JOHN DEERE 4895 SELF-PROPELLED HAY AND FORAGE WINDROWER TM2033 PDF MANUAL

4895 Self-Propelled Windrower Repair

REPAIR TECHNICAL MANUAL Self-Propelled Windrowers models 4895 TM2033 21 AUG 10 (ENGLISH)

For complete service information also see: 100 Series Hydraulic CylindersTM-H100A 4895 Self-Propelled Windrower DiagnosticTM2114 895 Auger and Specialty Crop PlatformsTM2037 4895 Self Propelled Windrower DiagnosticTM2034 GreenStar 2 Diagnosis and Tests ManualTM1061 Alternators and Starting MotorsCTM77 PowerTech 4.5L and 6.8L Diesel Engines Mechanical Fuel SystemsCTM207 120 Series Hydraulic CylindersCTM120519 120 Series Hydraulic CylindersCTM114319 PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine)CTM104

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4895 Self-Propelled Windrower Repair

(g) by Belgreen v2.5

Table of contents FOREWORD SERVICE TECHNICIAN RESPONSE Section 10 - GENERAL Group 05 - Safety Group 10 - Specifications Group 15 - Fuel, Coolant and Lubricants Section 20 - ENGINE Group 05 - Engine Group 10 - Cooling System Section 30 - FUEL AND AIR SYSTEMS Group 05 - Air Intake and Exhaust Group 10 - Diesel Fuel System Section 40 - ELECTRICAL Group 05 - Batteries Group 10 - Starter Group 15 - Alternator Group 20 - Engine Electrical Components Group 25 - Lighting and Accessory Components Group 30 - Gauges and Monitors Group 35 - Platform and Ground Speed Controls Group 40 - Cab Heat and A/C Electrical Components Group 45 - Connector Repair Section 50 - POWER TRAIN Group 05 - Hydrostatic System Flushing and Start-Up Group 10 - Tandem Ground Drive Pumps Group 15 - Ground Drive Motor Group 20 - Final Drive (Serial No. —310400) Group 25 - Final Drive With Internal Park Brake (Serial No. 310001—) Group 30 - Ground Drive Linkage Section 60 - STEERING AND BRAKES Group 05 - Steering System Group 10 - Brakes (Serial No. —310000) Section 70 - HYDRAULIC SYSTEM Group 05 - Component Location Group 10 - Auxiliary-Charge Pump Group 15 - Platform Drive Pump Group 20 - Platform Drive Motor Group 25 - Hydraulic Valves Group 30 - Hydraulic Cylinders Group 35 - Miscellaneous Section 80 - MISCELLANEOUS Group 05 - Rear Axle Group 10 - Drive Wheels Group 15 - Lift Arm Section 90 - OPERATOR STATION Group 05 - Air Conditioning Service Group 10 - Air Conditioning Repair Group 15 - Heater Controls Group 20 - Cab Section 99 - DEALER FABRICATED TOOLS Group 05 - Dealer Fabricated Tools

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4895 Self-Propelled Windrower Repair

For the full PDF version of this manual, Please click on the above download PDF button.

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4895 Self-Propelled Windrower Repair

4895 Self-Propelled Windrower Repair

(g) by Belgreen v2.5

Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

CAUTION:

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.

Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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4895 Self-Propelled Windrower Repair

GENERAL

(g) by Belgreen v2.0

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Section 10 page 1

4895 Self-Propelled Windrower Repair

4895 Self-Propelled Windrower Repair

(g) by Belgreen v2.5

Section 10 - GENERAL Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Handle Fluids Safely—Avoid Fires ......................................................................................................... 1 Prevent Battery Explosions ................................................................................................................... 2 Prepare for Emergencies ...................................................................................................................... 2 Prevent Acid Burns ............................................................................................................................... 4 Avoid High-Pressure Fluids ................................................................................................................... 4 Service Accumulator Systems Safely .................................................................................................... 5 Park Windrower Safely ......................................................................................................................... 5 Stay Clear of Rotating Driveline ........................................................................................................... 6 Support Machine Properly .................................................................................................................... 7 Wear Protective Clothing ...................................................................................................................... 8 Work in Clean Area ............................................................................................................................... 8 Service Machines Safely ....................................................................................................................... 9 Work In Ventilated Area ........................................................................................................................ 9 Illuminate Work Area Safely ................................................................................................................. 9 Replace Safety Signs .......................................................................................................................... 10 Use Proper Lifting Equipment ............................................................................................................. 10 Remove Paint Before Welding or Heating ........................................................................................... 10 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 12 Service Tires Safely ............................................................................................................................ 13 Avoid Harmful Asbestos Dust ............................................................................................................. 13 Practice Safe Maintenance ................................................................................................................. 15 Use Proper Tools ................................................................................................................................. 15 Construct Dealer-Made Tools Safely ................................................................................................... 16 Dispose of Waste Properly .................................................................................................................. 16 Live With Safety ................................................................................................................................. 17 Practice Safe Service Procedures ....................................................................................................... 17 Group 10 - Specifications ..................................................................................................................... 19 4895 Self-Propelled Windrower Specifications Specifications and design subject to change without notice. ......................................................................................................................................... 19 Dimensions ......................................................................................................................................... 22 Metric Bolt and Screw Torque Values ................................................................................................. 24 Unified Inch Bolt and Screw Torque Values ........................................................................................ 25 Service Recommendations For O-Ring Boss Fittings .......................................................................... 26 Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 28 Service Recommendations For 37° Flare and 30° Cone Seat Connectors .......................................... 29 Service Recommendations For Flare-Type Tube Fittings .................................................................... 30 Service Recommendations For Snap-To-Connect Fittings .................................................................. 31 Product Identification Number Plate ................................................................................................... 33 Windrower Product Identification Number Plate Location ................................................................... 34 Engine Serial Number Plate Location .................................................................................................. 34 Fuel Injection Pump Serial Number ..................................................................................................... 35 Cab Serial Number ............................................................................................................................. 35 Group 15 - Fuel, Coolant and Lubricants ........................................................................................... 36 Diesel Fuel .......................................................................................................................................... 36 Biodiesel Fuel ..................................................................................................................................... 37 Diesel Fuel Storage ............................................................................................................................. 37 Lubricity of Diesel Fuel ....................................................................................................................... 38

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4895 Self-Propelled Windrower Repair

4895 Self-Propelled Windrower Repair

(g) by Belgreen v2.5

Diesel Engine Coolant ......................................................................................................................... 38 Supplemental Coolant Additives ......................................................................................................... 39 Operating in Warm Temperature Climates ......................................................................................... 39 Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER ..................................................................................................................................................... 40 Testing Diesel Engine Coolant ............................................................................................................ 41 Diesel Engine Oil ................................................................................................................................ 42 Diesel Engine Break-In Oil .................................................................................................................. 44 Hydrostatic Drive Oil .......................................................................................................................... 45 Final Drive Oil ..................................................................................................................................... 46 Grease ................................................................................................................................................ 46 Alternative and Synthetic Lubricants .................................................................................................. 47 Lubricant Storage ............................................................................................................................... 47

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4895 Self-Propelled Windrower Repair

Section 10 - GENERAL

Group 05: Safety

Group 05 - Safety Recognize Safety Information

Safety-alert symbol This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

Follow recommended precautions and safe operating practices.

Understand Signal Words

Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards.

DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

CAUTION also calls attention to safety messages in this manual.

Handle Fluids Safely—Avoid Fires

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Section 10 page 1

4895 Self-Propelled Windrower Repair

Section 10 - GENERAL

Group 05: Safety

Avoid Fires When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

Prevent Battery Explosions

Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Prepare for Emergencies

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Section 10 page 2

4895 Self-Propelled Windrower Repair

Section 10 - GENERAL

Group 05: Safety

First Aid Kit Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

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Section 10 page 3

4895 Self-Propelled Windrower Repair

Section 10 - GENERAL

Group 05: Safety

Prevent Acid Burns

Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1.Filling batteries in a well-ventilated area.

2.Wearing eye protection and rubber gloves.

3.Avoiding breathing fumes when electrolyte is added.

4.Avoiding spilling or dripping electrolyte.

5.Use proper jump start procedure.

If you spill acid on yourself: 1.Flush your skin with water.

2.Apply baking soda or lime to help neutralize the acid.

3.Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed: 1.Do not induce vomiting.

2.Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3.Get medical attention immediately.

Avoid High-Pressure Fluids

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Section 10 page 4

4895 Self-Propelled Windrower Repair

Section 10 - GENERAL

Group 05: Safety

High-Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.

Service Accumulator Systems Safely

Hydraulic Accumulator Escaping fluid or gas from systems with pressurized accumulators that are used in air conditioning, hydraulic, and air brake systems can cause serious injury. Extreme heat can cause the accumulator to burst, and pressurized lines can be accidentally cut. Do not weld or use a torch near a pressurized accumulator or pressurized line.

Relieve pressure from the pressurized system before removing accumulator.

Relieve pressure from the hydraulic system before removing accumulator. Never attempt to relieve hydraulic system or accumulator pressure by loosening a fitting.

Accumulators cannot be repaired.

Park Windrower Safely

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Section 10 page 5

4895 Self-Propelled Windrower Repair

Section 10 - GENERAL

Group 05: Safety

Windrower

Park Windrower Safely Before leaving the operator′s station: 1.Park windrower on level surface.

2.Put hydrostatic drive lever in neutral park.

3.Disengage platform drive.

4.Wait until all moving parts have stopped.

5.Lower the platform to the ground.

6.Idle hot engine for two minutes prior to shut down.

7.Turn off engine and remove keys.

8.Check to see steering wheel is locked.

9.Lock cab door.

Before working on the machine: Disconnect the battery ground strap.

Hang a “DO NOT OPERATE” tag in operator station.

Stay Clear of Rotating Driveline

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Section 10 page 6

4895 Self-Propelled Windrower Repair

For the full PDF version of this manual, Please click on the above download PDF button.