Complete Repair manual for John Deere 4895 Self Propelled Hay & Forage Windrower (SN.-180000), with technical information to maintain, repair, and rebuild like professional mechanics.

John Deere Self-Propelled Hay and Forage Windrowers Models 4895 workshop 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.

TM2033 - John Deere Self Propelled Hay & Forage Windrower 4895 (SN. before 180000) Technical Manual (Repair).PDF
TM2033 - John Deere Self Propelled Hay & Forage Windrower 4895 (SN. before 180000) Technical Manual (Repair).epub

Total Pages: 1,012 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
  Foreword
   Service Technician Response
   General
      Safety
      Specifications
      Fuel, Coolant and Lubricants
   Engine
      Engine
      Cooling System
   Fuel and Air Systems
      Air Intake and Exhaust
      Diesel Fuel System
   Electrical
      Batteries
      Starter
      Alternator
      Engine Electrical Components
      Lighting and Accessory Components
      Gauges and Monitors
      Platform and Ground Speed Controls
      Cab Heat and A/C Electrical Components
      Connector Repair
   Power Train
      Hydrostatic System Flushing and Start-Up
      Tandem Ground Drive Pumps
      Ground Drive Motor
      Final Drive (Serial No. -310400)
      Final Drive With Internal Park Brake (Serial No. 310001-)
      Ground Drive Linkage
   Steering and Brakes
      Steering System
      Brakes (Serial No. -310000)
   Hydraulic System
      Component Location
      Auxiliary-Charge Pump
      Platform Drive Pump
      Platform Drive Motor
      Hydraulic Valves
      Hydraulic Cylinders
      Miscellaneous
   Miscellaneous
      Rear Axle
      Drive Wheels
      Lift Arm
   Operator Station
      Air Conditioning Service
      Air Conditioning Repair
      Heater Controls
      Cab
   Dealer Fabricated Tools
      Dealer Fabricated Tools

tm2033 - 4895 Self-Propelled Windrower Repair

Table of Contents

Foreword

Service Technician Response

Section 10: General

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Avoid High-Pressure Fluids

Service Accumulator Systems Safely

Park Windrower Safely

Stay Clear of Rotating Driveline

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

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Construct Dealer-Made Tools Safely

Dispose of Waste Properly

Live With Safety

Practice Safe Service Procedures

Group 10: Specifications

4895 Self-Propelled Windrower Specifications Specifications and design subject to change without notice.

Dimensions

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Service Recommendations For O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

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

Service Recommendations For Flare-Type Tube Fittings

Service Recommendations For Snap-To-Connect Fittings

Product Identification Number Plate

Windrower Product Identification Number Plate Location

Engine Serial Number Plate Location

Fuel Injection Pump Serial Number

Cab Serial Number

Group 15: Fuel, Coolant and Lubricants

Diesel Fuel

Biodiesel Fuel

Diesel Fuel Storage

Lubricity of Diesel Fuel

Diesel Engine Coolant

Supplemental Coolant Additives

Operating in Warm Temperature Climates

Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER

Testing Diesel Engine Coolant

Diesel Engine Oil

Diesel Engine Break-In Oil

Hydrostatic Drive Oil

Final Drive Oil

Grease

Alternative and Synthetic Lubricants

Lubricant Storage

Section 20: Engine

Group 05: Engine

John Deere Engine Repair—Use CTM104

Essential or Recommended Tools

Specifications

Remove and Install Engine

Replace Engine Mount Isolators

Remove and Install Serpentine Belt

Group 10: Cooling System

Engine Water Pump Repair—Use CTM104

Essential or Recommended Tools

Other Material

Specifications

Inspect Cooling System

Remove and Install Radiator

Fill Radiator

Winterize Cooling System

Flush Out Cooling System

Section 30: Fuel and Air Systems

Group 05: Air Intake and Exhaust

Turbocharger Repair—Use CTM104

Clean Filter Housing Air Precleaner

Clean Bowl-Type Air Precleaner

Clean Precleaner Screen

Remove and Install Air Filters

Clean and Inspect Primary Air Filter

Remove and Install Air Precleaner and Intake Tube

Remove and Install Exhaust Tube

Group 10: Diesel Fuel System

Injection Pump, Nozzle, and Governor Repair—Use CTM207

Specifications

Shut Off Fuel Supply

Drain Fuel Tank

Remove and Install Fuel Tank

Do Not Modify Fuel System

Drain Water From Fuel Filter

Bleed Fuel Filter

Change Fuel Filter

Bleed Fuel Injection Pump

Bleed Fuel Lines to Injectors

Check and Set Engine Speed

Section 40: Electrical

Group 05: Batteries

Specifications

Remove and Install Battery

Using Booster Battery—12 Volt System

Charging Battery

Checking Specific Gravity

Group 10: Starter

Starter Repair—Use CTM77

Specifications

Remove and Install Starter Motor

Group 15: Alternator

Alternator Repair—Use CTM77

Remove and Install Alternator

Group 20: Engine Electrical Components

Other Material

Replace Fuel Level Sensor

Replace Air Restriction Switch

Replace Engine Coolant Temperature Switch

Replace Engine Coolant Temperature Sensor

Replace Engine Oil Pressure Switch

Replace Engine Speed Sensor

Replace Throttle Motor

Disassemble and Inspect Throttle Motor

Remove Rotating Wand Motor

Rotating Wand Motor—Exploded View

Install Rotating Wand Motor

Group 25: Lighting and Accessory Components

Service Equipment and Tools

Specifications

Halogen Bulb Safety Guidelines

Replace and Adjust Cab Headlight Bulb

Replace Flood Light Bulb

Replace Rear Warning, Tail, and Side Marker Light Bulbs

Replace Turn Signal Indicator Bulb

Replace Dome and Console Light Bulb

Replace Key Switch

Replace Light Switches and Wiper Switch

Replace Turn Signal Switch

Replace Horn Switch

Replace Horn

Replace Overhead Console Horn

Replace Seat Switch

Replace Wiper Motor

Adjust Windshield Wiper—Short Arm

Adjust Windshield Wiper—Long Arm (Optional)

Replace Radio

Replace Radio Speaker

Replace Radio Antenna

Mount Communications/CB Radio

Install FM Radio

Group 30: Gauges and Monitors

Replace Warning Panel or Light Bulbs

Replace Gauges or Gauge Light Bulbs

Replace Tachometer

Program Tachometer

Group 35: Platform and Ground Speed Controls

Essential or Recommended Tools

Specifications

Replace Console Rocker Switches

Replace Hydro Lever Switch Module

Replace Hydro Lever Neutral Switch

Remove and Install Hydro Lever

Replace Steering Neutral Start Switch

Replace Hydraulic Filter Restriction Switch

Replace Hydraulic Charge Pressure Switch

Replace Hydraulic Oil Temperature Switch

Replace Hydraulic Float Pressure Transducer

Replace Ground Speed Sensor

Adjust Ground Speed Sensor Magnetic Pickup

Replace Solenoid Coils

Group 40: Cab Heat and A/C Electrical Components

Other Material

Replace Air Conditioning Temperature Control Switch

Replace Air Conditioning Thermostat

Replace Air Conditioning Low Pressure Switch

Replace Air Conditioning High Pressure Switch

Replace Blower Motor Control Switch

Replace Blower Motor Resistor

Replace Blower Motor

Replace Cab Pressurizer Motor

Group 45: Connector Repair

Essential or Recommended Tools

Other Material

Electrical Connector Handling

Use Contact Cleaner and Di-electric Grease

Replace WEATHER PACK Connector

Install WEATHER PACK Terminal

Remove Connector Body from Blade Terminals

Replace METRI-PACK (Push Type) Connectors

Replace CPC, Large MATE-N-LOK and METRIMATE METRIMATE is a trademark of AMP Inc. Pin Type Connectors

Replace DEUTSCH Connectors

Install DEUTSCH Terminals

Section 50: Power Train

Group 05: Hydrostatic System Flushing and Start-Up

Specifications

Flush Hydrostatic Ground Drive System

Hydrostatic Ground Drive System Start-Up

Group 10: Tandem Ground Drive Pumps

Essential or Recommended Tools

Other Material

Specifications

Flat Face O-Ring vs. Flare Hydraulic Fittings

Service Recommendations For Snap-To-Connect Fittings

Remove and Install Tandem Ground Drive Pumps

Disassemble Ground Drive Pump

Inspect Ground Drive Pump

Assemble Ground Drive Pump

Group 15: Ground Drive Motor

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Flat Face O-Ring vs. Flare Hydraulic Fittings

Service Recommendations For Snap-To-Connect Fittings

Remove and Install Ground Drive Motor (Serial No. — 310000)

Remove and Install Speed Rotor On RH Ground Drive Motor (Serial No. 310001—)

Remove and Install Ground Drive Motor (Serial No. 310001—)

Remove and Install Ground Drive Motor (Serial No. 320001—)

Disassemble Ground Drive Motor

Inspect Ground Drive Motor

Assemble Ground Drive Motor

Group 20: Final Drive (Serial No. —310400)

Essential Tools or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Final Drive

Disassemble Final Drive

Assemble Final Drive Hub

Group 25: Final Drive With Internal Park Brake (Serial No. 310001—)

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Final Drive With Internal Park Brake

Disassemble Final Drive With Internal Park Brake

Assemble Final Drive

Disassemble Internal Park Brake

Assemble Internal Park Brake

Internal Park Brake Pressure Check

Internal Park Brake Static Torque Check

Group 30: Ground Drive Linkage

Specifications

Remove and Install Drive Shaft

Drive Shaft—Exploded View

Remove and Install Ground Drive Control Cable

Remove and Install Ground Drive Linkage Rods

Section 60: Steering and Brakes

Group 05: Steering System

Service Equipment and Tools

Other Material

Specifications

Flat Face O-Ring vs. Flare Hydraulic Fittings

Service Recommendations For Snap-To-Connect Fittings

Remove Steering Mechanism

Disassemble and Inspect Steering Mechanism

Assemble Steering Mechanism

Install Steering Mechanism

Disassemble and Assemble Steering Column

Group 10: Brakes (Serial No. —310000)

Service Equipment and Tools

Specifications

Flat Face O-Ring vs. Flare Hydraulic Fittings

Remove and Install Brake Disk and Caliper

Disassemble Brake Disk and Caliper

Inspect Brake Disk and Caliper Components

Assemble Brake Disk and Caliper

Section 70: Hydraulic System

Group 05: Component Location

Platform Drive and Cylinders

Platform Drive and Cylinders (Serial No. 320001—)

Ground Drive System (Serial No. —310000)

Ground Drive System (Serial No. 310001—)

Ground Drive System (Serial No. 320001—)

Group 10: Auxiliary-Charge Pump

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Flat Face O-Ring vs. Flare Hydraulic Fittings

Remove and Install Auxiliary-Charge Pump

Disassemble Auxiliary-Charge Pump

Inspect Auxiliary-Charge Pump

Assemble Auxiliary-Charge Pump

Group 15: Platform Drive Pump

Essential or Recommended Tools

Other Material

Specifications

Flat Face O-Ring vs. Flare Hydraulic Fittings

Service Recommendations For Snap-To-Connect Fittings

Remove and Install Platform Drive Pump

Disassemble Platform Drive Pump

Inspect Platform Drive Pump Components

Assemble Platform Drive Pump

Group 20: Platform Drive Motor

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Flat Face O-Ring vs. Flare Hydraulic Fittings

Service Recommendations For Snap-To-Connect Fittings

Remove and Install Platform Drive Motor

Disassemble Platform Drive Motor

Inspect Platform Drive Motor Components

Assemble Platform Drive Motor

Group 25: Hydraulic Valves

Essential or Recommended Tools

Specifications

Flat Face O-Ring vs. Flare Hydraulic Fittings

Service Recommendations For Snap-To-Connect Fittings

Remove and Install Main Hydraulic Control Valve (Serial No. 300001—)

Remove and Install Main Hydraulic Control Valve (Serial No. 320001—)

Disassemble and Assemble Main Hydraulic Control Valve (Serial No. 300001—)

Disassemble and Assemble Main Hydraulic Control Valve (Serial No. 320001—)

Remove and Install Platform Control Valve (Serial No. 300001—)

Remove and Install High Pressure Valve Block (Serial No. —300000)

Disassemble And Inspect High Pressure Valve Block (Serial No. —300000)

Assemble High Pressure Valve Block (Serial No. —300000)

Remove and Install Charge Valve Block (Serial No. —300000)

Remove and Install Priority Valve (Serial No. —300000)

Replace Solenoid Coils and Valve Cartridges (Serial No. —300000)

Group 30: Hydraulic Cylinders

Service Equipment and Tools

Other Material

Specifications

Flat Face O-Ring vs. Flare Hydraulic Fittings

Remove and Install Lift Cylinders, Tilt Cylinders, and Float Cylinders with Adjusters

Disassemble and Inspect Float Cylinder or Lift Cylinder (Serial No. —181034)

Disassemble and Assemble Float or Lift Cylinder (Serial No. 181035—)

Replace Float Cylinder End Block Needle Bearings

Assemble Float Cylinder (Serial No. —181034)

Assemble Lift Cylinder (Serial No. —181034)

Disassemble and Inspect Tilt Cylinder (Serial No. —181354) (Black)

Assemble Tilt Cylinder (Serial No. —181354) (Black)

Disassemble and Inspect Tilt Cylinder (Serial No. 181355—) (Green)

Assemble Tilt Cylinder (Serial No. 181355—) (Green)

Repair Steering Lock Cylinder

Group 35: Miscellaneous

Essential or Recommended Tools

Specifications

Flat Face O-Ring vs. Flare Hydraulic Fittings

Service Recommendations For Snap-To-Connect Fittings

Adjust Platform Drive Pump Belt Tension

Remove and Install Platform Drive Pump Belt

Clean Oil Cooler/Condenser

Replace Oil Cooler/Condenser

Replace Hydraulic Accumulator

Drain and Fill Hydraulic Reservoir

Remove and Install Hydraulic Reservoir

Section 80: Miscellaneous

Group 05: Rear Axle

Service Equipment and Tools

Other Material

Specifications

Repair Caster Wheel Hub

Remove and Install Axle Knee

Remove and Inspect Rear Axle Assembly

Install Rear Axle Assembly

Replace Axle Knee Bushings

Replace Rear Axle Bushings

Adjust Caster Wheel Track Width

Group 10: Drive Wheels

Specifications

Remove and Install Drive Wheels

Group 15: Lift Arm

Service Equipment and Tools

Specifications

Replace Bearings

Section 90: Operator Station

Group 05: Air Conditioning Service

Essential or Recommended Tools

Other Material

Specifications

General Information

R134a Refrigerant Cautions

Air Conditioning System—Diagram

Air Conditioning System Fittings

Proper Refrigerant Handling

Refrigerant Hoses and Tubing Inspection

Recover R134a System

Flush Air Conditioning System

Purge Air Conditioning System

Evacuate R134a System

Charge R134a System

Refrigerant Oil Information

Check Compressor Oil Charge

Determine Correct Refrigerant Oil Charge

Add Refrigerant Oil to Pressurized System

Add Refrigerant Oil to System

Group 10: Air Conditioning Repair

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Service Parts Kits

Specifications

Remove and Install Compressor

Remove and Install Compressor Clutch Assembly

Check Clutch Hub Clearance

Inspect Compressor Manifold

Inspect Compressor Thermal Bypass Valve

Disassemble and Inspect Compressor

Assemble Compressor

Replace Receiver-Dryer

Remove and Install Compressor Relief Valve

Remove Evaporator/Heater Core

Install Evaporator/Heater Core

Cleaning Condenser

Repair Condenser

Group 15: Heater Controls

Replace Heater Control Valve

Group 20: Cab

Service Equipment and Tools

Specifications

Remove and Install Windshield

Replace Rear Window

Remove and Install Cab Roof

Remove and Install Operator Presence Switch

Remove and Install Operator's Seat

Operator Seat Exploded View

Operator's Seat Air Suspension Assembly—Exploded View

Disassemble Operator's Seat Air Suspension Assembly

Assemble Operator's Seat Air Suspension Assembly

Replace Cab Mount Isolators

Check Hydrostatic Ground Drive

Adjust Hydrostatic Ground Drive

Section 99: Dealer Fabricated Tools

Group 05: Dealer Fabricated Tools

DFEX1617C Guide

DFEX1617D Compressor Holding Fixture

DFEX1617E Support Plate

DFEXT2 Brake Release Bar With Forcing Screw

John Deere Self Propelled Hay & Forage Windrower 4895 (SN. before 180000) Repair Service Technical Manual (TM2033)