John Deere W235 W260 Rotary Self-Propelled Windrower Workshop Repair Manual TM129519 PDF - MJODTM129519.zip
Full workshop repair guide for the John Deere W235 and W260 Rotary Self-Propelled Hay & Forage Windrower, offering dealer-level instructions for servicing, troubleshooting, and rebuilding the machine.
This John Deere W235, W260 Rotary Self-Propelled Hay & Forage Windrower service and repair manual covers:
* 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.
TM129519 - John Deere Self-Propelled Hay and Forage Rotary Windrowers Models W235 and W260 Technical Manual (Repair).PDF
TM129519 - John Deere Self-Propelled Hay and Forage Rotary Windrowers Models W235 and W260 Technical Manual (Repair).EPUB
Total Pages: 1,230 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
Wiring 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
tm129519 - W235 and W260 Rotary 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
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 Rotary Self-Propelled Windrower Specifications
W260 Rotary Self-Propelled Windrower Specifications
W235 Machine Dimensions
W260 Machine 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—W260
Remove and Install Engine—W235
Remove and Install Engine Mount Isolators
Remove and Install Fan
Remove and Install Serpentine and Air Conditioning Compressor Belts
Remove and Install Bellows—W235
Remove and Install Bellows—W260
Remove and Install Aftertreatment Device Assembly—W260
Remove and Install Aftertreatment Device Assembly—W235
Remove and Install Decomposition Tube—W260 (S.N. —420000)
Remove and Install Decomposition Tube—W260 (S.N. 420001—)
Remove and Install Decomposition Tube—W235
Remove and Install SCR Converter (S.N. —420000)
Remove and Install SCR Converter (S.N. 420001—)
Remove and Install Diesel Oxidation Catalyst and Diesel Particulate Filter—W260 (S.N. —420000)
Remove and Install Diesel Oxidation Catalyst and Diesel Particulate Filter—W235 (S.N. —420000)
Remove and Install Diesel Oxidation Catalyst and Diesel Particulate Filter (S.N. 420001—)
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
Installation of Repair Wire Assembly (RWA)
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