Complete Repair  manual for John Deere Self-Propelled Hay and Forage Windrowers Models D450, with all the technical information to maintain, repair, and rebuild like professional mechanics.

TM108819 - John Deere Self-Propelled Hay and Forage Windrowers Models D450 Technical Manual (Repair).PDF

Total Pages: 1,192 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
 Foreword
   General
      Safety
      General Information
      Fuel, Coolant, and Lubricants
   Engine
      Engine
      Cooling System
   Fuel and Air Systems
      Air Intake and Exhaust
      Diesel Fuel System
   Electrical
      Battery
      Starter
      Alternator
      Engine Electrical Components
      Lighting and Accessory Components
      Operators Station
      Platform and Ground Speed Controls
      Cab Heat and A/C Electrical Components
      Harness and Connector Repair
      Wire Harness Routing
      Power Distribution
      GreenStar Components
   Power Train
      Hydrostatic System Flushing and Start-Up
      Pump Drive Gear Case
      Gear Case Cooling Pump
      Ground Drive Pumps
      Ground Drive Motor
      Final Drive With Internal Park Brake
      Ground Drive Linkage
   Steering
      Steering System
      Rear Assist Steering
   Hydraulic System
      Component Location
      Auxiliary Pump
      Triple Pump
      Charge Pump
      Platform Drive Pump
      Motor Repair
      Valve Repair
      Hydraulic Cylinders
      Miscellaneous
      Accumulator
   Miscellaneous
      Rear Axle
      Drive Wheels
      Lift Arm
   Operator Station
      Air Conditioning Service
      Air Conditioning Repair
      Cab
   Dealer Fabricated Tools
      Dealer Fabricated Tools

tm108819 - D450 Self-Propelled Windrower Repair

Table of Contents

Foreword

Section 10: General

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Practice Safe Maintenance

Park Windrower Safely

Prepare for Emergencies

Service Machines Safely

Practice Safe Service Procedures

Use Adequate Service Facilities

Support Machine Properly

Use Proper Tools

Wear Protective Clothing

Work in Clean Area

Avoid Harmful Asbestos Dust

Work In Ventilated Area

Illuminate Work Area Safely

Use Proper Lifting Equipment

Stay Clear of Rotating Driveline

Construct Dealer-Made Tools Safely

Remove Paint Before Welding or Heating

Handle Fluids Safely—Avoid Fires

Service Cooling System Safely

Service Accumulator Systems Safely

Service Tires Safely

Handling Batteries Safely

Prevent Battery Explosions

Prevent Acid Burns

Precautions for Welding

Servicing Electronic Control Units

Welding Near Electronic Control Units

Keep Electronic Control Unit Connectors Clean

Handle Electronic Components and Brackets Safely

Avoid High-Pressure Fluids

Do Not Open High-Pressure Fuel System

Wait Before Opening High-Pressure Fuel System

Avoid Heating Near Pressurized Fluid Lines

Replace Safety Signs

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Live With Safety

Group 10: General Information

D450 Self-Propelled Windrower Specifications

Dimensions

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Face Seal Fittings Assembly and Installation—All Pressure Applications

SAE Face Seal Fitting Torque Chart—Standard Pressure Applications

SAE Face Seal Fitting Torque Chart—High Pressure Applications

Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications

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

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: Fuel, Coolant, and Lubricants

Diesel Fuel

BioDiesel Fuel

Diesel Fuel Storage

Lubricity of Diesel Fuel

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Supplemental Coolant Additives

Operating in Warm Temperature Climates

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

Testing Diesel Engine Coolant

Drain Intervals for Diesel Engine Coolant

Mixing of Lubricants

Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I

Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III

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

Final Drive Oil

Grease

Alternative and Synthetic Lubricants

Lubricant Storage

Section 20: Engine

Group 05: Engine

John Deere Engine Repair—Use CTM

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Engine

Remove and Install Engine Mount Isolators

Remove and Install Serpentine Belt

Group 10: Cooling System

Engine Water Pump Repair—Use CTM

Essential or Recommended Tools

Other Material

Specifications

Test Surge Tank and Radiator

Test Surge Tank Cap

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

Fill Radiator

Winterize Cooling System

Flush Out Cooling System

Section 30: Fuel and Air Systems

Group 05: Air Intake and Exhaust

Other Material

Specifications

Turbocharger Repair—Use CTM

Remove and Install Air Check Valve

Remove and Install Air Restriction Switch

Remove and Install Air Filters

Clean and Inspect Primary Air Filter

Remove and Install Air Cleaner Inlet Tube

Remove and Install Muffler

Group 10: Diesel Fuel System

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

Shut Off Fuel Supply

Drain Fuel Tank

Remove and Install Fuel Level Sensor

Remove and Install Fuel Tank

Do Not Modify Fuel System

Drain Water From Fuel Filter

Change and Bleed Fuel Filter

Section 40: Electrical

Group 05: Battery

Specifications

Remove and Install Battery

Connecting Booster Battery

Charging Battery

Checking Specific Gravity

Group 10: Starter

Essential or Recommended Tools

Specifications

Starter Repair—Use CTM

Remove and Install Starter Motor

Group 15: Alternator

Specifications

Remove and Install Alternator

Group 20: Engine Electrical Components

Essential or Recommended Tools

Specifications

Replace Sensors and Switches

Remove and Install Engine Control Unit (ECU)

Remove and Install Rotating Wand Motor

Group 25: Lighting and Accessory Components

Specifications

Halogen Bulb Safety Guidelines

Remove, Install, and Adjust Cab Headlight Bulb

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

Remove and Install High Intensity Discharge (HID-Xenon) Lights (Optional)

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

Remove and Install Rear Flood Lights

Remove and Install Flood Light Bulb

Remove and Install Rear Warning and Tail Light Bulbs

Remove and Install Auxiliary Lights (Optional)

Remove and Install Auxiliary Light Bulb

Remove and Install Dome Light Bulb

Remove and Install Horn

Remove and Install Wiper Motor

Adjust Windshield Wiper

Remove and Install Windshield Washer

Group 30: Operators Station

Other Material

Specifications

Remove and Install Cornerpost Primary Display Unit

Remove and Install Key Switch

Remove and Install Wiper Switch

Remove and Install Hazard Light Switch

Remove and Install Platform Engage Switch

Remove and Install Turn Signal Switch

Remove and Install Horn Switch

Remove and Install Radio

Remove and Install Radio Speaker

Remove and Install Radio Antenna

Separate Armrest and Control Panel From Support Base

Remove and Install Armrest Control Panel Console

Remove and Install Armrest Display Unit

Remove and Install Backlighting Driver

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

Remove and Install Armrest Control Switch Panel

Replace Neutral Safety Switch

Remove and Install Multi-Function Lever

Remove and Install Remote Mirrors (Optional)

Remove and Install Remote Mirror Switch (Optional)

Remove and Install Mirror Heater Switch (Optional)

Group 35: Platform and Ground Speed Controls

Service Equipment and Tools

Other Material

Specifications

Remove and Install Steering Neutral Start Switch

Remove and Install Hydraulic Filter Restriction Switch

Remove and Install Hydraulic Charge Pressure Switch

Remove and Install Hydraulic Oil Temperature Switch

Remove and Install Platform Lift Pressure Sensor

Remove and Install Platform Lift Position Sensor

Remove and Install Platform Tilt Position Sensor

Remove and Install Ground Speed Sensor

Group 40: Cab Heat and A/C Electrical Components

Air Conditioning System With Precleaner (General Information)

Remove and Install Blower Motor

Remove and Install Recirculator Fan Motor Driver

Remove and Install Recirculator Motor

Remove and Install Temperature Control Door Actuator

Remove and Install Evaporator Temperature Sensor

Replace Air Temperature Sensors

Remove and Install Air Conditioning Low Pressure Switch

Remove and Install Air Conditioning High Pressure Switch

Group 45: Harness and Connector Repair

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

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 46: Wire Harness Routing

Electrical Component Identification and Location

Replace Harness

Cab Main Wiring Harness

Chassis Main Wiring Harness

Group 50: Power Distribution

Specifications

Remove and Install Cab Power Module

Remove and Install Cab Control Unit

Remove and Install Starter Relay

Fuse Panel

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

Section 50: Power Train

Group 05: Hydrostatic System Flushing and Start-Up

Flush Hydrostatic Ground Drive System

Hydrostatic Ground Drive System Start-Up

Group 10: Pump Drive Gear Case

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Pump Drive Gear Case

Disassemble and Inspect Pump Drive Gear Case

Assemble Pump Drive Gear Case

Group 15: Gear Case Cooling Pump

Service Equipment and Tools

Other Material

Specifications

Remove and Install Gear Case Cooling Pump

Disassemble Gear Case Cooling Pump

Inspect Pump Drive Gear Case Cooling Pump

Assemble Gear Case Cooling Pump

Group 20: Ground Drive Pumps

Essential or Recommended Tools

Service Equipment and 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 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 Pump

Group 25: Ground Drive Motor

Service Equipment and Tools

Other Material

Specifications

Remove and Install Ground Drive Motor

Disassemble and Assemble Ground Drive Motor

Disassemble and Assemble Ground Drive Motor Port Plate

Group 35: Final Drive With Internal Park Brake

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Final Drive With Internal Brake

Disassemble and Assemble Final Drive With Internal Brake

Disassemble and Assemble Internal Park Brake

Internal Park Brake Checks

Group 40: Ground Drive Linkage

Specifications

Remove and Install Ground Drive Control Cable

Remove and Install Ground Drive Linkage Rods

Section 60: Steering

Group 05: Steering System

Other Material

Specifications

Remove and Install Steering Mechanism

Disassemble and Assemble Steering Mechanism

Disassemble and Assemble Steering Column

Group 10: Rear Assist Steering

Service Equipment and Tools

Specifications

Remove and Install Rear Assist Steering Valve

Remove and Install Rear Assist Steering Control Valve Block

Disassemble and Assemble Rear Assist Steering Control Valve Block

Remove and Install Steering Lever

Remove and Install Rear Assist Steering Cylinder Bracket

Disassemble and Assemble Rear Assist Steering Cylinder Brackets

Section 70: Hydraulic System

Group 05: Component Location

Platform Drive and Cylinders

Ground Drive System

Rear Steering Components

Group 06: Auxiliary Pump

Service Equipment and Tools

Specifications

Remove and Install Auxiliary Pump

Group 07: Triple Pump

Service Equipment and Tools

Specifications

Remove and Install Triple Pump

Group 10: Charge Pump

Service Equipment and Tools

Specifications

Remove and Install Charge Pump

Group 15: Platform Drive Pump

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Platform Drive Pump

Disassemble Platform Drive Pump

Inspect Platform Drive Pump Components

Assemble Platform Drive Pump

Group 20: Motor Repair

Service Equipment and Tools

Remove and Install Platform Drive Motor

Group 25: Valve Repair

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Low Pressure Steering Control Valve

Low Pressure Steering Control Valve—Exploded View

Disassemble and Assemble Low Pressure Steering Control Valve

Remove and Install Reel Drive Control Valve

Reel Drive Control Valve—Exploded View

Disassemble and Assemble Reel Drive Control Valve

Remove and Install Reel Lift Control Valve

Reel Lift Control Valve—Exploded View

Disassemble and Assemble Reel Lift Control Valve

Remove and Install Platform Lift Control Valve

Disassemble and Assemble Platform Lift Control Valve

Remove and Install Accumulator Shutoff Valve

Remove and Install Platform Tilt Valve

Disassemble and Assemble Platform Tilt Valve

Multicoupler Valve Identification

Remove and Install Multicoupler

Disassemble and Assemble Multicoupler

Group 30: Hydraulic Cylinders

Service Equipment and Tools

Specifications

Remove and Install Platform Tilt Cylinder

Remove and Install Platform Lift Cylinder

Remove and Install Rear Assist Steering Cylinder

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

Remove and Install Steering Lock Cylinder

Repair Steering Lock Cylinder

Group 35: Miscellaneous

Service Equipment and Tools

Relieve Traction Unit Hydraulic System Pressure

Release Float Pressure

Remove and Install Combination Cooler

Drain and Fill Hydraulic Reservoir

Remove and Install Hydraulic Reservoir

Group 40: Accumulator

Essential or Recommended Tools

Specifications

Remove and Install Header Lift System Hydraulic Accumulator

Checking Accumulator Pressure

Section 80: Miscellaneous

Group 05: Rear Axle

Service Equipment and Tools

Other Material

Specifications

Repair Caster Wheel Hub

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 10: Drive Wheels

Service Equipment and Tools

Specifications

Remove and Install Drive Wheels

Group 15: Lift Arm

Service Equipment and Tools

Other Material

Specifications

Remove and Install Lift Arm Bearings

Section 90: Operator Station

Group 05: Air Conditioning Service

Essential or Recommended Tools

Other Material

Specifications

General Information

R-134a Refrigerant Cautions

Proper Refrigerant Handling

Refrigerant Hoses and Tubing Inspection

Recover R-134a System

Flush Air Conditioning System

Purge Air Conditioning System

Evacuate R-134a System

Charge R-134a 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

Specifications

Remove and Install Compressor

Remove and Install Compressor Clutch Assembly

Check Clutch Hub Clearance

Remove and Install Receiver-Dryer

Remove and Install Evaporator

Remove and Install Heater Core

Repair Condenser

Group 20: Cab

Service Equipment and Tools

Specifications

Remove and Install Cab Fascia

Remove and Install Cab

Remove and Install Windshield

Remove and Install Rear Window

Remove and Install Cab Outer Roof

Remove and Install Cab Inner Roof

Remove and Install Cab Headliner

Remove and Install Operator Presence Switch

Remove and Install Operator Seat

Operator Seat Exploded View

Operator Seat Air Suspension Assembly—Exploded View

Disassemble and Assemble Operator Seat Air Suspension Assembly

Remove and Install Cab Door

Disassemble and Assemble Cab Door

Repair Cab Door Latch Striker

Remove and Install Cab Mount Isolators

Check Hydrostatic Ground Drive

Adjust Hydrostatic Ground Drive

Section 99: Dealer Fabricated Tools

Group 05: Dealer Fabricated Tools

DFEX1819D Compressor Holding Fixture

DFEX1819E Support Plate

DFEXT4 Sizing Arbor

John Deere Self-Propelled Hay and Forage Windrowers Models D450 Repair Service Technical Manual (TM108819)