header Tilt Sensor........................................................................................... 77
4.3.3 Calibrating the Header Float Sensors ...................................................................................... 79
4.4 Programming the Windrower.......................................................................................................... 81
4.4.1 Activating the Hydraulic Center-Link........................................................................................ 81
4.4.2 Activating the Rotary Header Drive Hydraulics ......................................................................... 81
4.4.3 Setting the Header Knife Speed.............................................................................................. 82
4.4.4 Setting the Knife Overload Speed............................................................................................ 83
147764 iiiRevision A

TABLE OF CONTENTS
4.4.5 Setting the Rotary Disc Overload Speed.................................................................................. 84
4.4.6 Setting the Hydraulic Overload Pressure.................................................................................. 85
4.4.7 Setting the Header Index Mode............................................................................................... 86
4.4.8 Setting the Return to Cut Mode............................................................................................... 87
4.4.9 Setting the Header Cut Width.................................................................................................. 88
4.4.10 Activating the Double Windrow Attachment (DWA)................................................................... 88
4.4.11 Setting the Auto Raise Height .................................................................................................90
4.4.12 Activating the Hay Conditioner ................................................................................................ 91
4.4.13 Displaying Reel Speed ........................................................................................................... 92
4.4.14 Setting the Windrower’s Tire Size............................................................................................ 93
4.4.15 Setting the Engine Intermediate Speed Control (ISC) RPM....................................................... 94
4.4.16 Clearing Sub-Acres................................................................................................................ 95
4.5 Activating Cab Display Lockouts..................................................................................................... 96
4.5.1 Activating Knife Speed Control Lockout................................................................................... 96
4.5.2 Activating Rotary Disc Speed Control Lockout.......................................................................... 97
4.5.3 Activating the Header Float Control Lockout............................................................................. 98
4.5.4 Activating the Draper Speed Control Lockout........................................................................... 99
4.5.5 Activating the Auger Speed Control Lockout ...........................................................................101
4.5.6 Activating the Reel Speed Control Lockout .............................................................................102
4.5.7 Activating the Reel Fore-Aft Control Lockout...........................................................................103
4.5.8 Activating the Header Tilt Control Lockout...............................................................................104
4.6 Displaying Activated Cab Display Lockouts ....................................................................................105
4.7 Troubleshooting Windrower Problems............................................................................................107
4.7.1 Displaying the Windrower and Engine Error Codes..................................................................107
4.7.2 Switching the Installed Header Sensors On or Off ...................................................................108
4.7.3 Displaying Header Sensor Input Signals.................................................................................110
4.7.4 Forcing a Header ID..............................................................................................................111
4.8 Troubleshooting Header Problems.................................................................................................113
4.8.1 Testing the Header Up/Down Activate Function Using the Cab Display Module (CDM) ..............113
4.8.2 Testing the Reel Up/Down Activate Function Using the Cab Display Module (CDM)...................114
4.8.3 Testing the Header Tilt Activate Function Using the Cab Display Module (CDM)........................116
4.8.4 Testing the Reel Fore-Aft Activate Function Using the Cab Display Module (CDM) ....................118
4.8.5 Activating the Hydraulic Purge Using the Cab Display Module (CDM).......................................119
4.8.6 Testing the Knife Drive Circuit Using the Cab Display Module (CDM)........................................121
4.8.7 Testing the Draper Drive Circuit Activate Function Using the Cab Display Module (CDM) ...........123
4.8.8 Testing the Reel Drive Circuit Activate Function Using the Cab Display Module (CDM)..............124
4.8.9 Testing the Rotary Disc Drive Circuit Activate Function Using the Cab Display
Module (CDM)..................................................................................................................126
4.8.10 Testing the Double Windrower Attachment (DWA) Drive Activate Function Using the Cab
Display Module (CDM) ......................................................................................................128
5 Performing Predelivery Checks..........................................................................................................131
5.1 Recording Serial Numbers ............................................................................................................131
5.2 Checking Wheel Drive Lubricant Level...........................................................................................132
5.3 Checking Tire Pressures and Adding Tire Ballast............................................................................133
5.3.1 Checking Tire Pressures........................................................................................................133
5.3.2 Adding Tire Ballast ................................................................................................................133
5.4 Checking Engine Air Intake ...........................................................................................................135
5.5 Checking Hydraulic Oil..................................................................................................................137
5.6 Checking Fuel Separator...............................................................................................................138
5.7 Checking Engine Coolant..............................................................................................................139
5.8 Checking Gearbox Lubricant Level ................................................................................................140
5.9 Checking Air Conditioning (A/C) Compressor Belt...........................................................................141
5.10 Checking Safety System ...............................................................................................................142
5.11 Performing Operational Checks.....................................................................................................144
147764 iv Revision A

TABLE OF CONTENTS
5.11.1 Checking Engine Warning Lights............................................................................................145
5.11.2 Checking Engine Startup.......................................................................................................145
5.11.3 Checking Engine Speed ........................................................................................................146
5.11.4 Checking Gauges and Cab Display Module (CDM) Display on an M155E4...............................146
5.11.5 Checking Electrical System....................................................................................................147
5.11.6 Checking Operator's Presence System...................................................................................147
5.11.7 Checking Exterior Lights........................................................................................................149
Auto Road Light.............................................................................................................151
5.11.8 Checking Horn......................................................................................................................152
5.11.9 Checking Interior Lights.........................................................................................................152
5.11.10 Checking Air Conditioning (A/C) and Heater............................................................................153
5.12 Checking Manuals........................................................................................................................154
5.13 Performing Final Steps..................................................................................................................155
6 Reference...........................................................................................................................................157
6.1 Torque Specifications....................................................................................................................157
6.1.1 SAE Bolt Torque Specifications..............................................................................................157
6.1.2 Metric Bolt Specifications.......................................................................................................159
6.1.3 Metric Bolt Specifications Bolting into Cast Aluminum..............................................................162
6.1.4 Flare-Type Hydraulic Fittings..................................................................................................162
6.1.5 O-Ring Boss (ORB) Hydraulic Fittings (Adjustable)..................................................................164
6.1.6 O-Ring Boss (ORB) Hydraulic Fittings (Non-Adjustable) ..........................................................166
6.1.7 O-Ring Face Seal (ORFS) Hydraulic Fittings...........................................................................167
6.2 Conversion Chart..........................................................................................................................169
6.3 Definitions....................................................................................................................................170
Predelivery Checklist ........................................................................................................................173
147764 vRevision A

1Safety
1.1 Signal Words
Three signal words, DANGER,WARNING,andCAUTION, 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.
147764 1Revision A

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
•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
147764 2Revision A