John Deere W150 Self-Propelled Hay & Forage Windrower Service Repair Workshop Manual PDF Download (TM122219) - TM122219 - John Deere Self-Propelled Hay & Forage Windrower W150 Technical Manual (Diagnosis Operation Test Repair Service).PDF

Complete diagnostic, operational, testing, repair and service manual for the John Deere Self-Propelled Hay & Forage Windrower W150, packed with all the shop guidance needed to maintain, troubleshoot, fix, and fully rebuild or restore your machine just as a professional technician would.

The John Deere Self-Propelled Hay & Forage Windrower W150 workshop diagnostics and testing manual contains:

* 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