Complete service repair manual for John Deere Self-Propelled Draper Hay and Forage Windrowers Models W235, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

John Deere Self-Propelled Draper Hay and Forage Windrowers Models W235 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TM130119 - John Deere Self-Propelled Draper Hay and Forage Windrowers Models W235 Technical Manual (Repair).PDF
TM130119 - John Deere Self-Propelled Draper Hay and Forage Windrowers Models W235 Technical Manual (Repair).EPUB

Total Pages: 1,210 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   General
      Safety
      General Information
      Tune-UP and Adjustment
      Fuel, Coolant, and Lubricants
   Engine
      Component Removal and Installation
   Fuel, Air Intake, and Cooling Systems
      Component Removal and Installation
      Diesel Fuel System
      Cooling System
      Air Intake
   Electrical
      Batteries
      Harness and Connectors
      Charging Circuit
      Starting Circuit
      Fuses and Relays
      Engine Electrical Components
      Lighting
      Cab Components
      Sensors and Switches
      Wire Harness Routing
      GreenStar Components
      Chassis Control System
   Power Train
      Component Removal and Installation
      Hydrostatic Drive
      Pump Drive Gear Case
      Final Drive
   Steering
      Component Removal and Installation
      Steering System
   Hydraulic System
      Component Removal and Installation
      Component Location
      Hydraulic Pumps
      Valves
      Hydraulic Cylinders
      Miscellaneous
      Hydraulic Reservoir
      Accumulator
      Hydraulic Motors
   Miscellaneous
      Lift Arm
      Operator Platforms
      Rockshaft
   Doors and Hood
      Component Removal and Installation
      Doors
      Fiberglass
   Operator Station
      Component Removal and Installation
      Air Conditioning System
      Suspension Seat
      Cab Door
   Rear Axle
      Component Removal and Installation
      Rear Axle
   Dealer Fabricated Tools
      Dealer Fabricated Tools

tm130119 - W235 Draper Self-Propelled Windrower Repair

Table of Contents

Foreword

Section 10: General

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Avoid Static Electricity Risk When Refueling

Prepare for Emergencies

Handling Batteries Safely

Transport Windrower with Platform Attached

Park Windrower Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Avoid High-Pressure Fluids

Wait Before Opening High-Pressure Fuel System

Service Accumulator Systems Safely

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Follow Tire Recommendations

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Practice Safe Service Procedures

Use Proper Tools

Construct Dealer-Made Tools Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Precautions for Welding

Clean Exhaust Filter Safely

Servicing Electronic Control Units

Welding Near Electronic Control Units

Keep Electronic Control Unit Connectors Clean

Handle Electronic Components and Brackets Safely

Live With Safety

Group 10: General Information

W235 Draper Self-Propelled Windrower Specifications

Dimensions

Sealants and Adhesives Cross-Reference Chart

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Face Seal Fittings Assembly and Installation—All Pressure Applications

Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures

Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications

SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures

SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications

Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications

SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications

SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications

External Hexagon Port Plug Torque Chart

Service Recommendations For 37° Flare and 30° Cone Seat Connectors

Service Recommendations For Snap-To-Connect Fittings

Product Identification Number Plate

Windrower Product Identification Number Plate Location

Engine Serial Number

Programming Control Units

Group 15: Tune-UP and Adjustment

Tune-Up and Adjustment

Care and Maintenance of Belts

Defective Belts

Prevent Hydraulic System Contamination

Check Oil Lines and Fittings

Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems

Group 20: Fuel, Coolant, and Lubricants

Diesel Fuel

Lubricity of Diesel Fuel

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Operating in Warm Temperature Climates

John Deere COOL-GARD™ II Coolant Extender

Water Quality for Mixing with Coolant Concentrate

Testing Coolant Freeze Point

Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines

Storing Diesel Exhaust Fluid (DEF)

Testing Diesel Exhaust Fluid (DEF)

Disposal of Diesel Exhaust Fluid (DEF)

Pump Drive Gear Case, Hydrostatic Drive, and Main Hydraulic Systems Oil

Final Drive Oil

Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV

John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV

Multiluber Grease

Grease

Grease

Section 20: Engine

Group 00: Component Removal and Installation

Special Tools

Other Material

Specifications

John Deere Engine Repair—Use CTM

Remove and Install Engine

Remove and Install Engine Mount Isolators

Remove and Install Fan

Remove and Install Serpentine and Air Conditioning Compressor Belts

Remove and Install Bellows

Remove and Install Aftertreatment Device Assembly

Remove and Install Decomposition Tube

Remove and Install SCR Converter

Remove and Install Diesel Oxidation Catalyst and Diesel Particulate Filter

Remove and Install Exhaust Stack

Section 30: Fuel, Air Intake, and Cooling Systems

Group 00: Component Removal and Installation

Special Tools

Specifications

Remove and Install Combination Cooler

Remove and Install Hydraulic Oil Cooler

Remove and Install Fuel Cooler

Remove and Install DEF Dosing Injector

Remove and Install Diesel Exhaust Fluid (DEF) Tank

Remove and Install (DEF) Tank Header Assembly

Remove and Install Diesel Exhaust Fluid (DEF) Dosing Unit (S.N. —409999)

Remove and Install Diesel Exhaust Fluid (DEF) Dosing Unit (S.N. 410000—)

Remove and Install Left-Hand Fuel Tank

Remove and Install Right-Hand Fuel Tank

Remove and Install Radiator

Remove and Install Charge Air Cooler

Remove and Install Fan Shroud

Remove and Install Rotating Wand

Remove and Install Rear Door Screen

Remove and Install Air Cleaner Inlet Tube

Group 05: Diesel Fuel System

High Pressure Fuel Pump, Nozzle, and Governor Repair—Use CTM

Drain Fuel Tank

Group 10: Cooling System

Special Tools

Specifications

Engine Water Pump Repair—Use CTM

Test Cooling System

Test Surge Tank Cap

Fill Radiator

Flush, Drain, and Fill Cooling System

Group 15: Air Intake

Turbocharger Repair—Use CTM

Section 40: Electrical

Group 05: Batteries

Specifications

Prevent Damage to Electrical Systems

Remove and Install Battery (S.N. —409999)

Remove and Install Battery (S.N. 410000—)

Connecting Booster Battery

Charging Batteries

Checking Electrolyte Specific Gravity

Group 10: Harness and Connectors

Essential or Recommended Tools

Other Material

Use Electrical Insulating Compound

Using High-Pressure Washers

Electrical System Visual Inspection

Basic Electrical Component Handling / Precautions for Vehicles Equipped with Computer Controlled Systems

Electrical Connector / Wiring Harness Handling and Repair

Connector Information

Repair Procedure R-A

Repair Procedure R-B

Repair Procedure R-C

Repair Procedure R-D

Repair Procedure R-E

Repair Procedure R-F

Repair Procedure R-G

Repair Procedure R-I

Repair Procedure R-J

Repair Procedure R-K

Repair Procedure R-M

Repair Procedure R-N

Repair Procedure R-AE

Repair Procedure R-AF

Repair Procedure R-AG

Repair Procedure R-AH

Repair Procedure R-AI

Repair Procedure R-AJ

Repair Procedure R-AK

Repair Procedure R-AL

Group 15: Charging Circuit

Specifications

Remove and Install Alternator

Group 20: Starting Circuit

Special Tools

Specifications

Starter Repair—Use CTM

Remove and Install Starter Motor

Remove and Install Starter Relay

Group 25: Fuses and Relays

Fuse Center

Group 30: Engine Electrical Components

Specifications

Replace Sensors and Switches

Remove and Install Engine Control Unit (ECU)

Remove and Install Rotating Wand Motor

Group 35: Lighting

Specifications

Halogen Bulb Safety Guidelines

Safety Rules When Replacing High Intensity Discharge (HID) Xenon Bulbs

Cab Halogen Round Headlight Bulb Replacement and Adjustment

Cab Halogen Oval Light Bulb Replacement and Adjustment

High Intensity Discharge (HID-Xenon) Light Replacement and Adjustment

Remove and Install High Intensity Discharge (HID-Xenon) Ballasts (If Equipped)

Remove and Install Rear Flood Lights

Remove and Install Rear Flood Light Bulb

Remove and Install Rear Hazard and Tail Light Lamp and Bulbs

Remove and Install Side Lights

Remove and Install Side Light Bulb

Remove and Install Dome Light Bulb

Group 40: Cab Components

Other Material

Specifications

Instruments and Controls Identification

Remove and Install Cab Control Unit

Remove and Install Cab Power Module

Remove and Install Modular Telematics Gateway Control Unit

Remove and Install Overhead Console

Remove and Install Corner Post Display

Remove and Install Auxiliary Power Outlet Strip

Remove and Install Ignition Switch

Remove and Install Radio

Remove and Install Radio Speaker

Remove and Install Radio Antenna Base Assembly

Remove and Install Mobile Radio Antenna

Remove and Install Modular Telematics Gateway Antenna

Remove and Install Satellite Radio Module

Remove and Install Satellite Radio Antenna

Armrest Console Connector Locations

Remove and Install Side Console

Remove and Install Armrest Console Switch Panel

Remove and Install Armrest Display Unit

Remove and Install Header Engage Switch

Remove and Install Dial-A-Speed and Active Header Control Switches

Remove and Install Multi-Function Lever Position Switches

Remove and Install Multi-Function Lever

Remove and Install Steering Column Lever

Remove and Install Remote Mirrors

Remove and Install Remote Mirror Adjustment Switch

Remove and Install Heated Mirror Switch

Remove and Install Hands Free Microphone

Remove and Install Stereo Auxiliary Jack and USB Port

Remove and Install Map Light Assembly

Remove and Install Horn

Remove and Install Windshield Wiper Arms

Adjust Windshield Wiper Arms

Remove and Install Windshield Wiper Motor

Group 45: Sensors and Switches

Special Tools

Other Material

Specifications

Remove and Install Hydraulic Filter Restriction Switch

Remove and Install Hydraulic Charge Pressure Switch

Remove and Install Hydraulic Oil Temperature Switch

Remove and Install Float Pressure Sensor

Remove and Install Ground Speed Sensor

Remove and Install Evaporator Temperature Sensor

Remove and Install Air Restriction Switch

Remove and Install Air Temperature Sensors

Remove and Install DPF Pressure Sensor

Remove and Install DOC/DPF Temperature Sensors

Remove and Install Aftertreatment Outlet NOx Sensor

Remove and Install Aftertreatment Inlet NOx Sensor

Remove and Install SCR Temperature Sensors

Remove and Install Coolant Loss Sensor

Remove and Install Coolant Service Sensor

Remove and Install Fuel Level Sensor

Remove and Install Rear Steer Pressure Sensor

Remove and Install Platform Lift Pressure Sensor

Remove and Install Platform Lift Position Sensor

Remove and Install Platform Tilt Position Sensor

Remove and Install Steering Input Device Sensor

Remove and Install Steering Mechanism Sensors

Group 50: Wire Harness Routing

Cab Main Wiring Harness

Cab Roof Wiring Harness

Replace Harness

Group 55: GreenStar Components

Remove and Install Display Unit

Remove and Install Position Receiver

Position Receiver and Base (Exploded View)

Disassemble and Assemble Position Receiver

Group 60: Chassis Control System

Remove and Install Steering Control Unit (SCU)

Remove and Install Out Of Cab (OOC) Vehicle Control Unit

Remove and Install Out Of Cab (OOC) Control Unit Power Module

Section 50: Power Train

Group 00: Component Removal and Installation

Special Tools

Other Material

Specifications

Remove and Install Left-Hand Ground Drive Pump

Remove and Install Right-Hand Ground Drive Pump

Remove and Install Ground Drive Motor

Remove and Install Final Drive

Remove and Install Ground Drive Control Cable

Remove and Install Ground Drive Linkage Rods

Remove and Install Pump Drive Gear Case

Remove and Install Drive Wheels

Group 05: Hydrostatic Drive

Other Material

Specifications

Ground Drive Linkage Rods Assembly—Exploded View

Disassemble and Assemble Ground Drive Pump

Flush Hydrostatic Ground Drive System

Hydrostatic Ground Drive System Start-Up

Adjust Wheel Speed

Align Park and Steering Neutral

Remove and Install Ground Drive Pump Shaft Seal

Remove and Install Ground Drive Pump Cartridge Valves

Remove and Install Ground Drive Pump Charge Pressure Relief Valve

Repair Charge Pump

Remove and Install Ground Drive Pump Control Valve

Disassemble and Assemble Ground Drive Motor

Disassemble and Assemble Ground Drive Motor Port Plate

Group 10: Pump Drive Gear Case

Disassemble and Assemble Pump Drive Gear Case

Group 15: Final Drive

Special Tools

Other Material

Specifications

Disassemble and Assemble Final Drive

Disassemble and Assemble Internal Park Brake

Internal Park Brake Checks

Section 60: Steering

Group 00: Component Removal and Installation

Special Tools

Other Material

Specifications

Remove and Install Steering Wheel

Remove and Install Steering Column Covers

Remove and Install Steering Column

Remove and Install Steering Column Harness

Remove and Install Steering Column Tilt Struts

Remove and Install Steering Column Pivots

Remove and Install Steering Column Link Shaft

Remove and Install Tilt Adjust Pedal and Linkage

Remove and Install Steering Mechanism

Remove and Install Steering Assist Lever

Remove and Install Rear Assist Steering Cylinder Bracket

Group 05: Steering System

Specifications

Disassemble and Assemble Steering Mechanism

Steering Valve—Exploded View

Steering Column—Exploded Views

Disassemble and Assemble Rear Assist Steering Cylinder Brackets

Section 70: Hydraulic System

Group 00: Component Removal and Installation

Special Tools

Other Material

Specifications

Remove and Install Pump Drive Gear Case Cooling Pump

Remove and Install Auxiliary Pump

Remove and Install Charge Pump

Remove and Install Platform Drive Motor

Remove and Install Platform Drive Pump

Remove and Install Reel Belt Drive and Platform Lift Pumps

Remove and Install Platform Tilt Cylinder

Remove and Install Platform Lift Cylinder

Remove and Install Rear Assist Steering Cylinder

Remove and Install Steering Cylinder

Remove and Install Auxiliary Valve Block

Remove and Install Steering Valve

Remove and Install Rear Assist Steering Control Valve

Remove and Install Rear Assist Steering Valve

Remove and Install AutoTrac Valve

Remove and Install Platform Lift Control Valve

Remove and Install Multicoupler

Remove and Install Header Lift System Hydraulic Accumulator

Remove and Install Hydraulic Reservoir

Group 05: Component Location

Platform Drive and Cylinders

Ground Drive System

Steering Components

Group 10: Hydraulic Pumps

Other Material

Specifications

Disassemble Platform Drive Pump

Inspect Platform Drive Pump Components

Assemble Platform Drive Pump

Disassemble Pump Drive Gear Case Cooling Pump

Inspect Pump Drive Gear Case Cooling Pump

Assemble Pump Drive Gear Case Cooling Pump

Reel Belt Drive and Platform Lift Pumps—Exploded View

Disassemble and Assemble Reel Belt Drive and Platform Lift Pumps

Disassemble and Assemble Charge and Auxiliary Pumps

Group 15: Valves

Special Tools

Other Material

Specifications

Disassemble and Assemble Steering Valve

Disassemble and Assemble Rear Assist Steering Control Valve

Disassemble and Assemble Rear Assist Steering Valve

Disassemble and Assemble AutoTrac Valve

Disassemble and Assemble Auxiliary Valve Block

Disassemble and Assemble Platform Lift Control Valve

Multicoupler Valve Identification

Disassemble and Assemble Multicoupler

Group 20: Hydraulic Cylinders

Disassemble and Assemble Tilt, Lift, and Rear Assist Steering Cylinders

Disassemble and Assemble Steering Cylinder

Group 25: Miscellaneous

Release Float Pressure

Group 30: Hydraulic Reservoir

Special Tools

Drain and Fill Hydraulic Reservoir

Remove and Install Sight Gauge

Remove and Install Air Filter

Connecting Vacuum Pump to Hydraulic Reservoir

Group 35: Accumulator

Specifications

Checking Accumulator Pressure

Group 40: Hydraulic Motors

Specifications

Disassemble and Assemble Platform Drive Motor

Section 80: Miscellaneous

Group 05: Lift Arm

Special Tools

Other Material

Specifications

Remove and Install Lift Arm Bearings

Group 10: Operator Platforms

Remove and Install Operator Platforms

Group 15: Rockshaft

Remove and Install Rockshaft

Section 85: Doors and Hood

Group 00: Component Removal and Installation

Specifications

Remove and Install Rear Door Air Scoop

Remove and Install Rear Door Air Scoop Cylinders

Remove and Install Rear Door Air Scoop Frame

Remove and Install Rear Door Latch and Striker

Remove and Install Rear Door Air Scoop Strap

Remove and Install Rear Door

Remove and Install Gull Wing Door Cylinders

Remove and Install Gull Wing Doors

Remove and Install Left-Hand Side Doors and Panel

Remove and Install Gull Wing Door Struts

Remove and Install Hood Panels

Group 05: Doors

Other Material

Composite Panel Repair

Group 10: Fiberglass

General Information and Materials

Repair Surface Scratches and Gouges

Preparing Backing Patch

Using Backing Patch

Repair Small Cracks

Repair Small Fractures

Repair Large Fractures

Finishing Surface

Section 90: Operator Station

Group 00: Component Removal and Installation

Special Tools

Specifications

Remove and Install Lower Cab Fascia

Remove and Install Cab

Remove and Install Cab Windshield

Remove and Install Emergency Exit Glass

Remove and Install Rear Window

Remove and Install Front Portion of Cab Roof

Remove and Install Rear Portion of Cab Roof

Remove and Install Cab Inner Roof

Remove and Install Cab Headliner

Remove and Install Refrigerator

Remove and Install Refrigerator Doors

Remove and Install Refrigerator Control Unit

Remove and Install Refrigerator Thermostat

Remove and Install Cab Door

Remove and Install Air Conditioning Compressor

Remove and Install Heater Core

Heating, Ventilating, and Air Conditioning System—HVAC (General Information)

Remove and Install Pressurizer Blower Motor

Remove and Install Recirculator Fan Motor Driver

Remove and Install Recirculator Fan Motor

Remove and Install Actuator Valves

Remove and Install Climate Control Unit

Remove and Install Receiver-Dryer

Remove and Install Evaporator

Replace Expansion Valve

Replace Air Conditioning High/Low Pressure Switch

Remove and Install Operator Seat

Remove and Install Armrest Control Pivot

Remove and Install Operator Presence Switch

Remove and Install Seat Cushions

Remove and Install Lap Belt

Remove and Install Left-Hand Armrest

Remove and Install Operator Air Seat Suspension

Remove and Install Seat Suspension Bellows

Remove and Install Vertical Shock Absorber Control Cable Handle

Remove and Install Vertical Shock Absorber Control Cable

Remove and Install Vertical Shock Absorber

Remove and Install Horizontal Shock Absorber

Remove and Install Fore-Aft Isolator Assembly

Remove and Install Fore-Aft Isolator Handle

Remove and Install Fore-Aft Isolator Locking Mechanism

Remove and Install Seat Suspension Compressor

Remove and Install Seat Level Indicator

Remove and Install Seat Suspension Air Spring

Remove and Install Seat Air Reservoir

Remove and Install Seat Height Control

Remove and Install Upper Seat Suspension Frame

Remove and Install Lower Seat Suspension Frame

Group 05: Air Conditioning System

Special Tools

Other Material

Specifications

System Information

Service Parts Kits

Hose and Tubing O-Ring Connection Torques

Discharge and Recovery of Air Conditioning Refrigerant

Test Volumetric Efficiency

Leak Testing Air Conditioning System With Dye

Check Clutch Hub Clearance

Inspect Compressor Manifold

R-134a Refrigerant Cautions

Proper Refrigerant Handling

Refrigerant Hoses and Tubing Inspection

Flush Air Conditioning System

Purge Air Conditioning System

Evacuate Air Conditioning System

Charge Air Conditioning System

Compressor Oil Information

Check Refrigerant Oil Charge

Determine Correct Oil Charge

Repair Condenser

Group 10: Suspension Seat

Operator Seat—Exploded View

Seat Suspension Component Overview

Group 15: Cab Door

Specifications

Disassemble and Assemble Cab Door

Cab Door Latch Striker

Section 100: Rear Axle

Group 00: Component Removal and Installation

Other Material

Specifications

Remove and Install Rear Axle

Remove and Install Axle Knee Bushings

Remove and Install Rear Suspension

Remove and Install Rear Suspension Isolators

Remove and Install King Pin

Group 05: Rear Axle

Specifications

Repair Caster Wheel Hub

Section 199: Dealer Fabricated Tools

Group 05: Dealer Fabricated Tools

DFEXT4 Sizing Arbor

John Deere Self-Propelled Draper Hay and Forage Windrowers Models W235 Service Repair Technical Manual (TM130119)