John Deere Self-Propelled Hay & Forage Windrower W150 Diagnostic & Repair Technical Manual (TM122219)
Complete Diagnosis Operation Test Repair Service manual for John Deere Self-Propelled Hay & Forage Windrower W150, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.
John Deere Self-Propelled Hay & Forage Windrower W150 workshop Diagnosis Tests 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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.
TM122219 - John Deere Self-Propelled Hay & Forage Windrower W150 Technical Manual (Diagnosis Operation Test Repair Service).PDF
Total Pages: 880 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
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TABLE OF CONTENTS
Foreword
General
Safety
General Information
Fuel, Coolant, and Lubricants
Engine
Component Removal and Installation
Engine
Cooling System
Fuel and Air
Component Removal and Installation
Air Intake System
Diesel Fuel System
Electrical
Battery
Switches, Sensors, and Modules
Engine Electrical Components
Fuses and Relays
Harness and Connector Repair
Starter
Alternator
Power Train
Component Removal and Installation
Traction Drive
Steering
Component Removal and Installation
Steering
Hydraulic System
Component Removal and Installation
Hydraulic Pumps
Hydraulic Valves
Operator Station
Component Removal and Installation
Cab
Air Conditioning
Diagnostic Trouble Codes
CDM - Diagnostic Trouble Codes
ECU - Diagnostic Trouble Codes
Engine and Engine Exhaust
Theory of Operation
Fuel and Air Intake
Theory of Operation
Electrical
General Information
CanWin
Theory of Operation
Schematic
Diagnostic Tests and Adjustments
Electrical Component Information
General Information
Electrical Assemblies
Sensors
Lights
Gauges
Relays
Motors
Switches
Interconnects and Ground Points
Electronically Actuated Mechanical Devices
Drive Train
Theory of Operation
Diagnostic Tests and Adjustments
Steering and Brakes
Theory of Operation
Diagnostic Tests and Adjustments
Hydraulics
Theory of Operation
Schematic
Diagnostic Tests and Adjustments
Heating, Ventilation, and Air Conditioning
Theory of Operation
Diagnostic Tests and Adjustments
Dealer Fabricated Tools
Dealer Fabricated Tools
TABLE OF CONTENTS................1
Section 10: General................18
Group 05: Safety................18
Recognize Safety Information................22
Understand Signal Words................23
Practice Safe Maintenance................24
Park Windrower Safely................25
Prepare for Emergencies................27
Service Machines Safely................28
Practice Safe Service Procedures................29
Use Adequate Service Facilities................30
Support Machine Properly................31
Use Proper Tools................32
Wear Protective Clothing................33
Work in Clean Area................34
Avoid Harmful Asbestos Dust................35
Work In Ventilated Area................36
Illuminate Work Area Safely................37
Use Proper Lifting Equipment................38
Stay Clear of Rotating Driveline................39
Construct Dealer-Made Tools Safely................40
Remove Paint Before Welding or Heating................41
Handle Fluids Safely—Avoid Fires................42
Service Cooling System Safely................43
Service Accumulator Systems Safely................44
Service Tires Safely................45
Handling Batteries Safely................46
Prevent Battery Explosions................48
Prevent Acid Burns................49
Precautions for Welding................51
Servicing Electronic Control Units................53
Welding Near Electronic Control Units................54
Keep Electronic Control Unit Connectors Clean................55
Handle Electronic Components and Brackets Safely................56
Avoid High-Pressure Fluids................57
Wait Before Opening High-Pressure Fuel System................58
Avoid Heating Near Pressurized Fluid Lines................59
Replace Safety Signs................60
Decommissioning — Proper Recycling and Disposal of Fluids and Components................61
Live With Safety................62
Group 10: General Information................19
W150 Self-Propelled Windrower Specifications................827
Dimensions................69
Metric Bolt and Screw Torque Values................71
Unified Inch Bolt and Screw Torque Values................73
Face Seal Fittings Assembly and Installation—All Pressure Applications................76
SAE Face Seal Fitting Torque Chart—Standard Pressure Applications................77
SAE Face Seal Fitting Torque Chart—High Pressure Applications................79
Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications................81
SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications................82
Service Recommendations For 37° Flare and 30° Cone Seat Connectors................83
Product Identification Number Plate................84
Windrower Product Identification Number Plate Location................85
Group 15: Fuel, Coolant, and Lubricants................19
Diesel Fuel................88
Biodiesel Fuel................90
Diesel Fuel Storage................92
Lubricity of Diesel Fuel................93
Heavy Duty Diesel Engine Coolant................94
Diesel Engine Coolant (engine with wet sleeve cylinder liners)................96
Testing Diesel Engine Coolant................98
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender................102
Drain Intervals for Diesel Engine Coolant................101
John Deere COOL-GARD™ II Coolant Extender................102
Supplemental Coolant Additives................103
Mixing of Lubricants................104
Diesel Engine Oil — Tier 3 and Stage IIIA................105
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III................107
Hydraulic Systems Oil................109
Final Drive Oil................110
Grease................112
Alternative and Synthetic Lubricants................113
Lubricant Storage................114
Section 20: Engine................115
Group 00: Component Removal and Installation................115
Specifications................827
Other Material................453
Remove and Install Hood................119
Remove and Install Engine Fan................121
Remove and Install Radiator................124
Remove and Install Rotating Wand Screen................126
Remove and Install Air Conditioning Compressor Belt................127
Remove and Install Alternator Belt................128
Remove and Install Oil Cooler/Air Conditioning Condenser................129
Remove and Install Muffler................131
Remove and Install Engine Gear Case................132
Group 05: Engine................115
Other Material................453
Specifications................827
Adjust Hood................139
Engine Gearcase Check and Adjustment................143
Hood Position................146
Group 10: Cooling System................115
Specifications................827
Inspect Radiator Cap................150
Drain, Flush, and Fill Cooling System................151
Section 30: Fuel and Air................154
Group 00: Component Removal and Installation................154
Specifications................827
Remove and Install Fuel Tank................157
Remove and Install Secondary Fuel Filter................159
Remove and Install Primary Fuel Filter................161
Remove and Install Fuel Line Vent Filter................163
Remove and Install Charge Air Cooler................164
Remove and Install Air Filter Housing................166
Remove and Install Air Filter Elements................167
Remove and Install Fuel Cooler................169
Group 05: Air Intake System................154
Inspect Air Filters................172
Group 10: Diesel Fuel System................154
Bleed Fuel System................174
Drain Fuel Tank................175
Section 40: Electrical................177
Group 05: Battery................177
Remove and Install Battery Disconnect Switch................181
Remove and Install Battery Disconnect Switch Cables................182
Remove and Install Battery................184
Connecting Booster Battery................186
Charging Battery................188
Checking Specific Gravity................190
Add Electrolyte................193
Group 10: Switches, Sensors, and Modules................177
Specifications................827
Remove and Install Linkage Arm Neutral Start Switch................196
Remove and Install Throttle Sensor................197
Remove and Install Multi-Function Lever Position Switch................198
Remove and Install Multi-Function Lever Switch Panel................199
Remove and Install Air Conditioning Low Pressure Switch................200
Remove and Install Air Conditioning High Pressure Switch................201
Remove and Install Seat Base Position Switch................202
Remove and Install Float Sensor................203
Remove and Install Air Conditioning Thermostatic Control Switch................204
Remove and Install Hydraulic Oil Level Switch................205
Remove and Install Hydraulic Oil Temperature Switch................206
Remove and Install Header Height Sensor................207
Remove and Install Header Angle Sensor................208
Remove and Install Traction Supercharge Pressure Switch................209
Remove and Install Header Supercharge Switch................210
Remove and Install Brake Pressure Switch................211
Remove and Install Filter Pressure Differential Switch................212
Remove and Install Seat Switch................213
Remove and Install Engine Temperature and Fuel Gauges................215
Remove and Install Cab Display Module................217
Remove and Install Windrower Control Module................219
Group 15: Engine Electrical Components................178
Specifications................827
Remove and Install Rotating Wand Drive................223
Group 20: Fuses and Relays................228
Fuses and Relays................228
Group 25: Harness and Connector Repair................178
Other Material................453
Use Electrical Insulating Compound................232
Using High-Pressure Washers................233
Electrical System Visual Inspection................234
Basic Electrical Component Handling / Precautions for Vehicles Equipped with Computer Controlled Systems................235
Electrical Connector / Wiring Harness Handling and Repair................236
Installation of Repair Wire Assembly (RWA)................237
Repair Procedure R-A................246
Repair Procedure R-B................251
Repair Procedure R-C................255
Repair Procedure R-D................260
Repair Procedure R-E................263
Repair Procedure R-F................266
Repair Procedure R-G................269
Repair Procedure R-I................272
Repair Procedure R-J................275
Repair Procedure R-K................280
Repair Procedure R-M................283
Repair Procedure R-N................287
Repair Procedure R-AE................291
Repair Procedure R-AF................295
Repair Procedure R-AG................298
Repair Procedure R-AH................301
Repair Procedure R-AI................303
Repair Procedure R-AJ................306
Repair Procedure R-AK................310
Repair Procedure R-AL................313
Group 30: Starter................179
Specifications................827
Remove and Install Starter................318
Group 35: Alternator................179
Specifications................827
Remove and Install Alternator................322
Section 50: Power Train................324
Group 00: Component Removal and Installation................324
Other Material................453
Specifications................827
Drive Pump Port Identification and Pressure................328
Remove and Install Traction Drive Pump................330
Remove and Install Planetary Final Drive and Drive Wheel Motor................339
Remove and Install Drive Wheel................344
Group 05: Traction Drive................324
Special Tools................524
Specifications................827
Other Material................453
Traction Drive Pump Rebuild Startup Procedure................351
Test Traction Drive Right-Hand Wheel Motor................353
Test Traction Drive Left-Hand Wheel Motor................357
Prepare Windrower for Traction Drive Testing................361
Repair Wheel Drive Motor Shuttle Valve................363
Test Wheel Drive Motor Relief Valves................364
Traction Drive Pump Exploded View................368
Disengage and Engage Final Drive................370
Disassemble and Assemble Final Drive With Internal Brake................372
Disassemble and Assemble Internal Park Brake................378
Section 60: Steering................381
Group 00: Component Removal and Installation................381
Specifications................827
Remove and Install Steering Servo Assembly................384
Group 05: Steering................381
Other Material................453
Specifications................827
Disassemble and Assemble Steering Servo Assembly................389
Section 70: Hydraulic System................395
Group 00: Component Removal and Installation................395
Specifications................827
Configure Draper/Auger Speed Offset................398
Force Header Type................400
Record Existing Draper/Auger Speed Offset Values................402
Input Draper/Auger Speed Offset Values................404
Remove and Install Auxiliary Pads................406
Remove and Install Header Drive Pump................407
Remove and Install Hydraulic Reservoir................411
Group 05: Hydraulic Pumps................395
Other Material................453
Specifications................827
Bleed Header Drive Pump................417
Remove and Install Charge Pump and Auxiliary Pump Mounting Pad (Variable Pump)................419
Filtration and Charge Pump Options................423
Knife Drive Pump Exploded View................425
Remove and Install Knife Drive Pump Seal................427
Remove and Install Rear Shaft Cover (Tandem Pump)................429
Remove and Install Rear Shaft Cover (Tandem Pump) Auxiliary Pump Mounting Pad................431
Reel and Conveyor Pump Exploded View................433
Remove and Install Tandem Pump Shaft Seals................435
Remove and Install Tandem Pump Trunnion Cover (Plain)................438
Remove and Install Tandem Pump Trunnion Seal (Control Shaft Side)................439
Group 10: Hydraulic Valves................395
Specifications................827
Disassemble and Assemble Knife Drive Control Valve................443
Remove and Install Charge Pressure Relief Valve................447
Remove and Install Check and High Pressure Relief Valves................448
Section 90: Operator Station................450
Group 00: Component Removal and Installation................450
Other Material................453
Specifications................827
Remove and Install Front Windshield Wiper Motor................455
Remove and Install Rear Windshield Wiper Motor................458
Remove and Install Cab-Forward Mirrors and Supports................459
Remove and Install Front Cab Windshield................461
Remove and Install Engine-Forward Cab Windshield................468
Remove and Install Steering Column................470
Remove and Install Cab Door................484
Remove and Install Seat................486
Remove and Install Seat Base................489
Remove and Install Evaporator Core................499
Remove and Install Door Handle................500
Remove and Install Cab Roof................502
Roof and Headliner—Exploded View................507
Remove and Install Roof Electrical Harness................508
Remove and Install Cab Shock Absorbers................509
Remove and Install Cab Shock Absorber Supports................512
Remove and Install Cab Isolators (If Equipped)................515
Remove and Install Windshield Seals................517
Group 05: Cab................450
Adjust Door................520
Centering Steering Wheel................521
Group 10: Air Conditioning................450
Special Tools................524
Replace Thermostat Capillary Tube................525
Compressor Oil Level Check................526
Air Conditioning Refrigerant Oil................528
Charge Air Conditioning System................529
Discharge Air Conditioning System................530
Evacuate Air Conditioning System................531
Purge Air Conditioning System................533
Section 211: Diagnostic Trouble Codes................534
Group 10: CDM - Diagnostic Trouble Codes................534
Cab Display Module - Diagnostic Trouble Codes................539
Group 15: ECU - Diagnostic Trouble Codes................552
ECU - Diagnostic Trouble Codes................552
Section 220: Engine and Engine Exhaust................561
Group 20: Theory of Operation................561
Radiator Screen Theory of Operation................563
Section 230: Fuel and Air Intake................564
Group 20: Theory of Operation................564
Air Intake System Theory of Operation................566
Fuel System Priming Theory of Operation................567
Section 240: Electrical................568
Group 05: General Information................568
Electrical Troubleshooting................570
Wire Identification Convention................571
Group 10: CanWin................568
CanWin General Information................574
CanWin Chassis I/O Page................576
CanWin Display I/O Page................579
CanWin Header I/O Page................582
CanWin Frequency/Analog Page................586
CanWin Program CANBUS Page................587
Group 20: Theory of Operation................568
Throttle Lever Theory of Operation................597
Starting Circuit Theory of Operation................598
Platform Recognition Circuit Theory of Operation................599
Header Height Sensor Circuit Theory of Operation................601
Header Tilt Theory of Operation................602
Group 30: Schematic................568
Electrical Schematic................613
Group 50: Diagnostic Tests and Adjustments................568
Specifications................827
Starting Circuit Operational Check................625
Testing Relays................626
Windrower Control Module/Cab Display Module Power Failure or System Failure (Header Down)................627
Speed Sensor Adjustment................629
Relief Valve Check and Adjustment................631
Platform Recognition Circuit Diagnostic................632
Header Height Sensor Circuit Diagnostic................640
Section 249: Electrical Component Information................644
Group 05: General Information................644
How to use the Connector Information (end views, numbers, location photos)................648
Group 40A: Electrical Assemblies................644
Windrower Control Module Connector (P34)................650
Windrower Control Module Connector (P35)................651
Windrower Control Module Connector (P36)................653
Radio Connector (P15)................656
Group 40B: Sensors................644
Left-Hand Wheel Speed Connector (P81)................658
Header Height Connector (P82)................659
Header Angle Connector (P83)................660
Right-Hand Float Connector (P84)................661
Left-Hand Float Connector (P85)................662
Reel Speed Connector (P87)................663
Knife-Disk Speed Connector (P88)................664
Group 40E: Lights................644
Left-Hand Work Light (High-Low Beam) Connector (P26B)................666
Right-Hand Work Light (High-Low Beam) Connector (P26C)................667
High-Low Beam Relay Connector (P104)................668
Field Lights, Road Lights Relay Connector (P105)................669
Right-Hand (Cab Forward) Turn Light, Tail Light Connector (P107)................670
Left-Hand (Cab Forward) Turn Light, Tail Light Connector (P111)................671
Left-Hand Side Work Light Connector (P117)................672
Left-Hand Corner Work Light Connector (P118)................673
Left-Hand Inside Work Light, High Beam Connector (P119)................674
Center Lamp Connector (P120)................675
Right-Hand Inside Work Light, High Beam Connector (P121)................676
Right-Hand Corner Work Light Connector (P122)................677
Right-Hand Side Work Light Connector (P123)................678
Left-Hand Rear Side Lamp Connector (P124)................679
Right-Hand Tail/Stop Lamp Rear Connector................680
Left-Hand Tail/Stop Lamp Rear Connector................681
Beacon Relay Connector................682
Group 40P: Gauges................645
Engine Temperature Gauge Connector (P42)................684
Fuel Level Gauge Connector (P47)................685
Group 40K: Relays................645
K17 Starter Relay (P9)................687
Group 40M: Motors................645
Screen Sweepers Connector (P107)................689
Group 40S: Switches................645
Blower Speed Connector (P23)................691
Neutral Switch Linkage Arm Connector (P24)................692
Seat Position (Cab End) Connector (P32)................693
Seat Position (Engine End) Connector (P33)................694
Ignition Switch Connector (P8)................695
Air Conditioning On-Off Connector (P19)................696
Recirculation Fan Connector (P28)................697
Rear Auxiliary Power 1 Switch (PWR 1)................698
Rear Auxiliary Power 2 Switch (PWR 2)................699
Group 40X: Interconnects and Ground Points................645
Header Connector (C1A)................702
Roof Connector (C2A)................704
Roof Connector (C3A)................705
Roof Connector (C3B)................706
Cab Connector (C4A)................707
Left-Hand Wheel End Connector (C6A)................709
Right-Hand Wheel End Connector (C7A)................710
Roof Connector (P2B)................711
Roof Connector (P2C)................712
Roof Connector (P2D)................713
Front Wiper Connector (P11)................714
Rear Wiper (Engine End) Connector (P12)................715
Cab End Wiper Connector (P13)................716
Radio Memory Connector (P16)................717
Air Conditioning Compressor Clutch Connector (P18)................718
Air Conditioning System Connector (P22)................719
Hood Connector (P26A)................720
Temperature Control Connector (P27)................721
Fresh Air Boost Connector (P29)................722
CAN Stub Connector (P40)................723
Antenna Ground................724
Ground Point A Frame Rail................725
Ground Point B Engine Block................726
Ground Point D................727
Ground Point E................729
Ground Point F................730
Cab Display Module Ground................731
Group 40Y: Electronically Actuated Mechanical Devices................646
Brake Connector (P44)................733
Load Sense Dump Connector (P75)................734
Pressure Transducer Connector (P97)................735
Section 250: Drive Train................736
Group 20: Theory of Operation................736
Linkage Arm Neutral Switch Theory of Operation................738
Neutral Interlock and Steering Theory of Operation................739
Interlock Pivot Channel Theory of Operation................742
Wheel Motor Speed Theory of Operation................743
Neutral Adjustment Theory of Operation................745
Traction Pump Interlock Theory of Operation................747
Group 50: Diagnostic Tests and Adjustments................736
Specifications................827
Steering and Neutral Switch Troubleshooting................750
Interlock Pivot Channel Clearance Check and Adjustment................751
Neutral Switch Linkage Arm Check and Adjustment................753
Traction Pump Interlock Check and Adjustment................755
Equalize Neutral Inside Cab Check and Adjustment................761
Servo Input Check and Adjustment................763
Neutral Adjustment Chart................765
Neutral Fine Check and Adjustment................772
Neutral Adjustment Checks................773
Wheel Motor Adjustment—Low Speed................775
Wheel Motor Adjustment—Mid Range................778
Wheel Motor Adjustment—High Speed................781
Section 260: Steering and Brakes................784
Group 20: Theory of Operation................784
Brake Circuit Theory of Operation................786
Group 50: Diagnostic Tests and Adjustments................784
Brake Circuit Operational Check................789
Park Brake Circuit Operational Check................791
Park Brake Circuit Pressure Check................793
Section 270: Hydraulics................794
Group 20: Theory of Operation................794
Center Link Self Alignment Theory of Operation................797
Charge Pump (Furthest from Engine) Theory of Operation................798
Cooler Bypass Test Theory of Operation................799
Double Windrow Attachment Theory of Operation................800
Header Drive Theory of Operation................801
Header Return Manifold Theory of Operation................802
Hydraulic Filter Theory of Operation................803
Hydraulic Fore-Aft Theory of Operation................804
Multi-Function Control Block Theory of Operation................805
Piston Pumps Theory of Operation................806
Secondary (Fine) Float Adjustment Circuit Theory of Operation................808
Super Charge Pressure Valve Block Theory of Operation................809
Reel and Conveyer Test with Draper Head Theory of Operation................810
Reel and Auger Test with Auger Head Theory of Operation................811
Hydraulic Lift Block Theory of Operation................812
Group 30: Schematic................794
Hydraulic Schematics................825
Schematics................825
Group 50: Diagnostic Tests and Adjustments................794
Specifications................827
Combination Valve Relief Setting Check and Adjustment................828
Cooler Bypass System Check and Adjustment................830
Cooler Bypass Pressure Differential Check................833
Cooler Bypass Flow and Pressure Check................835
Cooler Bypass Relief Valve Adjustment................839
Header Charge Pressure System Checks................840
Header Hydraulic Check and Adjustment................842
Hydraulic Filter System Check and Adjustment................843
Super Charge Pressure Valve Block Check and Adjustment................846
Reel and Conveyor Test with Draper Header Checks................849
Reel and Auger Test with Auger Header Check and Adjustment................851
Knife Drive Check and Adjustment................853
Secondary (Fine) Float Adjustment Circuit................855
Section 290A: Heating, Ventilation, and Air Conditioning................861
Group 20: Theory of Operation................861
Air Conditioning Circuit Theory of Operation................863
Heating and Air Conditioning Theory of Operation................864
Heating and Air Conditioning Components Theory of Operation................865
Group 50: Diagnostic Tests and Adjustments................861
Air Conditioning Performance Troubleshooting................869
Replacing Heater Valve................871
Heater Valve Diagnostics................873
Section 299: Dealer Fabricated Tools................875
Group 05: Dealer Fabricated Tools................875
DFEXT5 Steering Wheel Removal Tool................877
John Deere Self-Propelled Hay & Forage Windrower W150 Diagnostic & Repair Technical Manual (TM122219)
