John Deere D450 Self-Propelled Windrower Repair Technical Manual TM108819 15MAY15

Index
10-General
05-Safety
Avoid Harmful Asbestos Dust
Avoid Heating Near Pressurized Fluid Lines
Avoid High-Pressure Fluids
Construct Dealer-Made Tools Safely
Do Not Open High-Pressure Fuel System
Handle Electronic Components and Brackets Safely
Handle Fluids Safely—Avoid Fires
Handling Batteries Safely
Illuminate Work Area Safely
Keep Electronic Control Unit Connectors Clean
Live With Safety
Park Windrower Safely
Practice Safe Maintenance
Practice Safe Service Procedures
Precautions for Welding
Prepare for Emergencies
Prevent Acid Burns
Prevent Battery Explosions
Proper Recycling and Disposal of Fluids and Components
Recognize Safety Information
Remove Paint Before Welding or Heating
Replace Safety Signs
Service Accumulator Systems Safely
Service Cooling System Safely
Service Machines Safely
Service Tires Safely
Servicing Electronic Control Units
Stay Clear of Rotating Driveline
Support Machine Properly
Understand Signal Words
Use Adequate Service Facilities
Use Proper Lifting Equipment
Use Proper Tools
Wait Before Opening High-Pressure Fuel System
Wear Protective Clothing
Welding Near Electronic Control Units
Work in Clean Area
Work In Ventilated Area
10-General Information
All Pressure Applications
D450 Self-Propelled Windrower Specifications
Dimensions
Engine Serial Number
Face Seal Fittings Assembly and Installation—All Pressure Applications
Metric Bolt and Screw Torque Values
Product Identification Number Plate
Programming Control Units
SAE Face Seal Fitting Torque Chart—High Pressure Applications
SAE Face Seal Fitting Torque Chart—Standard 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
Unified Inch Bolt and Screw Torque Values
Windrower Product Identification Number Plate Location
15-Fuel, Coolant and Lubricants
Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER
Alternative and Synthetic Lubricants
BioDiesel Fuel
Diesel Engine Coolant (engine with wet sleeve cylinder liners)
Diesel Fuel Storage
Diesel Fuel
Drain Intervals for Diesel Engine Coolant
Final Drive Oil
Grease
Hydraulic Pump Drive Gear Case, Hydrostatic Drive and Main Hydraulic Systems Oil
Lubricant Storage
Lubricity of Diesel Fuel
Mixing of Lubricants
Non-Emissions Certified and Certified Tier 1 and Stage I
Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III
Operating in Warm Temperature Climates
Supplemental Coolant Additives
Testing Diesel Engine Coolant
20-Engine
05-Engine
Essential or Recommended Tools
John Deere Engine Repair—Use CTM
Other Material
Remove and Install Engine Mount Isolators
Remove and Install Engine
Remove and Install Serpentine Belt
Service Equipment and Tools
Specifications
10-Cooling System
Engine Water Pump Repair—Use CTM
Essential or Recommended Tools
Fill Radiator
Flush Out Cooling System
Other Material
Remove and Install Charge Air Cooler
Remove and Install Fan Shroud
Remove and Install Radiator
Remove and Install Rear Door Screen
Remove and Install Rotating Wand
Specifications
Test Surge Tank and Radiator
Test Surge Tank Cap
Winterize Cooling System
30- Fuel and Air Systems
05- Air Intake and Exhaust
Clean and Inspect Primary Air Filter
Other Material
Remove and Install Air Check Valve
Remove and Install Air Cleaner Inlet Tube
Remove and Install Air Filters
Remove and Install Air Restriction Switch
Remove and Install Muffler
Specifications
Turbocharger Repair—Use CTM
10- Diesel Fuel Systems
Change and Bleed Fuel Filter
Do Not Modify Fuel System
Drain Fuel Tank
Drain Water From Fuel Filter
High Pressure Fuel Pump, Nozzle
Remove and Install Fuel Level Sensor
Remove and Install Fuel Tank
Shut Off Fuel Supply
40- Electrical
05- Battery
Charging Battery
Checking Specific Gravity
Connecting Booster Battery
Remove and Install Battery
Specifications
10- Starter
Essential or Recommended Tools
Remove and Install Starter Motor
Specifications
Starter Repair—Use CTM
15- Alternator
Remove and Install Alternator
Specifications
20- Engine Electrical Components
Essential or Recommended Tools
Remove and Install Engine Control Unit (ECU)
Remove and Install Rotating Wand Motor
Replace Sensors and Switches
Specifications
25- Lighting and Accessory Components
Adjust Windshield Wiper
Halogen Bulb Safety Guidelines
Remove and Install Auxiliary Light Bulb
Remove and Install Auxiliary Lights
Remove and Install Dome Light Bulb
Remove and Install Flood Light Bulb
Remove and Install High Intensity Discharge (HID-Xenon)
Remove and Install High Intensity Discharge
Remove and Install Horn
Remove and Install Rear Flood Lights
Remove and Install Rear Warning and Tail Light
Remove and Install Windshield Washer
Remove and Install Wiper Motor
Remove, Install, and Adjust Cab Headlight Bulb
Safety Rules When Replacing High Intensity
Specifications
30- Operators Station
Other Material
Remove and Install Armrest Control Panel Console
Remove and Install Armrest Control Switch
Remove and Install Armrest Display Unit
Remove and Install Backlighting Driver
Remove and Install Cornerpost Primary
Remove and Install Dial-A-Speed and Active
Remove and Install Hazard Light Switch
Remove and Install Horn Switch
Remove and Install Key Switch
Remove and Install Mirror Heater Switch
Remove and Install Multi-Function Lever
Remove and Install Platform Engage Switch
Remove and Install Radio Antenna
Remove and Install Radio Speaker
Remove and Install Radio
Remove and Install Remote Mirror Swit
Remove and Install Remote Mirrors
Remove and Install Turn Signal Switch
Remove and Install Wiper Switch
Replace Neutral Safety Switch
Separate Armrest and Control Panel
Specifications
35- Platform and Ground Speed Contros
Other Material
Remove and Install Ground Speed Sensor
Remove and Install Hydraulic Charge
Remove and Install Hydraulic Filter Restriction
Remove and Install Hydraulic Oil Temperature
Remove and Install Platform Lift Position Sensor
Remove and Install Platform Lift Pressure
Remove and Install Platform Tilt Position Sensor
Remove and Install Steering Neutral Start Switch
Service Equipment and Tools
Specifications
40- Cab Heat and AC Electrical Components
Air Conditioning System With Precleaner
Remove and Install Air Conditioning High
Remove and Install Air Conditioning Low
Remove and Install Blower Motor
Remove and Install Evaporator Temperature Sensor
Remove and Install Recirculator Fan Motor Driver
Remove and Install Recirculator Motor
Remove and Install Temperature Control
Replace Air Temperature Sensors
45- Harness and Connector Repair
Basic Electrical Component Handling
Electrical Connector
Electrical System Visual Inspection
Essential or Recommended Tools
Other Material
Repair Procedure R-A
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
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
Use Electrical Insulating Compound
Using High-Pressure Washers
46- Wire Harness Routing
Cab Main Wiring Harness
Chassis Main Wiring Harness
Electrical Component Identification and Location
Replace Harness
50- Power Distribution
Fuse Panel
Remove and Install Cab Control Unit
Remove and Install Cab Power Module
Remove and Install Starter Relay
Specifications
55- GreenStar Components
Disassemble and Assemble Position Receiver
Position Receiver and Base
Remove and Install Display Unit
Remove and Install Position Receiver
50- Power Train
05- Hydrostatic System Flushing and Start-up
Flush Hydrostatic Ground Drive System
Hydrostatic Ground Drive System Start-Up
10- Pump Drive Gear Case
Assemble Pump Drive Gear Case
Disassemble and Inspect Pump Drive Gear Case
Essential or Recommended Tools
Other Material
Remove and Install Pump Drive Gear Case
Service Equipment and Tools
Specifications
15- Gear Case Colling Pump
Assemble Gear Case Cooling Pump
Disassemble Gear Case Cooling Pump
Inspect Pump Drive Gear Case Cooling Pump
Other Material
Remove and Install Gear Case Cooling Pump
Service Equipment and Tools
Specifications
20- Ground Drive Pumps
Disassemble and Assemble Ground Drive Pump
Essential or Recommended Tools
Other Material
Remove and Install Ground Drive Pump Charge
Remove and Install Ground Drive Pump Control Valve
Remove and Install Ground Drive Pump Shaft Seal
Remove and Install Ground Drive Pump
Remove and Install Left-Hand Ground Drive Pump
Remove and Install Right-Hand Ground Drive
Repair Charge Pump
Service Equipment and Tools
Specifications
25- Ground Drive Motor
Disassemble and Assemble Ground Drive Motor
Disassemble and Assemble Ground Drive
Other Material
Remove and Install Ground Drive Motor
Service Equipment and Tools
Specifications
35- Final Drive With Internal Park Brake
Disassemble and Assemble Final Drive
Disassemble and Assemble Internal Park Brake
Essential or Recommended Tools
Internal Park Brake Checks
Other Material
Remove and Install Final Drive With Internal Brake
Specifications
40- Ground Drive Linkage
Remove and Install Ground Drive Control Cable
Remove and Install Ground Drive Linkage Rods
Specifications
60- Steering
05- Steering System
Disassemble and Assemble Steering Column
Disassemble and Assemble Steering Mechanism
Other Material
Remove and Install Steering Mechanism
Specifications
10- Rear Assist Steering
Disassemble and Assemble Rear Assist Steering Cylinder
Disassemble and Assemble Rear Assist Steering
Remove and Install Rear Assist Steering Cylinder
Remove and Install Rear Assist Steering Valve
Remove and Install Rear Assist Steering
Remove and Install Steering Lever
Service Equipment and Tools
Specifications
70 – Hydraulic System
05 – Component Location
Ground Drive System
Platform Drive and Cylinders
Rear Steering Components
06 – Auxiliary Pump
Remove and Install Auxiliary Pump
Service Equipment and Tools
Specifications
07 – Triple Pump
Remove and Install Triple Pump
Service Equipment and Tools
Specifications
10 – Charge Pump
Remove and Install Charge Pump
Service Equipment and Tools
Specifications
15 – Platform drive Pump
Assemble Platform Drive Pump
Disassemble Platform Drive Pump
Essential or Recommended Tools
Inspect Platform Drive Pump Components
Other Material
Remove and Install Platform Drive Pump
Service Equipment and Tools
Specifications
20 – Motor Repair
Remove and Install Platform Drive Motor
Service Equipment and Tools
25 – Valve Repair
Disassemble and Assemble Low Pressure Steering Control Valve
Disassemble and Assemble Multicoupler
Disassemble and Assemble Platform Lift Control Valve
Disassemble and Assemble Platform Tilt Valve
Disassemble and Assemble Reel Drive Control Valve
Disassemble and Assemble Reel Lift Control Valve
Essential or Recommended Tools
Low Pressure Steering Control Valve—Exploded View
Multicoupler Valve Identification
Other Material
Reel Drive Control Valve—Exploded View
Reel Lift Control Valve—Exploded View
Remove and Install Accumulator Shutoff Valve
Remove and Install Low Pressure Steering Control Valve
Remove and Install Multicoupler
Remove and Install Platform Lift Control Valve
Remove and Install Platform Tilt Valve
Remove and Install Reel Drive Control Valve
Remove and Install Reel Lift Control Valve
Service Equipment and Tools
Specifications
30 – Hydraulic Cylinders
Disassemble and Assemble Tilt, Lift, and Rear Assist Steering Cylinders
Remove and Install Platform Lift Cylinder
Remove and Install Platform Tilt Cylinder
Remove and Install Rear Assist Steering Cylinder
Remove and Install Steering Lock Cylinder
Repair Steering Lock Cylinder
Service Equipment and Tools
Specifications
35 – Miscellaneous
Drain and Fill Hydraulic Reservoir
Release Float Pressure
Relieve Traction Unit Hydraulic System Pressure
Remove and Install Combination Cooler
Remove and Install Hydraulic Reservoir
Service Equipment and Tools
40 – Accumulator
Checking Accumulator Pressure
Essential or Recommended Tools
Remove and Install Header Lift System Hydraulic Accumulator
Specifications
80 – Miscellaneous
05 – Real Axle
Other Material
Remove and Install Axle Knee Bushings
Remove and Install King Pin
Remove and Install Rear Axle
Remove and Install Rear Suspension Isolators
Remove and Install Rear Suspension
Repair Caster Wheel Hub
Service Equipment and Tools
Specifications
10 – Drive Wheels
Remove and Install Drive Wheels
Service Equipment and Tools
Specifications
15 – Lift Arm
Other Material
Remove and Install Lift Arm Bearings
Service Equipment and Tools
Specifications
90-Oparator Station
05-Air Conditioning Service
Add Refrigerant Oil to Pressurized System
Add Refrigerant Oil to System
Charge R-134a System
Check Compressor Oil Charge
Determine Correct Refrigerant Oil Charge
Essential or Recommended Tools
Evacuate R-134a System
Flush Air Conditioning System
General Information
Other Material
Proper Refrigerant Handling
Purge Air Conditioning System
R-134a Refrigerant Cautions
Recover R-134a System
Refrigerant Hoses and Tubing Inspection
Refrigerant Oil Information
Specifications
10-Air Conditioning Repair
Check Clutch Hub Clearance
Essential or Recommended Tools
Remove and Install Compressor Clutch Assembly
Remove and Install Compressor
Remove and Install Evaporator
Remove and Install Heater Core
Remove and Install Receiver-Dryer
Repair Condenser
Service Equipment and Tools
Specifications
20-Cab
Adjust Hydrostatic Ground Drive
Check Hydrostatic Ground Drive
Disassemble and Assemble Operator Seat Air Suspension Assembly
Operator Seat Air Suspension Assembly—Exploded View
Operator Seat Exploded View
Remove and Install Cab Door
Remove and Install Cab Fascia
Remove and Install Cab Headliner
Remove and Install Cab Inner Roof
Remove and Install Cab Mount Isolators
Remove and Install Cab Outer Roof
Remove and Install Cab
Remove and Install Operator Presence Switch
Remove and Install Operator Seat
Remove and Install Rear Window
Remove and Install Windshield
Repair Cab Door Latch Striker
Service Equipment and Tools
Specifications
99-Dealer Fabricated Tools
05-Dealer Fabricated Tools
DFEX1819D Compressor Holding Fixture
DFEX1819E Support Plate
DFEXT4 Sizing Arbor