DOWNLOAD PDF : John Deere R4030, R4038, and R4045 Self-Propelled Sprayers Installation Instructions

Direct Injection

BKK10302, BKK10303, BKK10304, BKK10305

INSTALLATION INSTRUCTIONS Direct Injection KK43425 11APR18

(ENGLISH)

R4030, R4038, and R4045 Self-Propelled Sprayers

John Deere Des Moines Works KK43425 (11APR18) PRINTED IN U.S.A. COPYRIGHT © 2018 DEERE & COMPANY Moline, Illinois All rights reserved.

A John Deere ILLUSTRUCTION ™ Manual Previous Editions Copyright © 2017 KK43425-19-11APR18

BKK10302, BKK10303, BKK10304, BKK10305

Introduction Instruction covers installation of Direct Injection System on R4030, R4038, and R4045 Self-Propelled Sprayers/Spreaders.

IMPORTANT: Read through instruction thoroughly and familiarize yourself with machine before performing procedure.

N102970 —UN—27MAR13

NOTE: Complete instructions on downloading and installing Software payload are given in PC20380 DOWNLOAD SOFTWARE PAYLOAD Installation Instruction.

Order software part number KK21835 through JDPoint—Machine model number and serial number are required at time of order. Download of updated software through Service Advisor Software Delivery System is required.

Four bundle options available for installation are as follows: One High-Volume Pump, 100 gal System Bundle consists of one high-volume pump (C), one 100 gal capacity tank system (two 50 gal tanks, A and B), one in-line mixer assembly (D), and necessary installation hardware.

A—Left-Hand Side Outer 50 gal Tank (A1) B—Right-Hand Side Outer 50 gal Tank (A2)

C—High-Volume Pump D—Mixer Assembly

CS12167,0000B05 -19-14DEC17-1/4

One High-Volume Pump, 200 gal System Bundle consists of one high-volume pump (A), two 100 gal tank systems (four 50 gal tanks, B, C, D and E), one in-line mixer assembly (F), and necessary installation hardware.

D—Left-Hand Side Inner 50 gal Tank (B1) E—Right-Hand Side Inner 50 gal Tank (B2) F— Mixer Assembly

N106874 —UN—10OCT13

A—High-Volume Pump B—Left-Hand Side Outer 50 gal Tank (A1) C—Right-Hand Side Outer 50 gal Tank (A2)

Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305 Two High-Volume Pumps, 200 gal System Bundle consists of two high-volume pumps (A and B), two 100 gal tank systems (four 50 gal tanks, C, D, E and F), one in-line mixer assembly (G), and necessary installation hardware.

E—Left-Hand Side Inner 50 gal Tank (B1) F— Right-Hand Side Inner 50 gal Tank (B2) G—Mixer Assembly N107026 —UN—10OCT13

A—High-Volume Pump B—High-Volume Pump C—Left-Hand Side Outer 50 gal Tank (A1) D—Right-Hand Side Outer 50 gal Tank (A2)

CS12167,0000B05 -19-14DEC17-3/4

Low-Volume Pump, 35 gal System

Low-volume bundle is ONLY available when machine is equipped WITH the high-volume 100 gal bundle.

Bundle consists of one low-volume pump (B), one 35 gal tank (A), and necessary installation hardware.

A—Tank

B—Low-Volume Pump

N102971 —UN—27MAR13

NOTE: Refer to the appropriate system instructions to ensure correct installation.

CS12167,0000B05 -19-14DEC17-4/4

To The Dealer Average time required to install the component(s) in this kit can be found at http://mst.deere.com.

OUO6092,00008F9 -19-07AUG14-1/1

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BKK10302, BKK10303, BKK10304, BKK10305

Dealer Supplied NOTE: Hoses are not included in the bundle. The bulk hose numbers shown are clear PVC material, with helical reinforcement. This material is compatible with a wide range of injectable chemicals, but not all possible chemical options. Dealers should

consult with their operators and chemical company representatives to determine the optimum hose material for their application.

The following quantities of hose are NOT included in the Direct Injection Bundles.

Low Volume ID

Hose Length

Description

John Deere Bulk Part Number

1 in

3750 mm (148 in)

Clear PVC, Woven Polyester Reinforced

PMK3150-16

1/2 in

5000 mm (197 in)

3/4 in

500 mm (20 in)

ID

Hose Length

Description

John Deere Bulk Part Number

1 in

12 500 mm (492 in)

Clear PVC, Woven Polyester Reinforced

PMK3150-16

1/2 in

5100 mm (201 in)

3/4 in

1200 mm (47 in)

ID

Hose Length

Description

John Deere Bulk Part Number

1 in

26 384 mm (1039 in)

Clear PVC, Woven Polyester Reinforced

PMK3150-16

1/2 in

13 168 mm (518 in)

3/4 in

5178 mm (204 in)

ID

Hose Length

Description

John Deere Bulk Part Number

1 in

26 384 mm (1039 in)

Clear PVC, Woven Polyester Reinforced

PMK3150-16

1/2 in

19 534 mm (769 in)

3/4 in

6241 mm (246 in)

Clear PVC, Woven Polyester Reinforced Clear PVC, Woven Polyester Reinforced

PMK3150-08 PMK3150-12

1 Pump 100 Gallon

Clear PVC, Woven Polyester Reinforced Clear PVC, Woven Polyester Reinforced

PMK3150-08 PMK3150-12

1 Pump 200 Gallon

Clear PVC, Woven Polyester Reinforced Clear PVC, Woven Polyester Reinforced

PMK3150-08 PMK3150-12

2 Pump 200 Gallon

Clear PVC, Woven Polyester Reinforced Clear PVC, Woven Polyester Reinforced

PMK3150-08 PMK3150-12 OUO6092,0000C88 -19-01MAY17-1/1

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BKK10302, BKK10303, BKK10304, BKK10305

Parts List BKK10303

BKK10304

BKK10305

Flange Nut, M8

Description

BKK10302

10

16

16

Flange Lock Nut, M6

1

1

1

Cap Screw, M6 x 30

1

1

7

Flange Lock Nut, M8

11

16

16

14

Flange Lock Nut, M10

9

14

17

16

Flange Lock Nut, M12

4

4

4

Cap Screw, M10 x 130

2

Cap Screw, M10 x 70

3

2

2

Cap Screw, M10 x 25

2

2

2

Cap Screw, M10 x 40

4

6

3

Cap Screw, M10 x 30

1

5

4

4

4

Cap Screw, M8 x 20

4

10

14

13

Cap Screw, M8 x 25

4

6

6

6

Cap Screw, M8 x 30

3

4

7

5

Cap Screw, M8 x 60

1

1

1

Cap Screw, M8 x 160

1

1

1

Flat Washer, M8

4

2

4

Bushing, M12 x 57 mm

2

Fuse, 60A

2

2

2

U-Bolt, M8 x 108

1

1

1

Bracket, Hoop Hose Support

1

1

1

Agitator Kit

1

1

1

Valve Assembly, Outer

1

1

1

Valve Assembly, Outer Left

1

2

2

1

1

Cap Screw, M12 x 140

Cap Screw, M8 x 100

2

Cap Screw, M10 x 35

1

Cap Screw, M10 x 45

1

Cap Screw, M10 x 150

2

Flange Lock Nut, 5/16 in.

4

Hose Fitting Assembly, In Tool, Valve Open

1

1

1

Gasket, 2.62 in.

5

5

5

Fitting, 2 in. Flange Hose Barb

1

1

1

Hose Barb, 3/4 in. NPT x 1 in. Barb 90°

2

3

3

U-Bolt

1

1

1

Fitting, 90° Swept

1

1

1

U-Bolt, Check Valve Mount

3

3

3

1

1

4

5

5

6

1

3

2

Label, Trapped Pressure Warning

2

2

2

Label, Trapped Pressure Warning

2

2

2

Label, Trapped Pressure Warning

2

2

2

Label, Caution Pressure

2

2

2

Label, Caution Exposure

1

1

1

Bracket, Hose Support

1

1

1

1

4

4

Hose Tee, 3/4 in. Barb

1

1

Label Label

1

Label Fitting, Female Push Connect

Clamp

1

3

Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305 BKK10303

BKK10304

BKK10305

DI Tank and Support

Description

BKK10302

2

4

4

Fitting, 2 in Flange x 3/4 in. NPT Port

1

1

1

Pipe Tee, 3/4 in. NPT

1

1

Fitting, Reducer

1

1

Fitting, Male 3/8 in. NPT x 1/4 in. PTC

1

1

1

Hose Fitting, 1/4 in. Elbow

1

1

1

Electric Valve, 3-Way

1

1

1

Instructions

1

1

1

Relay Module, Power

1

1

Clip Assembly, Insulated

14

24

21

Clamp

5

3

5

1

1

Anchor, Panel Fir Tree Strap, Power Relay

1

1

1

Hose, 2 in. Pressure

1

1

1

Clamp, Coated

1

2

1

Clamp, Stainless

7

16

Clamp, Stainless

2

4

4

P-Clamp

3

3

3

1

1

2

2

2

2

Pipe Nipple, Short 1 in. NPT 1

Hose, 3/4 in. ID Fitting, Hose Barb 1 in.

Fitting, Hose Barb 3/4 in.

5

5

6

Pipe Nipple, Short 3/4 in. NPT

2

2

2

Hose, 2 in. Pressure

1

1

1

Hose Tee, 1 in. Barb

2

2

2

Label, Spanish Caution

1

1

1

Gasket, 1 in. EPDM

3

4

4

Label, French Caution

1

Check Valve

2

2

2

Tee Fitting, 2 in. Flange

1

1

1

Fitting, 3/4 in x 90°

3

3

5

Decal, Caution

1

1

1

1

Clamp, Stainless

5

14

25

25

Clamp, Stainless

1

6

7

18

Clamp, T-Bolt

8

8

8

Clamp, 1 in. Flange

2

4

4

Check Valve

1

1

2

Bracket, Hoop Support

1

1

1

Clamp

4

4

4

Plate, Cover Twin Clamp

2

2

2

Tie Band

23

25

25

Hand Operated Valve, 3/4 in. Hose Barb

2

2

2

Label, Inject/Recirculate

1

1

2

Plate, DI Mixer Hose Support

1

1

1

Bracket, DI Hose Support

2

2

2

Elbow Fitting, 45°

1

1

1

Bracket, DI Hose Support

1

3

3

Bracket

1

1

1

Bracket, DI Post Mix

1

1

1

Operator’s Manual DI

1

1

1

Bracket, Boom Valve Hose Support

1

1

1

Pipe Tee, 1 in. NPT

2 Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305 BKK10303

BKK10304

BKK10305

Pipe Plug, 3/4 in. NPT

Description

BKK10302

1

2

2

Elbow Fitting, 1 in. x 90°

2

5

5

Elbow Fitting

1

2

2

3

3

3

1

1

1

Pipe Fitting, 1 in. NPT x 3/4 in. NPT Clamp Hose Fitting

1

1

Elbow Fitting

1

Wire Harness

1

1

1

Wire Harness

1

1

1

Valve Kit

1

Tank Assembly, 35 Gallon

1

Spacer, Clean Water

1

Structure Tubing, Low Volume Tank

2

Bracket, Brake Light

1

Check Valve

1

Strainer, 3/4 in. Tee

1

Pump, DI Low Volume Bottom Valve, DI Low Volume

1

Valve Kit, DI Pump

1 1

Valve Kit, DI 200 Gallon

OUO6435,0002CC6 -19-05JUN15-3/3

Recognize Safety Information 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.

T81389 —UN—28JUN13

Follow recommended precautions and safe operating practices.

DX,ALERT -19-29SEP98-1/1

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BKK10302, BKK10303, BKK10304, BKK10305

Understand Signal Words DANGER; The signal word DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

TS187 —19—30SEP88

WARNING; The signal word WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION; The signal word CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION may also be used to alert against unsafe practices associated with events which could lead to personal injury.

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.

DX,SIGNAL -19-05OCT16-1/1

Carefully read all safety messages in this instruction. Read the product operators manual for operating instructions and safety messages. Do not let anyone operate without instruction. (A copy of the operators manual may also be available from the Service ADVISOR™ application.)

TS201 —UN—15APR13

Follow Safety Instructions

Service ADVISOR is a trademark of Deere & Company DX,READ,INS -19-23JUN09-1/1

Replace Safety Signs

TS201 —UN—15APR13

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

DX,SIGNS1 -19-04JUN90-1/1

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BKK10302, BKK10303, BKK10304, BKK10305

Prepare for Emergencies Be prepared if a fire starts.

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

TS291 —UN—15APR13

Keep a first aid kit and fire extinguisher handy.

DX,FIRE2 -19-03MAR93-1/1

Wear Protective Clothing

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

TS206 —UN—15APR13

Wear close fitting clothing and safety equipment appropriate to the job.

DX,WEAR2 -19-03MAR93-1/1

There are many variables that affect the sound level range, including machine configuration, condition and maintenance level of the machine, ground surface, operating environmental, duty cycles, ambient noise, and attachments.

Exposure to loud noise can cause impairment or loss of hearing.

Always wear hearing protection. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

TS207 —UN—23AUG88

Protect Against Noise

DX,NOISE -19-03OCT17-1/1

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BKK10302, BKK10303, BKK10304, BKK10305

Practice Safe Maintenance Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet, and clothing away from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed.

Fix damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Falling while cleaning or working at height can cause serious injury. Use a ladder or platform to easily reach each location. Use sturdy and secure footholds and handholds.

TS218 —UN—23AUG88

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

DX,SERV -19-28FEB17-1/1

Park Machine Safely Before working on the machine:

TS230 —UN—24MAY89

• Lower all equipment to the ground.

• Stop the engine and remove the key.

• Disconnect the battery ground strap.

• Hang a "DO NOT OPERATE" tag in operator station.

DX,PARK -19-04JUN90-1/1

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BKK10302, BKK10303, BKK10304, BKK10305

Work in Clean Area Before starting a job:

T6642EJ —UN—18OCT88

• Clean work area and machine.

• Make sure you have all necessary tools to do your job.

• Have the right parts on hand.

• Read all instructions thoroughly; do not attempt shortcuts.

DX,CLEAN -19-04JUN90-1/1

Avoid High-Pressure Fluids

X9811 —UN—23AUG88

Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage.

Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.

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.

DX,FLUID -19-12OCT11-1/1

• Clean vehicle (see Clean Vehicle of Hazardous

Decontaminate Spray Equipment Before Servicing

Chemicals, Including Pesticides in this section).

CAUTION: Spray solutions or vapors can be extremely dangerous. Treat all spray chemicals, solutions, and solution residues with great caution. DO NOT take chances. When in doubt, proceed as though contamination is present.

• Drain Solution Tank (see machine operator’s manual).

• Rinse wet system (see operator’s manual).

Keep spray material from contacting skin. If spray material contacts skin, wash off immediately with clean water and detergent, or follow manufacturers instructions for chemical used last.

Wear protective clothing, goggles, and gloves while attaching parts.

Before performing any service activity:

• Wear appropriate personal protective equipment.

LD45720,0000462 -19-24JAN18-1/1

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BKK10302, BKK10303, BKK10304, BKK10305

Clean Vehicle of Hazardous Chemicals, Including Pesticides

T6642EJ —UN—18OCT88

CAUTION: During application of hazardous chemicals, including pesticides, residue can build up on the inside or outside of the vehicle.

Clean vehicle according to use instructions of hazardous chemical.

When exposed to hazardous chemicals, clean exterior and interior of vehicle daily to keep free of the accumulation of visible dirt and contamination.

1. Sweep or vacuum the floor of cab.

2. Clean headliners and inside cowlings of cab.

3. Wash entire exterior of vehicle.

IMPORTANT: Directing pressurized water at electronic/electrical components or connectors, bearings and hydraulic seals, fuel injection pumps or other sensitive parts and components may cause product malfunctions. Reduce pressure, and spray at a 45 to 90 degree angle.

4. Dispose of any wash water with hazardous concentrations of active or non-active ingredients according to published regulations or directives.

OUO6092,000081B -19-23JUN05-1/1

Use Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

Use only service parts meeting John Deere specifications.

TS779 —UN—08NOV89

Use power tools only to loosen threaded parts and fasteners.

DX,REPAIR -19-17FEB99-1/1

Work In Ventilated Area

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

TS220 —UN—15APR13

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

DX,AIR -19-17FEB99-1/1

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BKK10302, BKK10303, BKK10304, BKK10305

One High-Volume Pump, 100 gal System Bundle consists of one high-volume pump (C), one 100 gal capacity tank system (two 50 gal tanks, A and B), one in-line mixer assembly (D), and necessary installation hardware.

C—High-Volume Pump D—Mixer Assembly

N102970 —UN—27MAR13

A—Left-Hand Side Outer 50 gal Tank (A1) B—Right-Hand Side Outer 50 gal Tank (A2)

One High-Volume Pump, 100 gal System CS12167,0000B01 -19-05APR18-1/93

1. Install label (A) on 50 gallon tank assembly at locations (B). Repeat for the other tank.

2. Mark one tank assembly with a number “1” after the “A” decals, making it “A1”.

B—Location

N116095 —UN—18FEB15

A—Label A (2 used per tank)

N116094 —UN—18FEB15

3. Mark other tank assembly with a number “2” after the “A” decals, making it “A2”.

Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305

4. Install tank P-clamps—A1: Install P-clamps (B), using cap screws (C), and nuts (D) as shown.

C—Cap Screw, M8 x 20 (2 used) D—Flange Nut, M8 (2 used)

N116098 —UN—19MAR15

A—Tank Assembly A1 B—P-Clamp, 38 mm (1-1/2 in) Diameter (2 used)

Tank A1 CS12167,0000B01 -19-05APR18-3/93

5. Install tank P-clamps—A2: Install P-clamps (B), using cap screws (C), and nuts (D) as shown.

6. Install double P-clamp (E) using cap screw (F), flat washer (G), and flange nut (H) at location shown.

7. Remove and retain cap screws and nuts (I).

8. Install bracket (J) using previously removed cap screws and nuts.

A—Tank Assembly A2 B—P-Clamp, 38 mm (1-1/2 in) (2 used) C—Cap Screw, M8 x 20 (2 used) D—Flange Nut, M8 (2 used) E—Double P-Clamp F— Cap Screw, M8 x 20

N116099 —UN—24FEB15

9. Install P-clamp (K) to bracket with a cap screw (L) and flange lock nut.

G—Flat Washer, M8 H—Flange Nut, M8 I— Cap Screws and Nuts (2 used) J— Bracket K—P-Clamp, 38 mm (1-1/2 in) L— Cap Screw, M10 x 30

N116101 —UN—24FEB15

Tank A2

Lower P-Clamp Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305

NOTE: Loosen or remove tank as necessary to install some P-clamps.

10. Install tank P-clamps—Low-Volume System—If Equipped: Install P-clamps (A) using cap screws and flange lock nuts (B). Position as shown.

11. Install double P-clamp (C) using cap screw and nut (D).

12. Remove and retain cap screw and nut (E).

13. Install double P-clamp (F) using previously removed cap screw and nut.

A—P-Clamp, 22.3 mm (7/8 in) (2 used) B—Cap Screw, M8 x 20, and Flange Nut (2 used) C—Double P-Clamp, 36.5 mm (1-1/2 in) D—Cap Screw, M8 x 20, and Flange Nut

N116102 —UN—19MAR15

14. Install double P-clamp (G) using cap screw, spacer, and flange lock nut (H). Position as shown.

E—Cap Screw and Flange Nut F— Double P-Clamp, 36.5 mm (1-1/2 in) G—Double P-Clamp, 36.5 mm (1-1/2 in) H—Cap Screw, M10 x 45, Spacer, 21 mm (0.82 in), and Flange Lock Nut

Low-Volume P-Clamps CS12167,0000B01 -19-05APR18-5/93

IMPORTANT: Clamp (A) must be installed before installing plug (B) to minimize the chance of the tank splitting.

N116097 —UN—24FEB15

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

15. Install Upper Tank Fittings and Hoses—A1: Install clamp (A) to tank.

16. Apply sealant to plug (B) and install in tank.

17. Apply sealant to hose barb fittings (C and D) and install in tank. Position as shown.

A—Clamp B—Plug, 3/4 in NPT

A1 Upper Fittings

C—Hose Barb Fitting, 1 in 90° D—Hose Barb Fitting, 1 in Barb x 3/4 in NPT 90° Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305

NOTE: To simplify the text and photos, the following procedure does not call out the installation of hose clamps.

Install hose clamps on each hose end and tighten to specification.

Specification Hose Clamps—Torque........................................................ 3.9—4.5 N·m (35—40 lb·in)

N116325 —UN—25FEB15

Hose-to-Clamp Reference • 1/2 in ID hoses, use 1 in clamps • 3/4 in ID hoses, use 1 in clamps • 1 in ID hoses, use 1-1/2 in clamps 18. Cut hose (A) to 1930 mm (76 in).

19. Route through P-clamp (B) and install onto the rinse fitting (C).

20. Cut hose (D) to 2550 mm (100 in).

A1 Upper Hoses

21. Route through P-clamps (E) and install onto the vent fitting (F).

A—Hose, 1 in ID x 1930 mm (76 in) B—P-Clamp C—Rinse Fitting

D—Hose, 1 in ID x 2550 mm (100 in) E—P-Clamp (2 used) F— Vent Fitting CS12167,0000B01 -19-05APR18-7/93

IMPORTANT: Clamp (A) must be installed before installing hose barb fitting (B) to minimize the chance of the tank splitting.

N102977 —UN—27MAR13

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

22. Install Upper Tank Fittings and Hoses—A2: Install clamp (A) to tank.

23. Apply sealant to the hose barb fitting (B) and install in tank.

A2 Upper Fittings

24. Apply sealant to hose barb fittings (C and D) and install in tank. Position as shown.

A—Clamp B—Hose Barb Fitting, 3/4 in NPT x 1/2 in Barb 90° Continued on next page

KK43425 (11APR18)

15

C—Hose Barb Fitting, 1 in 90° D—Hose Barb Fitting, 1 in Barb x 3/4 in NPT 90° CS12167,0000B01 -19-05APR18-8/93

041118

PN=17

BKK10302, BKK10303, BKK10304, BKK10305

25. Cut hose (A) to 2362 mm (93 in).

26. Route through P-clamps (B) and install onto the vent fitting (C).

27. Cut hose (D) to 2030 mm (80 in).

28. Route through double P-clamp (E) and install onto the tank return fitting (F).

29. Cut hose (G) to 2441 mm (96 in).

A—Hose, 1 in ID x 2362 mm (93 in) B—P-Clamp (2 used) C—Vent Fitting D—Hose, 1/2 in ID x 2030 mm (80 in)

N116326 —UN—25FEB15

30. Route through double P-clamp (E) and install onto the rinse fitting (H).

E—Double P-Clamp F— Tank Return Fitting G—Hose, 1 in ID x 2441 mm (96 in) H—Rinse Fitting

A2 Upper Hoses CS12167,0000B01 -19-05APR18-9/93

IMPORTANT: Clamp (A) must be installed before installing hose barb fitting (B) to minimize the chance of the tank splitting.

N116330 —UN—26FEB15

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

31. Install Upper Tank Fittings and Hoses—LowVolume System—If Equipped: Install clamp (A) to tank.

32. Apply sealant to the hose barb fitting (B) and install in tank. Position as shown.

33. Apply sealant to hose barb fittings (C and D) and install in tank. Position as shown.

Low-Volume Upper Fittings A—Clamp B—Hose Barb Fitting, 3/4 in NPT x 1/2 in Barb 90°

Continued on next page

KK43425 (11APR18)

16

C—Hose Barb Fitting, 1 in 90° D—Hose Barb Fitting, 1 in Barb x 3/4 in NPT 90° CS12167,0000B01 -19-05APR18-10/93

041118

PN=18

BKK10302, BKK10303, BKK10304, BKK10305

34. Cut hose (A) to 1983 mm (78 in).

35. Route through double P-clamps (C) and install onto the rinse fitting (B).

36. Cut hose (D) to 1628 mm (64 in).

37. Route through double P-clamps (C) and install onto the vent fitting (E).

38. Cut hose (F) to 1400 mm (55 in).

A—Hose, 1 in ID x 1983 mm (78 in) B—Rinse Fitting C—Double P-Clamp (2 used) D—Hose, 1 in ID x 1628 mm (64 in)

N116329 —UN—26FEB15

39. Route through double P-clamps (H) and install onto the tank return fitting (G).

E—Vent Fitting F— Hose, 1/2 in ID x 1400 mm (55 in) G—Tank Return Fitting H—P-Clamp (2 used)

Low-Volume Upper Hoses CS12167,0000B01 -19-05APR18-11/93

40. Install High-Volume Pump: Raise boom to highest position.

42. Remove and discard cap screws and nuts (C) and bracket (D).

43. Remove cap screws and nuts (E). Retain hardware for attaching the rinse valve.

44. Move hose clamp assembly off to the left side.

D—Bracket E—Cap Screw and Nut (2 used) F— Hose Clamp Assembly

N116104 —UN—24FEB15

A—Cap Screw and Nut B—P-Clamp C—Cap Screw and Nut (2 used)

N116103 —UN—24FEB15

41. Remove and retain cap screw and nut (A) and P-clamp (B).

Continued on next page

KK43425 (11APR18)

17

CS12167,0000B01 -19-05APR18-12/93

041118

PN=19

BKK10302, BKK10303, BKK10304, BKK10305

CAUTION: High-volume pump assembly (A) is awkward to handle. Two people are required to install. Plan a safe installation procedure. Use appropriate lifting device to install.

N116105 —UN—24FEB15

NOTE: As necessary, loosen pump mounting hardware (B) to aid in alignment of assembly mounting holes.

High-volume pump assembly weighs approximately 35.9 kg (79.1 lb).

45. Install high-volume pump assembly to mounting tabs (C).

High-Volume Pump

46. Retain using cap screws (D).

47. Tighten any hardware loosened during installation.

A—High-Volume Pump Assembly B—Pump Mounting Hardware C—Mounting Tab

IMPORTANT: Verify that check valve (E) is stamped 046 and contains a hole in the poppet.

Otherwise, contact your John Deere Dealer for a proper replacement. This check valve is necessary for pump priming and is not to be used in a traditional check valve application.

D—Cap Screw, M8 x 25 (4 used) E—Check Valve

48. Retain vent hoses to high-volume pump assembly using previously removed P-clamps, cap screws, and nuts.

CS12167,0000B01 -19-05APR18-13/93

49. Identify rinse valve ports (A—C) for future reference.

• Rinse water is always connected to port “AUX” (A).

• Chemical is always connected to port “MAIN” (B).

• DI Pump is always connected to port “COMMON” (C).

C—COMMON Port

N118300 —UN—27MAY15

A—AUX Port B—MAIN Port

Continued on next page

KK43425 (11APR18)

18

CS12167,0000B01 -19-05APR18-14/93

041118

PN=20

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

N116745 —UN—25MAR15

50. Attach bracket (A) to rinse valve assembly (B) using cap screws and flange nuts (C).

51. Apply sealant to hose barb fittings (D, E, and F) and install in the rinse valve. Position as shown.

52. Install P-clamp (J) to bracket using cap screw (G), washer (H), spacer (I), and flange nut (K).

G—Cap Screw, M8 x 50 H—Washer I— Spacer J— P-Clamp, 38 mm (1-1/2 in) K—Flange Nut, M8

N116746 —UN—25MAR15

A—Bracket B—Rinse Valve Assembly C—Cap Screw, M8 x 30 and Flange Nuts (2 used) D—Hose Barb Fitting, 3/4 in Barb x 3/4 in NPT 90° E—Hose Barb Fitting, 3/4 in Barb x 3/4 in NPT Straight F— Hose Barb Fitting, 3/4 in Barb x 3/4 in NPT 90°

CS12167,0000B01 -19-05APR18-15/93

53. Attach rinse valve assembly (A) to front side of frame (B) using previously removed hardware.

B—Frame

N116108 —UN—24FEB15

A—Rinse Valve Assembly

N116106 —UN—21APR15

View from Rear

Continued on next page

KK43425 (11APR18)

19

CS12167,0000B01 -19-05APR18-16/93

041118

PN=21

BKK10302, BKK10303, BKK10304, BKK10305

54. Remove nut (A) from the cap screw (B).

55. Remove and discard the hose mount (C).

C—Hose Mount D—Rinse Bracket

N116322 —UN—24FEB15

A—Nut B—Cap Screw

N116107 —UN—24FEB15

56. Move clamp assembly over to rinse bracket (D) and reinstall previously removed nut.

CS12167,0000B01 -19-05APR18-17/93

57. Retain vent hose (A) to pump mount (B) using previously removed P-clamp, cap screw, and nut (C).

C—Nut

N116323 —UN—24FEB15

A—Vent Hose B—Pump Mount

Continued on next page

KK43425 (11APR18)

20

CS12167,0000B01 -19-05APR18-18/93

041118

PN=22

BKK10302, BKK10303, BKK10304, BKK10305

IMPORTANT: Do not disconnect battery on machines equipped with Final Tier 4 engines until LED (A) has turned off. This indicates that the DEF system purge is complete.

A—LED

N102417 —UN—01MAR13

58. Install Wiring Harness: Rotate handle (B) counterclockwise to disconnect batteries.

B—Handle

Disconnect Switch CS12167,0000B01 -19-05APR18-19/93

59. Install bulkhead connector (A) at shown location.

Retain using nut (B).

B—Nut

N105682 —UN—05AUG13

A—Bulkhead Connector

Bulkhead Connector Continued on next page

KK43425 (11APR18)

21

CS12167,0000B01 -19-05APR18-20/93

041118

PN=23

BKK10302, BKK10303, BKK10304, BKK10305

N105205 —UN—07AUG13

B

A

Harness Routing Diagram

60. Route direct injection (DI) harness (A) behind cab mount (C).

61. Locate chassis harness (B).

N105809 —UN—08AUG13

IMPORTANT: Avoid rub or pinch points when routing harness to prevent damage.

62. Route DI harness along chassis harness.

63. Route DI harness forward as shown.

IMPORTANT: Use additional tie bands if necessary to prevent harness rub points.

64. Retain DI harness to chassis harness with tie bands as needed.

A—Direct Injection (DI) Harness B—Chassis Harness Continued on next page

KK43425 (11APR18)

22

C—Cab Mount

CS12167,0000B01 -19-05APR18-21/93

041118

PN=24

BKK10302, BKK10303, BKK10304, BKK10305

65. Remove and retain the nut (A) and wire (B) from the starter relay (C) in the battery box.

66. Locate chassis harness connector (D) and red wire (E).

D—Chassis Harness Connector E—Red Wire

N105207 —UN—05AUG13

A—Nut B—Wire C—Starter Relay

Starter Relay CS12167,0000B01 -19-05APR18-22/93

67. Install DI relay (A) using cap screw (B) and nut.

NOTE: Wire (F) is to be installed in its previous position on the starter relay.

N105679 —UN—05AUG13

68. Install bus bar (C) to the starter relay and DI relay using nut (D) and previously removed nut (E) and wire.

69. Connect chassis harness connector (I) to the DI relay.

70. Install red wire (G) to bottom stud of the DI relay, retain using nut (H).

71. Remove and retain cap screw (J).

Direct Injection Relay

72. Install DI harness ground (K) as shown using previously removed cap screw.

G—Red Wire H—Nut I— Chassis Harness Connector J— Cap Screw K—DI Harness Ground

N111104 —UN—09APR14

A—DI Relay B—Cap Screw, M6 x 50 C—Bus Bar D—Nut E—Nut, Previously Removed F— Wire

DI Ground Continued on next page

KK43425 (11APR18)

23

CS12167,0000B01 -19-05APR18-23/93

041118

PN=25

BKK10302, BKK10303, BKK10304, BKK10305

73. Connect DI harness connector (A) to chassis harness (B) at the battery box.

B—Chassis Harness

N105931 —UN—28AUG13

A—DI Harness Connector

CS12167,0000B01 -19-05APR18-24/93

74. Remove and retain cap screws (A) and nuts.

75. Position fuse box (B) as desired to access the rear of box.

Fuse Name

DI Harness Wire Code

N105689 —UN—05AUG13

76. Install DI harness (C) to the fuse box terminals. See table for proper placement.

Fuse Box Location

F111

8722

11

F112

8712

12

F113

8702

13

77. Install fuse box using previously removed cap screws and nuts.

C—DI Harness

N105690 —UN—05AUG13

A—Cap Screw (2 used) B—Fuse Box

Continued on next page

KK43425 (11APR18)

24

CS12167,0000B01 -19-05APR18-25/93

041118

PN=26

BKK10302, BKK10303, BKK10304, BKK10305

78. Connect rear bulkhead connector (A) to the front bulkhead connector (B).

B—Front Bulkhead Connector

N105691 —UN—05AUG13

A—Rear Bulkhead Connector

Bulkhead Connectors CS12167,0000B01 -19-05APR18-26/93

B

N105206 —UN—05MAR14

A

Harness Routing Diagram

NOTE: Some parts have been removed to provide clarity.

79. Route DI harness (A) rearward along solution system harness (B). Retain with tie bands as needed.

B—Solution System Harness

N105810 —UN—08AUG13

A—DI Harness

Continued on next page

KK43425 (11APR18)

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CS12167,0000B01 -19-05APR18-27/93

041118

PN=27

N110779 —UN—04MAR14

N110781 —UN—04MAR14

BKK10302, BKK10303, BKK10304, BKK10305

Bracket Identification

80. Remove and retain cap screws (A) and flange lock nuts.

N110782 —UN—04MAR14

NOTE: If the boom air purge is not installed on machine, install bracket (C) using two M8 x 20 cap screws (D) and M8 flange lock nuts.

81. Install bracket (C) using previously removed cap screws (A) and flange lock nuts.

A—Cap Screw (2 used) B—Air Purge Valve

C—Bracket D—Cap Screw, M8 x 20 (2 used)

N110780 —UN—04MAR14

Bracket Installed with Air Purge

Bracket Installed without Air Purge Continued on next page

KK43425 (11APR18)

26

CS12167,0000B01 -19-05APR18-28/93

041118

PN=28

BKK10302, BKK10303, BKK10304, BKK10305

82. Install harness (A) in P-clamp (B).

83. Install P-clamps (B and C) to bracket as shown using cap screw (D), washer, and flange lock nut.

C—Double P-Clamp, 36.5 mm (1-7/16 in) D—Cap Screw, M8 x 30

N110795 —UN—04MAR14

A—Harness B—P-Clamp, 38.1 mm (1-1/2 in)

CS12167,0000B01 -19-05APR18-29/93

84. Install P-clamps (A and B) to bracket as shown using cap screw (C), washer, and flange lock nut.

C—Cap Screw, M8 x 30

N110796 —UN—04MAR14

A—Double P-Clamp, 36.5 mm (1-7/16 in) B—Double P-Clamp, 19 mm (3/4 in)

CS12167,0000B01 -19-05APR18-30/93

85. Continue routing DI harness (A) along boom support (B) to the high-volume pump. Use tie bands (C) to retain harness.

C—Tie Band (5 used) N116096 —UN—24FEB15

A—DI Harness B—Boom Support

Continued on next page

KK43425 (11APR18)

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CS12167,0000B01 -19-05APR18-31/93

041118

PN=29

BKK10302, BKK10303, BKK10304, BKK10305

86. Install high-volume pump harness (A) to high-volume pump assembly (B).

87. Retain connector (C) as shown using supplied tie band (D).

IMPORTANT: Verify wires (E) are not under tension. Water or chemical may enter the connection, causing damage.

88. Connect high-volume pump harness to DI harness (F).

89. Retain connector (G) to solution system harness (H) using tie bands.

E—Wires F— DI Harness G—Connector H—Solution System Harness

N107959 —UN—21FEB14

A—High-Volume Pump Harness B—High-Volume Pump Assembly C—Connector D—Tie Band

N107958 —UN—21FEB14

NOTE: If the low-volume bundle is not installed, coil harness breakout and retain to machine using tie bands.

Continued on next page

KK43425 (11APR18)

28

CS12167,0000B01 -19-05APR18-32/93

041118

PN=30

BKK10302, BKK10303, BKK10304, BKK10305

90. Connect CAN connections on machines NOT equipped with ExactApply™. a. Disconnect harness connectors (A and B) on main solution harness (C).

N110777 —UN—04MAR14

b. Disconnect harness connectors (D and E) on DI harness (F). c. Connect harness connectors (A) and (D) together. d. Connect harness connectors (B) and (E) together.

D—DI Harness Connector E—DI Harness Connector F— DI Harness

N110778 —UN—04MAR14

A—Main Solution Harness Connector B—Main Solution Harness Connector C—Main Solution Harness

ExactApply is a trademark of Deere & Company CS12167,0000B01 -19-05APR18-33/93

NOTE: CAN connections are located under the solution system control unit.

A

91. Connect CAN connections on machines EQUIPPED with ExactApply™. a. Disconnect CAN connectors (D, E, F, and G) between main solution harness (A) and the ExactApply™ harness (B). b. Disconnect CAN connectors (H and I) on the DI harness (C).

B

E

D

c. Connect CAN connectors (D and H). d. Connect CAN connectors (I and F).

C

A—Main Solution Harness B—ExactApply™ Harness C—Direct Injection (DI) Harness D—Main Solution Harness CAN Connector E—Main Solution Harness CAN Connector

F— ExactApply™ Harness CAN Connector G—ExactApply™ Harness CAN Connector H—DI Harness CAN Connector I— DI Harness CAN Connector

Continued on next page

KK43425 (11APR18)

29

G

F

H

I

N130202 —UN—03MAY17

e. Connect CAN connectors (E and G).

CS12167,0000B01 -19-05APR18-34/93

041118

PN=31

BKK10302, BKK10303, BKK10304, BKK10305

92. Install Tank Assemblies—Without Low-Volume Kit: Tank placement from left to right is A1 and A2.

B—Tank Assembly A2

N116806 —UN—19MAR15

A—Tank Assembly A1

CS12167,0000B01 -19-05APR18-35/93

93. Loosely install bracket (A) to the tank assembly bracket (B) using cap screws (C) and flange nuts (D).

94. Loosen cap screws and nuts (E).

A—Bracket B—Tank Assembly Bracket C—Cap Screw, M10 x 40 (2 used)

N116100 —UN—25FEB15

95. Repeat procedure for other tank assembly.

D—Flange Nut, M10 (2 used) E—Cap Screw and Nut (4 used)

CS12167,0000B01 -19-05APR18-36/93

CAUTION: Tank assemblies are awkward to handle. Two people are required to install.

Plan a safe installation procedure. Use appropriate lifting device to install.

NOTE: Tank assemblies weigh approximately 47 kg (103 lb) each.

96. Slide tank assembly A2 (B) to upper mounting tube (C).

N116328 —UN—25FEB15

NOTE: Install spacer cap screws from the front, flange lock nuts to the rear.

97. Install spacers (D) between tank assembly and lower mounting tube (E) using cap screws and flange lock nuts (F). Tighten lower hardware.

98. Tighten upper hardware (A).

99. Repeat procedure for tank assembly A1.

Assembly A2 A—Upper Hardware B—Tank Assembly A2 C—Upper Mounting Tube

D—Spacer (2 used) E—Lower Mounting Tube F— Cap Screw, M10 x 100 and Flange Lock Nut (2 used) Continued on next page

KK43425 (11APR18)

30

CS12167,0000B01 -19-05APR18-37/93

041118

PN=32

BKK10302, BKK10303, BKK10304, BKK10305

100.Install Tank Assemblies—With Low-Volume Kit: Tank placement from left to right is Low-Volume, A1, and A2.

C—Tank Assembly A2 N116747 —UN—25MAR15

A—Tank Assembly—LowVolume B—Tank Assembly A1

CS12167,0000B01 -19-05APR18-38/93

101.Install Tank Assemblies—With Low-Volume Kit: Loosely install bracket (A) to the A2 tank assembly bracket (B) using cap screws (C) and flange nuts (D).

102.Loosen cap screws and nuts (E).

D—Flange Nut, M10 (2 used) E—Cap Screw and Nut (4 used)

N116100 —UN—25FEB15

A—Bracket B—Tank Assembly Bracket C—Cap Screw, M10 x 40 (2 used)

Assembly A2 CS12167,0000B01 -19-05APR18-39/93

CAUTION: Tank assemblies are awkward to handle. Two people are required to install.

Plan a safe installation procedure. Use appropriate lifting device to install.

103.Slide tank assembly A2 (B) to upper mounting tube (C).

NOTE: Install spacer cap screws from the front, flange lock nuts to the rear.

N116328 —UN—25FEB15

104.Install spacers (D) between tank assembly and lower mounting tube (E) using cap screws and flange lock nuts (F). Tighten lower hardware.

105.Tighten upper hardware (A).

A—Upper Hardware B—Tank Assembly A2 C—Upper Mounting Tube

D—Spacer (2 used) E—Lower Mounting Tube F— Cap Screw, M10 x 100 and Flange Lock Nut (2 used)

Assembly A2 Continued on next page

KK43425 (11APR18)

31

CS12167,0000B01 -19-05APR18-40/93

041118

PN=33

BKK10302, BKK10303, BKK10304, BKK10305

106.Remove and retain cap screws and nuts (A) from low-volume tank assembly (C).

107.Loosen cap screws and nuts (B).

C—Low-Volume Tank Assembly

N116331 —UN—27FEB15

A—Cap Screw and Nut (4 used) B—Cap Screw and Nut (4 used)

Low-Volume Tank Assembly CS12167,0000B01 -19-05APR18-41/93

108.Remove and retain tank strap nuts (A).

109.Remove tank A1 (B) from the support bracket.

A—Tank Strap Nut (2 used) B—Tank A1

N116332 —UN—27FEB15

110.Remove and discard cap screws and nuts (D), and mounting bracket (C).

C—Mounting Bracket D—Cap Screw and Nut (4 used)

Tank Mounting Bracket CS12167,0000B01 -19-05APR18-42/93

111.Install lifting strap or chain to hole (A) in tank assembly A1.

112.Attach low-volume tank mounting bracket (B) to A1 support (C). Loosely retain with previously removed cap screws and nuts (D).

113.Reinstall tank A1 (E) to support bracket.

D—Cap Screw and Nut (4 used) E—Tank A1 F— Low-Volume Tank Assembly N116333 —UN—27FEB15

A—Hole B—Mounting Bracket C—A1 Support

Attach Tank Assemblies Continued on next page

KK43425 (11APR18)

32

CS12167,0000B01 -19-05APR18-43/93

041118

PN=34

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: The combined weight of the A1 assembly and the low-volume assembly is 88.5 kg (195 lb).

114.Slide tank assemblies onto upper mounting tube (A).

115.Install spacer (B) between tank assembly A1 and mounting tube. Retain with cap screws and flange lock nuts (C).

116.Install spacer tubes (E) between low-volume tank assembly and support. Retain with cap screws and flange lock nuts (D).

A—Upper Mounting Tube B—Spacer C—Cap Screw, M10 x 100 and Flange Lock Nut (2 used)

N116334 —UN—27FEB15

117.Tighten all hardware starting at lower mount and working up.

D—Cap Screw, M10 x 150 and Flange Lock Nut (2 used) E—Spacer Tube (2 used)

Install Tanks CS12167,0000B01 -19-05APR18-44/93

NOTE: Install tank sump valve assemblies from right to left.

A—Valve Assembly B—Gasket

N102986 —UN—27MAR13

118. Install Tank Sump Valve Assemblies: Install valve assembly (A) to the A2 tank sump using gasket (B) and flange clamp (C). Position as shown.

C—Flange Clamp, 1 in

Tank A2 Sump Valve CS12167,0000B01 -19-05APR18-45/93

119.Install valve assembly (A) to the A1 tank sump using gasket (B) and flange clamp (C). Position as shown.

C—Flange Clamp, 1 in

N103020 —UN—27MAR13

A—Valve Assembly B—Gasket

Tank A1 Sump Valve Continued on next page

KK43425 (11APR18)

33

CS12167,0000B01 -19-05APR18-46/93

041118

PN=35

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

N105197 —UN—05AUG13

120.Install Low-Volume Tank Sump Valve and Fittings—Low-Volume System—If Equipped: Apply sealant to low-volume sump valve assembly (A).

121.Install low-volume sump valve assembly to the tank sump fitting (B). Position as shown.

A—Low-Volume Sump Valve Assembly

B—Tank Sump Fitting

CS12167,0000B01 -19-05APR18-47/93

CAUTION: Low-volume pump assembly weighs approximately 22.3 kg (49 lb).

Pump assembly is awkward, two people or lifting device are required for installation.

122.Install Low-Volume Pump Assembly and Strainer—If Equipped: Install low-volume pump assembly (A) to the low-volume tank bracket (B) using cap screws (C and D) and flange lock nuts.

C—Cap Screw, M10 x 30 (2 used) D—Cap Screw, M8 x 30 (3 used)

N116335 —UN—27FEB15

A—Low-Volume Pump Assembly B—Low-Volume Tank Bracket

N116336 —UN—27FEB15

Low-Volume Pump Assembly

Continued on next page

KK43425 (11APR18)

34

CS12167,0000B01 -19-05APR18-48/93

041118

PN=36

BKK10302, BKK10303, BKK10304, BKK10305

123.Install valve and strainer assembly (A) to mount (B) using cap screws (C) and flange lock nuts.

C—Cap Screw, M8 x 100 (2 used) N116828 —UN—25MAR15

A—Valve and Strainer Assembly B—Mount

CS12167,0000B01 -19-05APR18-49/93

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

N110521 —UN—25FEB14

124.Install Check Valves in Mixer: Apply sealant to the hose barb (A) and install in the check valve (B).

125.Apply sealant to check valve (B) and install in fitting (C).

A—90° Hose Barb for 1/2 in ID Hose B—Check Valve

C—45° Fitting

Continued on next page

KK43425 (11APR18)

35

CS12167,0000B01 -19-05APR18-50/93

041118

PN=37

BKK10302, BKK10303, BKK10304, BKK10305

126.Remove plug (A) from mixer assembly (B).

127.Apply sealant to check valve assembly (C) and install in mixer. Position check valve assembly as shown.

N110463 —UN—25FEB14

C—Check Valve Assembly

N110464 —UN—25FEB14

A—Plug B—Mixer Assembly

CS12167,0000B01 -19-05APR18-51/93

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

N110521 —UN—25FEB14

128.Low-Volume System—If Equipped: Apply sealant to the hose barb (A) and install in the check valve (B).

129.Apply sealant to check valve (B) and install in fitting (C).

A—Straight Hose Barb for 1/2 in ID Hose B—Check Valve

C—45° Fitting

Continued on next page

KK43425 (11APR18)

36

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041118

PN=38

BKK10302, BKK10303, BKK10304, BKK10305

130.Remove plug (A) from mixer assembly (B).

131.Apply sealant to check valve assembly (C) and install in mixer. Position check valve assembly as shown.

N110522 —UN—25FEB14

C—Check Valve Assembly

N110523 —UN—25FEB14

A—Plug B—Mixer Assembly

CS12167,0000B01 -19-05APR18-53/93

132.Install Mixer Assembly and Brackets: Remove and retain flange clamps (A) and gaskets (B).

133.Remove and discard fitting (C).

C—Fitting N105189 —UN—05AUG13

A—Flange Clamp (2 used) B—Gasket (2 used)

Continued on next page

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041118

PN=39

BKK10302, BKK10303, BKK10304, BKK10305

134.Install mixer assembly (A) to the suspended center frame (B). Position as shown.

135.Retain mixer assembly with U-bolts (C) and nuts (D).

A—Mixer Assembly B—Suspended Center Frame C—U-Bolt, M8 (2 used)

N105190 —UN—05AUG13

136.Install bracket (E) using U-bolt (F) and nuts.

D—Nut, M8 (6 used) E—Bracket F— U-Bolt, M8

Mixer Assembly CS12167,0000B01 -19-05APR18-55/93

137.Install hose bracket (A) and plate (B) using cap screws (C) and flange lock nuts (D). Position at measurement (E) from right-hand tilt cylinder mount (F).

D—Flange Lock Nut, M12 (4 used) E—Measurement, 936 mm (37 in) F— Right-Hand Tilt Cylinder Mount

N105191 —UN—04MAR14

A—Hose Bracket B—Plate C—Cap Screw, M12 x 140 (4 used)

CS12167,0000B01 -19-05APR18-56/93

138.Install P-clamps (A) on hoses (B) and (C) in shown orientation.

C—Inlet Hose, 1550 mm (61 in)

N110574 —UN—25FEB14

A—P-Clamps, 63.5 mm (2-1/2 in) B—Outlet Hose, 1289 mm (50-3/4 in)

Continued on next page

KK43425 (11APR18)

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041118

PN=40

N105192 —UN—08AUG13

BKK10302, BKK10303, BKK10304, BKK10305

Mixer Plumbing A—Flange Clamp B—Elbow Fitting C—Hose Barb Fitting D—Inlet Hose, 1550 mm (61 in)

E—Band Clamps F— Flange Clamp G—Mixer Assembly Inlet H—Band Clamps I— Outlet Hose, 1289 mm (50-3/4 in)

J— Mixer Assembly Outlet K—Band Clamps L— Barbed Elbow Fitting M—Band Clamps

N—Flange Clamp O—Boom Isolation Valve

139.Loosen flange clamp (A).

144.Route outlet hose (I) through P-clamps as shown.

140.Rotate elbow fitting (B) to the position shown.

145.Install outlet hose to the mixer assembly outlet (J) and retain using band clamps (K).

141.Install hose barb fitting (C) to the elbow fitting and retain with a flange clamp (F) and gasket.

146.Install barbed elbow fitting (L) to the outlet hose and retain with band clamps (M).

142.Route inlet hose (D) through P-clamps as shown.

147.Install barbed elbow fitting to boom isolation valve (O) using flange clamp (N) and gasket.

143.Install inlet hose to the hose barb fitting and mixer assembly inlet (G) as shown using band clamps (E) and (H).

Continued on next page

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041118

PN=41

BKK10302, BKK10303, BKK10304, BKK10305

148.Retain P-clamps (A) using cap screws (B) and flange lock nuts.

149.Retain P-clamp (C) using cap screw (D) and flange lock nut.

D—Cap Screw, M10 x 40 E—P-Clamp, 63.5 mm (2-1/2 in) F— Cap Screw, M10 x 40 (3 used)

N110575 —UN—25FEB14

A—P-Clamp, 63.5 mm (2-1/2 in) B—Cap Screws M10 x 30 (2 used) C—P-Clamp, 63.5 mm (2-1/2 in)

N110573 —UN—25FEB14

150.Retain P-clamps (E) using cap screws (F) and flange lock nuts.

Mixer P-Clamps Continued on next page

KK43425 (11APR18)

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041118

PN=42

N105797 —UN—08AUG13

BKK10302, BKK10303, BKK10304, BKK10305

A—P-Clamp, 38.1 mm (1-1/2 in) B—Cap Screw, M8 x 30 C—Double P-Clamp, 38.1 mm (1-1/2 in)

D—Cap Screw, M8 x 30 E—P-Clamp, 38.1 mm (1-1/2 in) F— P-Clamp, 25.4 mm (1 in) G—Cap Screw, M10 x 130

H—Spacer, 57.1 mm (2-1/4 in) I— Flange Lock Nut, M10 J— P-Clamp, 38.1 mm (1-1/2 in)

K—P-Clamp, 38.1 mm (1-1/2 in) L— Cap Screw, M10 x 70

151.P-clamp Installation: Install P-clamp (A) using cap screw (B) and flange nut.

154.Install P-clamps (J) using cap screw (G), spacer (H), and flange lock nut.

152.Install double P-clamp (C) using cap screw (D), washer, and flange nut.

155.Install P-clamp (K) using cap screw (L) and flange lock nut.

153.Install P-clamps (E and F) using cap screw (G), spacer (H), and flange lock nut (I).

CS12167,0000B01 -19-05APR18-60/93

156.Install P-clamp (A) using cap screw (B) and flange nut. Position as shown.

B—Cap Screw, M10 x 70

N110626 —UN—04MAR14

A—P-Clamp, 38.1 mm (1-1/2 in)

Continued on next page

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041118

PN=43

BKK10302, BKK10303, BKK10304, BKK10305

157.Install bracket (A) to upper mounting tube (B) using U-bolt (C) and flange lock nuts.

159.Install bracket (F) to lift arm tube (G) using U-bolt (H) and flange lock nuts.

160.Install hose retainer (I) to the retainer bracket using cap screw (J) and flange lock nut.

NOTE: Install P-clamp (K) to the hose retainer if the low-volume bundle is installed.

G—Lift Arm Tube H—U-Bolt, M8 x 112 I— Hose Retainer J— Cap Screw, M8 x 60 K—P-Clamp, 19 mm (3/4 in)—Low-Volume Bundle ONLY

N110630 —UN—05MAR14

A—Bracket B—Upper Mounting Tube C—U-Bolt, M10 x 114 D—Hose Support E—Cap Screw, M10 x 25 (2 used) F— Bracket

N110629 —UN—05MAR14

158.Install hose support (D) to bracket using cap screws (E) and flange lock nuts.

CS12167,0000B01 -19-05APR18-62/93

161.Remove upper nut (A) from the hose retainer (B).

162.Install P-clamp (C) using previously removed nut.

N110930 —UN—12MAR14

NOTE: Install P-clamp (F) to hose retainer if low-volume bundle is installed.

163.Install hose retainers (D) to lift arm frame using cap screw (E) and flange nut.

A—Nut B—Hose Retainer C—Double P-Clamp, 36.5 mm (1-7/16 in)

D—Hose Retainers E—Cap Screw, M8 x 160 F— P-Clamp, 19 mm (3/4 in)—Low -Volume Bundle ONLY Continued on next page

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041118

PN=44

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: Electrical harness retainers must be removed before installing bracket. After bracket installation, retain the harness to the bracket using provided holes (D).

A—Bracket B—Boom Frame

N116810 —UN—20MAR15

164.Install bracket (A) to the boom frame (B) using cap screws (C) and flange lock nuts.

C—Cap Screws, M8 x 25 and Flange Nuts (2 used) D—Holes for Retaining Electrical Harness

CS12167,0000B01 -19-05APR18-64/93

NOTE: To simplify the text and photos, the following procedure does not call out the installation of hose clamps.

N116451 —UN—03MAR15

Install hose clamps on each hose end and tighten to specification.

Specification Hose Clamps—Torque........................................................ 3.9—4.5 N·m (35—40 lb·in)

Hose-to-Clamp Reference • 1/2 in ID hoses, use 1 in clamps • 3/4 in ID hoses, use 1 in clamps • 1 in ID hoses, use 1-1/2 in clamps

Rinse Tank Connection

165.Models R4030 and R4038 Only: Depending on configuration, remove foam marker fitting (B) or plug (C) from T-fitting (D).

A—Rinse Tank B—Foam Marker Fitting

C—Plug D—T-Fitting CS12167,0000B01 -19-05APR18-65/93

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

A—Pipe Nipple, 3/4 in B—T-Fitting, 3/4 in C—Straight Hose Barb for 3/4 in ID Hose

N116452 —UN—03MAR15

166.Models R4030 and R4038 Only With Foam Marker: Apply sealant to threads and assemble parts (A—E) as shown.

D—Foam Marker Fitting E—T-Fitting

With Foam Marker Continued on next page

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041118

PN=45

BKK10302, BKK10303, BKK10304, BKK10305

167.Models R4030 and R4038 Only Without Foam Marker: Apply sealant to threads and install 90° hose barb (B) to T-fitting (A) as shown.

B—90° Hose Barb for 3/4 in ID Hose N128686 —UN—11APR17

A—T-Fitting

Without Foam Marker CS12167,0000B01 -19-05APR18-67/93

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

N116453 —UN—03MAR15

168.Models R4030 and R4038 Only: Cut hose (A) to 336 mm (13.25 in).

169.Models R4030 and R4038 Only: Install one end of hose (A) to barb fitting (B).

170.Models R4030 and R4038 Only: Assemble straight hose barbs (C) and check valve (D).

IMPORTANT: Proper check valve installation is necessary to prevent contamination of rinse water.

171.Models R4030 and R4038 Only: Install check valve assembly to hose (A), making sure that arrow on valve is pointing away from the rinse tank.

A—Rinse Hose, 3/4 in ID x 336 mm (13.25 in) B—Barb Fitting for 3/4 in ID Hose

C—Straight Hose Barbs for 3/4 in ID Hose D—Check Valve

Continued on next page

KK43425 (11APR18)

44

N116454 —UN—04MAR15

NOTE: Arrows on check valve show direction of flow.

CS12167,0000B01 -19-05APR18-68/93

041118

PN=46

BKK10302, BKK10303, BKK10304, BKK10305

172.Models R4030 and R4038 Only: Cut hose (A) to 1329 mm (52.25 in).

C—Rinse Valve Fitting

N116456 —UN—04MAR15

A—Rinse Hose, 3/4 in ID x 1329 mm (52.25 in) B—Check Valve Barb Fitting

N116455 —UN—04MAR15

173.Models R4030 and R4038 Only: Install one end of hose (A) to check valve barb fitting (B) and the other end to rinse valve fitting (C).

Rinse Valve CS12167,0000B01 -19-05APR18-69/93

IMPORTANT: Proper check valve installation is necessary to prevent contamination of rinse water.

N116738 —UN—25MAR15

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

Arrows on check valve show direction of flow.

174.Model R4045 Only: Assemble parts (A—G) as shown.

A—T-Fitting, 2 in B—Gasket C—Clamp, 2 in D—Adaptor, 2 in flange with 3/4 in NPT port

E—Pipe Nipple, 3/4 in F— Check Valve G—Straight Hose Barb for 3/4 in ID Hose

Continued on next page

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041118

PN=47

N130079 —UN—24APR17

N116729 —UN—25MAR15

BKK10302, BKK10303, BKK10304, BKK10305

175.Model R4045 Only: Loosen flange clamp (A) and separate rinse hose (B) from manifold (C).

A—Flange Clamp B—Rinse Hose C—Manifold

N116739 —UN—25MAR15

176.Model R4045 Only: Install T-fitting assembly (D) between rinse hose and manifold using gaskets (E) and flange clamps (F). Align fitting as shown and tighten clamps.

D—T-Fitting Assembly E—Gaskets (2 used) F— Flange Clamps (2 used)

Alignment Shown Continued on next page

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041118

PN=48

BKK10302, BKK10303, BKK10304, BKK10305

177.Model R4045 Only: Cut hose (A) to 813 mm (32 in).

178.Model R4045 Only: Install one end of hose (A) to check valve barb fitting (B) and the other end to rinse valve fitting (C).

N116743 —UN—25MAR15

C—Rinse Valve Fitting

N116741 —UN—07MAY15

A—Rinse Hose, 3/4 in ID x 813 mm (32 in) B—Check Valve Barb Fitting

Continued on next page

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041118

PN=49

N116446 —UN—02MAR15

BKK10302, BKK10303, BKK10304, BKK10305

Rinse Hose Routing

179.Hose Routing: Route hose (A) through P-clamps (B and C) as shown and install to pump return fitting (D).

180.Route hose (E) through P-clamps (B and F) as shown and install to T-fitting (G).

N116447 —UN—03MAR15

181.Route hose (H) through P-clamps (I) as shown and install to the tank T-fitting (G).

182.Cut hose (J) to 660 mm (26 in).

183.Install one end of hose (J) onto T-fitting (G) and the other to rinse/fill valve fitting (K). Route as shown.

A—Hose, 1/2 in ID B—Double P-Clamp C—P-Clamp D—Pump Return Fitting E—Hose, 1 in ID F— P-Clamp

G—T-Fitting, 1 in H—Hose, 1 in ID I— P-Clamp J— Hose, 1 in ID x 660 mm (26 in) K—Rinse/Fill Valve Fitting Continued on next page

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041118

PN=50

N116449 —UN—03MAR15

BKK10302, BKK10303, BKK10304, BKK10305

Fill Hose Routing

184.Cut hose (A) to 1070 mm (42 in).

185.Route fill hose (A) through P-clamps (C and D) and install to tank A1 lower fitting (B).

N116448 —UN—03MAR15

186.Install other end of hose (A) to T-fitting (E).

187.Cut hose (F) to 1117 mm (44 in).

188.Install one end of hose (F) to tank A2 supply fitting (G) and the other end to the strainer fitting (H).

189.Cut hose (I) to 862 mm (34 in).

190.Route fill hose (I) through P-clamps (K) and install to tank A2 lower fitting (J).

191.Install other end of hose (I) to T-fitting (E).

192.Retain hoses (F) and (I) together using tie bands (L) as shown.

193.Cut hose (M) to 687 mm (27 in).

194.Install one end of hose (M) to T-fitting (E) and the other end to rinse/fill valve fitting (N). Route as shown.

A—Fill Hose, 1 in ID x 1070 mm (42 in) B—Tank A1 Lower Fitting C—Double P-Clamps D—P-Clamp E—T-Fitting, 1 in F— Supply Hose, 3/4 in ID x 1117 mm (44 in) G—Supply Fitting

Continued on next page

KK43425 (11APR18)

49

H—Strainer Fitting I— Fill Hose, 1 in ID x 862 mm (34 in) J— Tank A2 Lower Fitting K—P-Clamps L— Tie Bands M—Fill Hose, 1 in ID x 687 mm (27 in) N—Rinse/Fill Valve Fitting CS12167,0000B01 -19-05APR18-74/93

041118

PN=51

BKK10302, BKK10303, BKK10304, BKK10305

195.Cut hose (A) to 3112 mm (122.5 in).

196.Attach mixer supply hose (A) to pump output fitting (B).

197.Install bracket (F) using cap screws and nuts (G).

N116457 —UN—04MAR15

NOTE: Ensure that hose has sufficient length for all boom positions.

198.Route mixer supply hose through P-clamps (C), brackets (D and F), and hose retainers (E) as shown.

199.Install mixer supply hose to the barbed fitting (G).

E—Hose Retainers F— Bracket G—Cap Screws M8 x 25 and Nuts M8 (2 used) H—Barbed Fitting, 1/2 in

N116460 —UN—04MAR15

N116459 —UN—04MAR15

N116458 —UN—04MAR15

A—Mixer Supply Hose, 1/2 ID x 3112 mm (122.5 in) B—Pump Output Fitting C—Double P-Clamps D—Bracket

Continued on next page

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041118

PN=52

BKK10302, BKK10303, BKK10304, BKK10305

N116461 —UN—05MAR15

IMPORTANT: There are two different types of hose used in this procedure. Most hoses used in this system are braided. There are some locations where a spiral wound hose is needed. See pictorial legend for the proper hose type, if the specified braided hose is not used.

NOTE: To simplify the text and photos, the following procedure does not call out the installation of hose clamps on hose ends.

Hose clamps are to be installed on each hose end and tightened to specification.

Specification Hose Clamps—Torque........................................................ 3.9—4.5 N·m (35—40 lb·in)

Low-Volume Pump and Tank

Hose-to-Clamp Reference • 1/2 in ID hoses, use 1 in clamps • 3/4 in ID hoses, use 1 in clamps • 1 in ID hoses, use 1-1/2 in clamps

N116463 —UN—05MAR15

200.Hose Routing—Low-Volume Pump and Tank—If Equipped: Attach rinse hose (A) to rinse fitting (C).

201.Attach return hose (B) to pump return fitting (D).

202.Cut hose (E) to 246 mm (9.5 in).

203.Attach strainer supply hose (E) to the strainer inlet fitting (F) and tank supply fitting (G).

204.Cut hose (H) to 345 mm (13.5 in).

205.Attach tank fill hose (H) to fill fitting (I) and tank fill fitting (J).

206.Cut hose (K) to 537 mm (21 in).

207.Attach pump supply hose (K) to pump inlet fitting (L) and rinse valve fitting (M).

H—Tank Fill Hose, 1 in Spiral Wound I— Fill Fitting J— Tank Fill Fitting K—Pump Supply Hose, 3/4 in L— Pump Inlet Fitting M—Rinse Valve Fitting

N116462 —UN—05MAR15

A—Rinse Hose, 1 in B—Return Hose, 1/2 in C—Rinse Fitting D—Pump Return Fitting E—Strainer Supply Hose, 3/4 in F— Strainer Inlet Fitting G—Tank Supply Fitting

Continued on next page

KK43425 (11APR18)

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041118

PN=53

BKK10302, BKK10303, BKK10304, BKK10305

208.Cut hose (A) to 458 mm (18 in).

209.Attach pump supply hose (A) to the strainer valve fitting (B).

210.Route pump supply hose through P-clamp (C) and install to pump inlet fitting (D).

C—P-Clamp D—Pump Inlet Fitting N116525 —UN—05MAR15

A—Pump Supply Hose, 3/4 in B—Strainer Valve Fitting

Continued on next page

KK43425 (11APR18)

52

CS12167,0000B01 -19-05APR18-77/93

041118

PN=54

BKK10302, BKK10303, BKK10304, BKK10305

211.Models R4030 and R4038 Only: Cut hose (B) approximately 203 mm (8 in) from previously installed check valve (A).

212.Install T-fitting (C) as shown.

N116464 —UN—05MAR15

213.Cut hose (D) to 1676 mm (66 in).

214.Attach low-volume rinse hose (D) to T-fitting (C).

215.Route low-volume rinse hose through double P-clamps (E) and install to the valve inlet fitting (F).

D—Low-Volume Rinse Hose, 3/4 ID x 1676 mm (66 in).

E—Double P-Clamps (3 used) F— Valve Inlet Fitting, 3/4 in

N116526 —UN—05MAR15

N116527 —UN—06MAR15

A—Check Valve B—Rinse Hose C—T-Fitting, 3/4 in

Continued on next page

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041118

PN=55

BKK10302, BKK10303, BKK10304, BKK10305

216.Model R4045 Only: Cut hose (B) approximately 203 mm (8 in) from previously installed check valve (A).

217.Install T-fitting (C) as shown.

218.Cut hose (D) to 1575 mm (62 in).

219.Attach low-volume rinse hose (D) to T-fitting (C).

D—Low-Volume Rinse Hose, 3/4 ID x 1575 mm (62 in).

E—Double P-Clamps (3 used) F— Valve Inlet Fitting, 3/4 in

N116526 —UN—05MAR15

N116740 —UN—25MAR15

A—Check Valve B—Rinse Hose C—T-Fitting, 3/4 in

N116742 —UN—25MAR15

220.Route low-volume rinse hose through double P-clamps (E) and install to the valve inlet fitting (F).

Continued on next page

KK43425 (11APR18)

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CS12167,0000B01 -19-05APR18-79/93

041118

PN=56

N116531 —UN—06MAR15

N116528 —UN—06MAR15

BKK10302, BKK10303, BKK10304, BKK10305

221.Cut hose (A) to 3444 mm (135.5 in).

222.Attach mixer supply hose (A) to pump outlet fitting (B).

224.Route mixer supply hose through P-clamps (F).

IMPORTANT: Ensure adequate hose length to prevent damage or stress in all boom positions.

225.Install mixer supply hose to the barbed fitting (G).

E—Bracket F— P-Clamps (3 used) G—Barbed Fitting, 1/2 in

N116530 —UN—23MAR15

A—Mixer Supply Hose B—Pump Outlet Fitting, 1/2 in C—P-Clamp D—Double P-Clamps (4 used)

N105203 —UN—05AUG13

223.Route mixer supply hose through P-clamp (C), double P-clamps (D), and bracket (E) as shown.

Continued on next page

KK43425 (11APR18)

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CS12167,0000B01 -19-05APR18-80/93

041118

PN=57

BKK10302, BKK10303, BKK10304, BKK10305

CAUTION: Spray system can contain hazardous material which can cause serious injury or death to you or others. Wear protective clothing, eyewear, and gloves.

N105698 —UN—06AUG13

Do not drain solution onto the ground. Drain into a container. Drain solution in an area where people, animals, vegetation, and water supply, cannot be contaminated.

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

226.Install Strainer Drain Valves: Remove and discard plugs (A). Use a suitable container to catch solution in strainers.

N130080 —UN—24APR17

227.Apply sealant to valves (B).

228.Install valves in strainers (C).

A—Plug B—Valve

C—Strainer

Continued on next page

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041118

PN=58

BKK10302, BKK10303, BKK10304, BKK10305

229.Low-Volume Harness Routing—If Equipped: Continue routing DI harness (A) rearward as shown.

230.Retain DI harness to supply hose (B) using tie bands (C).

N105683 —UN—05AUG13

231.Install low-volume harness (D) to the low-volume pump (E).

NOTE: Ensure tie band (G) does not interfere with connector latch.

232.Retain connector (F) as shown using tie band.

IMPORTANT: Verify wires (H) are not under tension. Water or chemical may enter the connection, causing damage.

233.Connect low-volume harness to DI harness.

234.Retain connector (I) to pump bracket using tie bands through holes (J).

F— Connector G—Tie Band H—Wires I— Connector J— Holes

N107961 —UN—21FEB14

A—DI Harness B—Supply Hose C—Tie Bands D—Low-Volume Harness E—Low-Volume Pump

Continued on next page

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041118

PN=59

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: Tail light relocation is required on North American machines only.

235.Install light bracket (A) using cap screws (B) and nuts.

N105686 —UN—28AUG13

236.Disconnect harness connector (C).

237.Remove harness (D) from retainers (E).

238.Remove and retain cap screws (F) and tail light assembly (G).

E—Retainer F— Cap Screw, 2 used G—Tail Light Assembly

N105687 —UN—05AUG13

A—Light Bracket B—Cap Screw, M8 x 25 (2 used) C—Harness Connector D—Light Harness

Continued on next page

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041118

PN=60

BKK10302, BKK10303, BKK10304, BKK10305

239.Install tail light assembly (A) to the light bracket (B) using previously removed cap screws (C).

240.Connect tail light connector (D) to the DI harness connector (E).

241.Retain tail light harness (F) with tie bands as needed.

242.Connect chassis harness (G) to DI harness (H).

E—DI Harness Connector F— Tail Light Harness G—Chassis Harness H—DI Harness

N105688 —UN—05AUG13

N105685 —UN—28AUG13

A—Tail Light Assembly B—Light Bracket C—Cap Screw D—Tail Light Connector

Continued on next page

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IMPORTANT: Ensure decal adhesion. Before applying decals, clean all dirt, grease, oil, and moisture from application area. Surface temperature should be greater than 15°C (60°F) for best adhesion.

243.Install Decals: Correctly identify the decal and locate decal placement.

N116744 —UN—25MAR15

244.Remove paper backing from decal.

245.Press one edge of decal on application area.

246.Smooth out air pockets while slowly pressing across the decal to the opposite edge. Verify complete decal adhesion.

247.Install decals (A, B, and C) as shown.

Decal Placement C—Decal C

N105696 —UN—05AUG13

A—Decal A B—Decal B

Decal Identification Continued on next page

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248.Install decals (A and B) as shown. See table to determine the correct decals for your location.

NOTE: Install text-free decal (A) at alternate location shown.

Decal A N203265

Decal B

N105935 —UN—04SEP13

Location North America, English

N409438

North America, French N208394

N409815

North America, Spanish

N204114

N409814

All Others (Text Free)

N409946 (use alternate location)

N409944

NOTE: Complete instructions on downloading and installing Software Payload are given in PC20380 DOWNLOAD SOFTWARE PAYLOAD Installation Instruction.

N105938 —UN—04SEP13

Order software part number KK21835 through JDPoint. Machine model number and serial number are required at time of order. Download of updated software through Service ADVISOR™ Software Delivery System is required.

Direct Injection software is the same for both high and low-volume pumps. Software does not need to be ordered for each pump on the machine.

Alternate Location

249.Download and Install Software Payload: Download Software Payload through Service ADVISOR™ Software Delivery Service.

B—Decal

N105937 —UN—04SEP13

A—Decal

N105936 —UN—04SEP13

If the machine has multiple pumps, the following instructions must be followed for each individual pump to update software on the machine.

Service ADVISOR is a trademark of Deere & Company Continued on next page

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NOTE: Disconnect all injection pumps that are not being programmed at this time.

250.Disconnect pump connector (A) from direct injection harness (B).

A—Pump Connector

N111100 —UN—25MAR14

251.Assign the connected pump as Pump #1.

B—Direct Injection Harness

Single Pump, 100 gal System Shown CS12167,0000B01 -19-05APR18-87/93

252.Select a pump for setup on the GreenStar™ 3 2630 Display. a. Select Menu button (A). b. Select pump button (B) of the pump to be set up.

B—Pump Button

N106032 —UN—28AUG13

A—Menu Button

GreenStar is a trademark of Deere & Company CS12167,0000B01 -19-05APR18-88/93

253.Select a pump for setup on the CommandCenter™ display. a. Select Menu button (A).

N133483 —UN—27NOV17

A—Menu Button

CommandCenter is a trademark of Deere & Company Continued on next page

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b. Select the applications tab (A). c. Select the ISOBUS VT application (B).

B—ISOBUS VT Application N133484 —UN—27NOV17

A—Applications Tab

CS12167,0000B01 -19-05APR18-90/93

d. Select setup button (A) and select Raven Industries. e. Select pump button (B) of the pump to be set up.

B—Pump Button

N133485 —UN—27NOV17

A—Setup Button

CS12167,0000B01 -19-05APR18-91/93

254.Select Tools softkey (A) from Direct Injection Main Page.

N93500 —UN—23APR12

A—Tools Softkey

Continued on next page

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255.Select Info Tab (A). Product information appears.

256.Select Pump #1 from drop-down menu (B). Pumps #1, #2, and #3 are available.

257.Select the direct injection software, and load it from Service ADVISOR™.

N93830 —UN—22AUG11

NOTE: If all injection pump options and features are not available after programming, then programming was not successful. Perform programming procedure again if necessary to obtain all injection pump options.

258.System Test: Test the DI system with water after installation is complete to ensure that there are no system leaks and that it functions properly.

Refer to the following DI Operation Manual procedures:

• Fill Chemical Tank • Priming Injection Pump • Rinse System • Drain Chemical Tanks

A—Info Tab

B—Drop-Down Menu

• Prepare Direct Injection System for Storage • Shipping Machine During Cold-Weather Months

If machine is going into storage or cold weather:

CS12167,0000B01 -19-05APR18-93/93

One High-Volume Pump, 200 gal System Bundle consists of one high-volume pump (A), two 100 gal tank systems (four 50 gal tanks, B, C, D and E), one in-line mixer assembly (F), and necessary installation hardware.

D—Left-Hand Side Inner 50 gal Tank (B1) E—Right-Hand Side Inner 50 gal Tank (B2) F— Mixer Assembly

N106874 —UN—10OCT13

A—High-Volume Pump B—Left-Hand Side Outer 50 gal Tank (A1) C—Right-Hand Side Outer 50 gal Tank (A2)

Continued on next page

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1. Install label (A) on two 50 gallon tank assemblies at locations (C).

2. Mark one tank assembly with a number “1” after the “A” decals, making it “A1”.

N110145 —UN—25FEB14

3. Mark other tank assembly with a number “2” after the “A” decals, making it “A2”.

4. Install label (B) on two 50 gallon tank assemblies at locations (C).

5. Mark one tank assembly with a number “1” after the “B” decals, making it “B1”.

6. Mark other tank assembly with a number “2” after the “B” decals, making it “B2”.

C—Locations

N116549 —UN—16MAR15

A—Label A (2 used per tank) B—Label B (2 used per tank)

Continued on next page

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7. Install tank P-clamps—A1: Install P-clamps (B), using cap screws (C), and nuts (D) as shown.

8. Install P-clamp (E), using cap screw and flange nut (F) as shown.

9. Remove and retain flange nut (G) and install P-clamp (H).

E—P-Clamp, 22 mm (7/8 in) F— Cap Screw, M8 x 20 and Flange Nut G—Flange Nut, M10 H—P-Clamp, 22 mm (7/8 in)

N116819 —UN—24MAR15

A—Tank Assembly A1 B—P-Clamps, 38 mm (1-1/2 in) Diameter C—Cap Screw, M8 x 20 (3 used) D—Flange Nut, M8 (3 used)

N116820 —UN—24MAR15

Tank A1

Lower P-Clamps Continued on next page

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10. Install tank P-clamps—A2: Install P-clamps (B), using cap screws and flange nuts (C) as shown.

11. Install P-clamps (D), using cap screws and flange nuts (E) as shown.

12. Remove and retain flange nuts (F) and install bracket (G).

F— Flange Nuts G—Bracket H—P-Clamp, 38 mm (1-1/2 in) I— Cap Screw, M10 x 30 and Flange Nut Tank A2

N116817 —UN—24MAR15

A—Tank Assembly A2 B—P-Clamps, 38 mm (1-1/2 in) (3 used) C—Cap Screws, M8 x 20 and Flange Nuts (3 used) D—P-Clamps, 38 mm (1-1/2 in) (2 used) E—Cap Screws, M10 x 30 and Flange Nuts (2 used)

N116816 —UN—23MAR15

13. Install P-clamp (H) to bracket with a cap screw and flange nut (I).

Lower P-Clamps Continued on next page

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14. Install tank P-clamps—B1: Install P-clamps (B and C) using cap screws (D) and flange nuts (E). Position as shown.

15. Remove and retain the nut (F).

16. Install P-clamp (G) using previously removed nut.

Position as shown.

E—Flange Nuts, M8 (2 used) F— Nut G—P-Clamp, 22 mm (7/8 in)

N107952 —UN—25MAR15

N107951 —UN—21FEB14

A—Tank Assembly B1 B—P-Clamp, 22 mm (7/8 in) C—P-Clamp, 38 mm (1-1/2 in) D—Cap Screws, M8 x 20 (2 used)

CS12167,0000B02 -19-05APR18-5/107

17. Remove and retain nuts (A).

18. Install bracket (B) and P-clamp (C) using previously removed nuts.

A—Nuts B—Bracket C—P-Clamp, 38 mm (1-1/2 in)

N116807 —UN—19MAR15

19. Install P-clamp (D) using cap screw (E) and flange lock nut (F). Position as shown.

D—P-Clamp, 38 mm (1-1/2 in) E—Cap Screw, M10 x 30 F— Flange Lock Nut, M10

Continued on next page

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20. Install tank P-clamps—B2: Install P-clamps (A) using cap screws and flange nuts (B).

B—Cap Screws, M8 x 20 and Flange Nuts

N116808 —UN—19MAR15

A—P-Clamps, 38 mm (1-1/2 in)

CS12167,0000B02 -19-05APR18-7/107

21. Remove and retain nuts (A).

22. Install bracket (B) using previously removed nuts.

A—Nuts B—Bracket C—P-Clamp, 38 mm (1-1/2 in)

N116809 —UN—20MAR15

23. Install P-clamp (C) using cap screw (D) and flange lock nut (E). Position as shown.

D—Cap Screw, M10 x 30 E—Flange Lock Nut, M10

Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305

NOTE: Loosen or remove tank as necessary to install some P-clamps.

24. Install tank P-clamps—Low-Volume System—If Equipped: Install P-clamps (A) using cap screws and flange lock nuts (B). Position as shown.

25. Install double P-clamp (C) using cap screw and nut (D).

26. Remove and retain cap screw and nut (E).

27. Install double P-clamp (F) using previously removed cap screw and nut.

A—P-Clamps, 22.3 mm (7/8 in) B—Cap Screws, M8 x 20, and Flange Nuts C—Double P-Clamp, 36.5 mm (1-1/2 in) D—Cap Screw, M8 x 20, and Flange Nut

N116102 —UN—19MAR15

28. Install double P-clamp (G) using cap screw, spacer, and flange lock nut (H). Position as shown.

E—Cap Screw and Flange Nut F— Double P-Clamp, 36.5 mm (1-1/2 in) G—Double P-Clamp, 36.5 mm (1-1/2 in) H—Cap Screw, M10 x 45, Spacer, 21 mm (0.82 in), and Flange Lock Nut

Low-Volume P-Clamps CS12167,0000B02 -19-05APR18-9/107

IMPORTANT: Clamp (A) must be installed before installing hose barb fitting (B) to minimize the chance of the tank splitting.

N107033 —UN—10OCT13

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

29. Install Upper Tank Fittings and Hoses—A1: Install clamp (A) to tank.

30. Apply sealant to the hose barb fitting (B) and install in tank.

A1 Upper Fittings

31. Apply sealant to hose barb fittings (C and D) and install in tank. Position as shown.

A—Clamp B—Hose Barb Fitting, 3/4 in NPT x 1/2 in Barb 90° Continued on next page

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NOTE: To simplify the text and photos, the following procedure does not call out the installation of hose clamps.

Install hose clamps on each hose end and tighten to specification.

Specification Hose Clamps—Torque........................................................ 3.9—4.5 N·m (35—40 lb·in)

N116535 —UN—12MAR15

Hose-to-Clamp Reference • 1/2 in ID hoses, use 1 in clamps • 3/4 in ID hoses, use 1 in clamps • 1 in ID hoses, use 1-1/2 in clamps 32. Cut hose (A) to 2450 mm (96.5 in).

33. Route through P-clamps (B) and install onto the vent fitting (C).

34. Cut hose (D) to 2134 mm (84 in).

A1 Upper Hoses

35. Route through P-clamps (E) and install onto the tank return fitting (F).

A—Hose, 1 in ID x 2450 mm (96.5 in) B—P-Clamps (2 used) C—Vent Fitting D—Hose, 1/2 in ID x 2134 mm (84 in) E—Double P-Clamps (2 used)

36. Cut hose (G) to 1930 mm (76 in).

37. Route through P-clamp (H) and install onto the tank rinse fitting (I).

F— Tank Return Fitting G—Hose, 1 in ID x 1930 mm (76 in) H—P-Clamp I— Rinse Fitting

CS12167,0000B02 -19-05APR18-11/107

IMPORTANT: Clamp (A) must be installed before installing plug (B) to minimize the chance of the tank splitting.

N107034 —UN—10OCT13

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

38. Install Upper Tank Fittings and Hoses—A2: Install clamp (A) to tank.

39. Apply sealant to plug (B) and install in tank.

40. Apply sealant to hose barb fittings (C and D) and install in tank. Position as shown.

A—Clamp B—Plug, 3/4 in NPT

A2 Upper Fittings

C—Hose Barb Fitting, 1 in 90° D—Hose Barb Fitting, 1 in Barb x 3/4 in NPT 90° Continued on next page

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41. Cut hose (A) to 2413 mm (95 in).

42. Route through P-clamps (B) and install onto the vent fitting (C).

43. Cut hose (D) to 1930 mm (76 in).

44. Route through P-clamp (E) and install onto the tank rinse fitting (F).

D—Hose, 1 in ID x 1930 mm (76 in) E—P-Clamp F— Rinse Fitting N116533 —UN—12MAR15

A—Hose, 1 in ID x 2413 mm (95 in) B—P-Clamps (2 used) C—Vent Fitting

A2 Upper Hoses CS12167,0000B02 -19-05APR18-13/107

IMPORTANT: Clamp (E) must be installed before installing hose barb fitting (F) to minimize the chance of the tank splitting.

N107036 —UN—10OCT13

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

45. Install Upper Tank Fittings and Hoses—B1: Apply sealant to nipple (A) and install in T-fitting (B).

46. Apply sealant to the hose barb fitting (C) and install to T-fitting.

47. Apply sealant to the hose barb fitting (D) and install in T-fitting. Position as shown.

48. Set fitting assembly to the side for later installation.

49. Install clamp (E) to tank.

N107035 —UN—10OCT13

50. Apply sealant to the hose barb fitting (F) and install in the tank as shown.

51. Apply sealant to the hose barb fitting (G) and install in the tank as shown.

52. Apply sealant to fitting assembly (H) and install in the tank as shown.

B1 Upper Fittings A—Nipple, 3/4 in NPT x 1 in B—T-Fitting, 1 in C—Hose Barb Fitting, 1 in NPT x 1 in Barb, Straight D—Hose Barb Fitting, 1 in NPT x 1 in Barb, 90°

E—Clamp F— Hose Barb Fitting, 3/4 in NPT x 1/2 in Barb, 90° G—Hose Barb Fitting, 1 in NPT x 1 in Barb, 90° H—Fitting Assembly Continued on next page

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53. Cut hose (A) to 380 mm (15 in) and attach to vent fitting (B).

54. Cut hose (C) to 400 mm (15.75 in) and attach to rinse fitting (D).

55. Cut hose (E) to 2264 mm (89 in).

56. Route hose (E) through P-clamps (F) and install onto the rinse fitting (G).

57. Cut hose (H) to 1747 mm (68.75 in).

A—Hose, 1 in ID x 380 mm (15 in) B—Vent Fitting C—Hose, 1 in ID x 400 mm (15.75 in) D—Rinse Fitting E—Hose, 1 in ID x 2264 mm (89 in)

N116534 —UN—12MAR15

58. Route through P-clamps (I) and install onto the tank return fitting (J).

F— P-Clamps (2 used) G—Rinse Fitting H—Hose, 1/2 in ID x 1747 mm (68.75 in) I— P-Clamps (2 used) J— Tank Return Fitting B1 Upper Hoses

CS12167,0000B02 -19-05APR18-15/107

IMPORTANT: Clamp (E) must be installed before installing plug (F) to minimize the chance of the tank splitting.

N107037 —UN—10OCT13

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

59. Install Upper Tank Fittings and Hoses—B2: Apply sealant to nipple (A) and install in T-fitting (B).

60. Apply sealant to the hose barb fitting (C) and install to T-fitting.

61. Apply sealant to the hose barb fitting (D) and install in T-fitting. Position as shown.

62. Set fitting assembly to the side for later installation.

63. Install clamp (E) to tank.

N107038 —UN—10OCT13

64. Apply sealant to plug (F) and install in the tank as shown.

65. Apply sealant to the hose barb fitting (G) and install in the tank as shown.

66. Apply sealant to fitting assembly (H) and install in the tank as shown.

B2 Upper Fittings A—Nipple, 1 in NPT x 1 in B—T-Fitting, 1 in C—Hose Barb Fitting, 1 in NPT x 1 in Barb, Straight D—Hose Barb Fitting, 1 in NPT x 1 in Barb, 90°

E—Clamp F— Plug G—Hose Barb Fitting, 3/4 in NPT x 1 in Barb, 90° H—Fitting Assembly

Continued on next page

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67. Cut hose (A) to 2431 mm (95.75 in).

68. Route through P-clamps (B) and install onto the vent fitting (C).

C—Vent Fitting

N116536 —UN—12MAR15

A—Hose, 1 in ID x 2431 mm (95.75 in) B—P-Clamps (2 used)

B2 Upper Hoses CS12167,0000B02 -19-05APR18-17/107

IMPORTANT: Clamp (A) must be installed before installing hose barb fitting (B) to minimize the chance of the tank splitting.

N116330 —UN—26FEB15

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

69. Install Upper Tank Fittings and Hoses—LowVolume System—If Equipped: Install clamp (A) to tank.

70. Apply sealant to the hose barb fitting (B) and install in tank. Position as shown.

71. Apply sealant to hose barb fittings (C and D) and install in tank. Position as shown.

Low-Volume Upper Fittings A—Clamp B—Hose Barb Fitting, 3/4 in NPT x 1/2 in Barb 90°

Continued on next page

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72. Cut hose (A) to 1983 mm (78 in).

73. Route through double P-clamps (C) and install onto the rinse fitting (B).

74. Cut hose (D) to 1628 mm (64 in).

75. Route through double P-clamps (C) and install onto the vent fitting (E).

76. Cut hose (F) to 1400 mm (55 in).

A—Hose, 1 in ID x 1983 mm (78 in) B—Rinse Fitting C—Double P-Clamps (2 used) D—Hose, 1 in ID x 1628 mm (64 in)

N116329 —UN—26FEB15

77. Route through double P-clamps (H) and install onto the tank return fitting (G).

E—Vent Fitting F— Hose, 1/2 in ID x 1400 mm (55 in) G—Tank Return Fitting H—P-Clamps (2 used)

Low-Volume Upper Hoses CS12167,0000B02 -19-05APR18-19/107

78. Install High-Volume Pump: Raise boom to highest position.

80. Remove and discard cap screws and nuts (C) and bracket (D).

81. Remove cap screws and nuts (E). Retain hardware for attaching the rinse valve.

82. Move hose clamp assembly (F) off to the side.

D—Bracket E—Cap Screws and Nuts (2 used) F— Hose Clamp Assembly

N116104 —UN—24FEB15

A—Cap Screws and Nuts (2 used) B—P-Clamps (2 used) C—Cap Screws and Nuts (2 used)

N116537 —UN—12MAR15

79. Remove and retain cap screws and nuts (A) and P-clamps (B).

Continued on next page

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CAUTION: High-volume pump assembly (A) is awkward to handle. Two people are required to install. Plan a safe installation procedure. Use appropriate lifting device to install.

NOTE: As necessary, loosen pump mounting hardware (B) to aid in alignment of assembly mounting holes.

N116538 —UN—12MAR15

High-volume pump assembly weighs approximately 43 kg (94.8 lb).

83. Install high-volume pump assembly (A) to mounting tabs (C).

84. Retain using cap screws (D).

85. Tighten any hardware loosened during installation.

86. Retain vent hoses (F) to high-volume pump assembly using previously removed P-clamps, cap screws, and nuts.

A—High-Volume Pump Assembly B—Pump Mounting Hardware C—Mounting Tabs

D—Cap Screw, M8 x 25 (4 used) E—Check Valve F— Vent Hoses

N116539 —UN—23MAR15

One High-Volume Pump, 200 gal System

IMPORTANT: Verify that check valve (E) is stamped 046 and contains a hole in the poppet.

Otherwise, contact your John Deere Dealer for a proper replacement. This check valve is necessary for pump priming and is not to be used in a traditional check valve application.

CS12167,0000B02 -19-05APR18-21/107

87. Identify rinse valve ports (A—C) for future reference.

• Rinse water is always connected to port “AUX” (A).

• Chemical is always connected to port “MAIN” (B).

• DI Pump is always connected to port “COMMON” (C).

C—COMMON Port

N118300 —UN—27MAY15

A—AUX Port B—MAIN Port

Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

N116542 —UN—13MAR15

88. Attach bracket (A) to rinse valve assembly (B) using cap screws and flange nuts (C).

89. Apply sealant to hose barb fittings (D, E, and F) and install in the rinse valve. Position as shown.

90. Attach P-clamp (G) to bracket using cap screw and flange nut (H).

E—Hose Barb Fitting, 3/4 in Barb x 3/4 in NPT Straight F— Hose Barb Fitting, 3/4 in Barb x 3/4 in NPT 90° G—P-Clamp, 38 mm (1-1/2 in) H—Cap Screw, M8 x 20 and Flange Nut

N116543 —UN—07MAY15

A—Bracket B—Rinse Valve Assembly C—Cap Screws, M8 x 30 and Flange Nuts D—Hose Barb Fitting, 3/4 in Barb x 3/4 in NPT 90°

CS12167,0000B02 -19-05APR18-23/107

91. Attach rinse valve assembly (A) to front side of frame (B) using P-clamp (D) and previously removed hardware (C).

C—Cap Screws and Nuts D—P-Clamp N116540 —UN—07MAY15

A—Rinse Valve Assembly B—Frame

N116541 —UN—07MAY15

View from Rear

Continued on next page

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041118

PN=79

BKK10302, BKK10303, BKK10304, BKK10305

92. Remove nut (A) from the cap screw (B).

93. Remove and discard the hose mount (C).

C—Hose Mount D—Rinse Bracket

N116544 —UN—07MAY15

A—Nut B—Cap Screw

N116545 —UN—13MAR15

94. Move clamp assembly over to rinse bracket (D) and reinstall previously removed nut.

CS12167,0000B02 -19-05APR18-25/107

IMPORTANT: Do not disconnect battery on machines equipped with Final Tier 4 engines until LED (A) has turned off. This indicates that the DEF system purge is complete.

A—LED

N102417 —UN—01MAR13

95. Install Wiring Harness: Rotate handle (B) counterclockwise to disconnect batteries.

B—Handle

Disconnect Switch Continued on next page

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041118

PN=80

BKK10302, BKK10303, BKK10304, BKK10305

96. Install bulkhead connector (A) at shown location.

Retain using nut (B).

B—Nut

N105682 —UN—05AUG13

A—Bulkhead Connector

Bulkhead Connector Continued on next page

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041118

PN=81

BKK10302, BKK10303, BKK10304, BKK10305

N105205 —UN—07AUG13

B

A

Harness Routing Diagram

97. Route direct injection (DI) harness (A) behind cab mount (C).

98. Locate chassis harness (B).

N105809 —UN—08AUG13

IMPORTANT: Avoid rub or pinch points when routing harness to prevent damage.

99. Route DI harness along chassis harness.

100.Route DI harness forward as shown.

IMPORTANT: Use additional tie bands if necessary to prevent harness rub points.

101.Retain DI harness to chassis harness with tie bands as needed.

A—Direct Injection (DI) Harness B—Chassis Harness Continued on next page

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80

C—Cab Mount

CS12167,0000B02 -19-05APR18-28/107

041118

PN=82

BKK10302, BKK10303, BKK10304, BKK10305

102.Remove and retain the nut (A) and wire (B) from the starter relay (C) in the battery box.

A—Nut B—Wire C—Starter Relay

N105207 —UN—05AUG13

103.Locate chassis harness connector (D) and red wire (E).

D—Chassis Harness Connector E—Red Wire

Starter Relay CS12167,0000B02 -19-05APR18-29/107

104.Install DI relay (A) using cap screw (B) and nut.

NOTE: Wire (F) is to be installed in its previous position on the starter relay.

N105679 —UN—05AUG13

105.Install bus bar (C) to the starter relay and DI relay using nut (D) and previously removed nut (E) and wire.

106.Connect chassis harness connector (I) to the DI relay.

107.Install red wire (G) to bottom stud of the DI relay, retain using nut (H).

108.Remove and retain cap screw (J).

Direct Injection Relay

109.Install DI harness ground (K) as shown using previously removed cap screw.

G—Red Wire H—Nut I— Chassis Harness Connector J— Cap Screw K—DI Harness Ground

N111104 —UN—09APR14

A—DI Relay B—Cap Screw, M6 x 50 C—Bus Bar D—Nut E—Nut, Previously Removed F— Wire

DI Ground Continued on next page

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041118

PN=83

BKK10302, BKK10303, BKK10304, BKK10305

110.Connect DI harness connector (A) to chassis harness (B) at the battery box.

B—Chassis Harness

N105931 —UN—28AUG13

A—DI Harness Connector

CS12167,0000B02 -19-05APR18-31/107

111.Remove and retain cap screws (A) and nuts.

112.Position fuse box (B) as desired to access the rear of box.

Fuse Name

DI Harness Wire Code

N105689 —UN—05AUG13

113.Install DI harness (C) to the fuse box terminals. See table for proper placement.

Fuse Box Location

F111

8722

11

F112

8712

12

F113

8702

13

114.Install fuse box using previously removed cap screws and nuts.

C—DI Harness

N105690 —UN—05AUG13

A—Cap Screws B—Fuse Box

Continued on next page

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041118

PN=84

BKK10302, BKK10303, BKK10304, BKK10305

115.Connect rear bulkhead connector (A) to the front bulkhead connector (B).

B—Front Bulkhead Connector

N105691 —UN—05AUG13

A—Rear Bulkhead Connector

Bulkhead Connectors CS12167,0000B02 -19-05APR18-33/107

B

N105206 —UN—05MAR14

A

Harness Routing Diagram

NOTE: Some parts have been removed to provide clarity.

116.Route DI harness (A) rearward along solution system harness (B). Retain with tie bands as needed.

B—Solution System Harness

N105810 —UN—08AUG13

A—DI Harness

Continued on next page

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041118

PN=85

N110779 —UN—04MAR14

N110781 —UN—04MAR14

BKK10302, BKK10303, BKK10304, BKK10305

Bracket Identification

117.Remove and retain cap screws (A) and flange lock nuts.

N110782 —UN—04MAR14

NOTE: If the boom air purge is not installed on machine, then install bracket (C) using two M8 x 20 cap screws (D) and flange lock nuts.

118.Install bracket (C) using previously removed cap screws (A) and flange lock nuts.

A—Cap Screws (2 used) B—Air Purge Valve

C—Bracket D—Cap Screws, M8 x 20 (2 used)

N110780 —UN—04MAR14

Bracket Installed with Air Purge

Bracket Installed without Air Purge Continued on next page

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041118

PN=86

BKK10302, BKK10303, BKK10304, BKK10305

119.Install harness (A) in P-clamp (B).

120.Install P-clamps (B and C) to bracket as shown using cap screw (D), washer, and flange lock nut.

C—Double P-Clamp, 36.5 mm (1-7/16 in) D—Cap Screw, M8 x 30

N110795 —UN—04MAR14

A—Harness B—P-Clamp, 38.1 mm (1-1/2 in)

CS12167,0000B02 -19-05APR18-36/107

121.Install P-clamps (A and B) to bracket as shown using cap screw (C), washer, and flange lock nut.

C—Cap Screw, M8 x 30

N110796 —UN—04MAR14

A—Double P-Clamp, 36.5 mm (1-7/16 in) B—Double P-Clamp, 19 mm (3/4 in)

CS12167,0000B02 -19-05APR18-37/107

122.Continue routing DI harness (A) along boom support (B) to the high-volume pump. Use tie bands (C) to retain harness.

C—Tie Bands (4 used) N116550 —UN—16MAR15

A—DI Harness B—Boom Support

Continued on next page

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041118

PN=87

BKK10302, BKK10303, BKK10304, BKK10305

123.Install high-volume pump harness (A) to high-volume pump assembly (B).

124.Retain connector (C) as shown using supplied tie band (D).

IMPORTANT: Verify wires (E) are not under tension. Water or chemical may enter the connection, causing damage.

125.Connect high-volume pump harness to DI harness (F).

126.Retain connector (G) to solution system harness (H) using tie bands.

E—Wires F— DI Harness G—Connector H—Solution System Harness

N107959 —UN—21FEB14

A—High-Volume Pump Harness B—High-Volume Pump Assembly C—Connector D—Tie Band

N107958 —UN—21FEB14

NOTE: If the low-volume bundle is not installed, coil harness breakout and retain to machine using tie bands.

Continued on next page

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041118

PN=88

BKK10302, BKK10303, BKK10304, BKK10305

127.Connect CAN connections on machines NOT equipped with ExactApply™. a. Disconnect harness connectors (A and B) on main solution harness (C).

N110777 —UN—04MAR14

b. Disconnect harness connectors (D and E) on DI harness (F). c. Connect harness connectors (A) and (D) together. d. Connect harness connectors (B) and (E) together.

D—DI Harness Connector E—DI Harness Connector F— DI Harness

N110778 —UN—04MAR14

A—Main Solution Harness Connector B—Main Solution Harness Connector C—Main Solution Harness

ExactApply is a trademark of Deere & Company CS12167,0000B02 -19-05APR18-40/107

NOTE: CAN connections are located under the solution system control unit.

A

128.Connect CAN connections on machines EQUIPPED with ExactApply™. a. Disconnect CAN connectors (D, E, F, and G) between main solution harness (A) and the ExactApply™ harness (B). b. Disconnect CAN connectors (H and I) on the DI harness (C).

B

E

D

c. Connect CAN connectors (D and H). d. Connect CAN connectors (I and F).

C

A—Main Solution Harness B—ExactApply™ Harness C—Direct Injection (DI) Harness D—Main Solution Harness CAN Connector E—Main Solution Harness CAN Connector

F— ExactApply™ Harness CAN Connector G—ExactApply™ Harness CAN Connector H—DI Harness CAN Connector I— DI Harness CAN Connector

Continued on next page

KK43425 (11APR18)

87

G

F

H

I

N130202 —UN—03MAY17

e. Connect CAN connectors (E and G).

CS12167,0000B02 -19-05APR18-41/107

041118

PN=89

BKK10302, BKK10303, BKK10304, BKK10305

129.Install Tank Assemblies—Without Low-Volume Kit: Tank placement from left to right is A1, B1, B2, and A2.

C—Tank Assembly B2 D—Tank Assembly A2 N107044 —UN—10OCT13

A—Tank Assembly A1 B—Tank Assembly B1

CS12167,0000B02 -19-05APR18-42/107

CAUTION: Tank assemblies are awkward to handle. Two people are required to install.

Plan a safe installation procedure. Use appropriate lifting device to install.

N116546 —UN—16MAR15

NOTE: Tank assemblies weigh approximately 47 kg (103 lb) each.

130.Loosen cap screws and nuts (A).

A—Cap Screws and Nuts (4 used)

CS12167,0000B02 -19-05APR18-43/107

131.Install tank assembly (A) to upper mounting tube (B).

132.Loosely install cap screws (G), nuts, and clamp bracket (F).

133.Install spacer (C) between tank assembly and lower mounting tube (D).

NOTE: Install spacer cap screws from the front, flange lock nuts to the rear.

N116547 —UN—16MAR15

134.Retain tank assembly and spacer to lower mounting tube with the cap screws and flange lock nuts (E).

135.Tighten hardware (E, G, and H) starting from the bottom and working up.

136.Repeat procedure for the remaining tank assemblies.

A—Tank Assembly B—Upper Mounting Tube C—Spacer D—Lower Mounting Tube

E—Cap Screws, M10 x 100 and Flange Lock Nuts F— Clamp Bracket G—Cap Screws, M10 x 40 and Nuts (2 used) H—Cap Screw and Nut (4 used) Continued on next page

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A2 Tank Assembly

CS12167,0000B02 -19-05APR18-44/107

041118

PN=90

BKK10302, BKK10303, BKK10304, BKK10305

137.Install Tank Assemblies—With Low-Volume Kit: Tank placement from left to right is Low-Volume, A1, B1, B2, and A2.

D—Tank Assembly B2 E—Tank Assembly A2 N116548 —UN—16MAR15

A—Tank Assembly—LowVolume B—Tank Assembly A1 C—Tank Assembly B1

CS12167,0000B02 -19-05APR18-45/107

NOTE: Tank assemblies weigh approximately 47 kg (103 lb) each.

138.Tanks A2, B1, and B2: Loosen cap screws and nuts (A).

A—Cap Screws and Nuts (4 used) Continued on next page

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89

N116546 —UN—16MAR15

CAUTION: Tank assemblies are awkward to handle. Two people are required to install.

Plan a safe installation procedure. Use appropriate lifting device to install.

CS12167,0000B02 -19-05APR18-46/107

041118

PN=91

BKK10302, BKK10303, BKK10304, BKK10305

139.Tanks A2, B1, and B2: Install tank assembly (A) to upper mounting tube (B).

140.Loosely install cap screws (G), nuts, and clamp bracket (F).

NOTE: Install spacer cap screws from the front, flange lock nuts to the rear.

141.Install spacer (C) between tank assembly and lower mounting tube (D).

N116547 —UN—16MAR15

142.Retain tank assembly and spacer to lower mounting tube with the cap screws and flange lock nuts (E).

143.Tighten hardware (E, G, and H) starting from the bottom and working up.

NOTE: Do not install A1 tank assembly at this time.

144.Repeat procedure for the remaining tank assemblies.

A2 Tank Assembly A—Tank Assembly B—Upper Mounting Tube C—Spacer D—Lower Mounting Tube

E—Cap Screws, M10 x 100 and Flange Lock Nuts (2 used) F— Clamp Bracket G—Cap Screws, M10 x 40 and Nuts (2 used) H—Cap Screw and Nut (4 used) CS12167,0000B02 -19-05APR18-47/107

145.Remove and retain cap screws and nuts (A) from low-volume tank assembly (C).

146.Loosen cap screws and nuts (B).

C—Low-Volume Tank Assembly

N116331 —UN—27FEB15

A—Cap Screws and Nuts (4 used) B—Cap Screws and Nuts (4 used)

Low-Volume Tank Assembly Continued on next page

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041118

PN=92

BKK10302, BKK10303, BKK10304, BKK10305

147.Remove and retain tank strap nuts (A).

148.Remove tank A1 (B) from the support bracket.

A—Tank Strap Nuts B—Tank A1

N116332 —UN—27FEB15

149.Remove and discard cap screws and nuts (D), and mounting bracket (C).

C—Mounting Bracket D—Cap Screws and Nuts (4 used)

A1 Tank Mounting Bracket CS12167,0000B02 -19-05APR18-49/107

150.Install lifting strap or chain to hole (A) in tank assembly A1.

151.Attach low-volume tank mounting bracket (B) to A1 support (C). Loosely retain with previously removed cap screws and nuts (D).

152.Reinstall tank A1 (E) to support bracket.

D—Cap Screws and Nuts (4 used) E—Tank A1 F— Low-Volume Tank Assembly N116333 —UN—27FEB15

A—Hole B—Mounting Bracket C—A1 Support

Attach Tank Assemblies Continued on next page

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041118

PN=93

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: The combined weight of the A1 assembly and the low-volume assembly is 88.5 kg (195 lb).

153.Slide tank assemblies onto upper mounting tube (A).

154.Install spacers (B) between tank assembly A1 and mounting tube. Retain with cap screws and flange lock nuts (C).

155.Install spacer tubes (E) between low-volume tank assembly and support. Retain with cap screws and flange lock nuts (D).

A—Upper Mounting Tube B—Spacers C—Cap Screws, M10 x 100 and Flange Lock Nuts (2 used)

N116334 —UN—27FEB15

156.Tighten all hardware starting at lower mount and working up.

D—Cap Screw, M10 x 150 and Flange Lock Nut (2 used) E—Spacer Tubes (2 used)

Install Tanks CS12167,0000B02 -19-05APR18-51/107

NOTE: Install tank sump valve assemblies from right to left.

A—Valve Assembly B—Gasket

N102986 —UN—27MAR13

157. Install Tank Sump Valve Assemblies: Install valve assembly (A) to the A2 tank sump using gasket (B) and flange clamp (C). Position as shown.

C—Flange Clamp, 1 in

Tank A2 Sump Valve CS12167,0000B02 -19-05APR18-52/107

158.Install B1 valve assembly (A) to tank assembly B1 (B) using gasket (C) and flange clamp (D). Position as shown.

A—B1 Valve Assembly B—Tank Assembly B1 C—Gasket

N107045 —UN—10OCT13

159.Install B2 valve assembly (E) to tank assembly B2 (F) using gasket and flange clamp. Position as shown.

D—Flange Clamp, 1 in E—B2 Valve Assembly F— Tank Assembly B2

Continued on next page

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041118

PN=94

BKK10302, BKK10303, BKK10304, BKK10305

160.Install valve assembly (A) to the A1 tank sump using gasket (B) and flange clamp (C). Position as shown.

C—Flange Clamp, 1 in

N103020 —UN—27MAR13

A—Valve Assembly B—Gasket

Tank A1 Sump Valve CS12167,0000B02 -19-05APR18-54/107

161.Install Low-Volume Tank Sump Valve and Fittings—Low-Volume System—If Equipped: Apply sealant to low-volume sump valve assembly (A).

162.Install low-volume sump valve assembly (A) to the tank sump fitting (B). Position as shown.

A—Low-Volume Sump Valve Assembly

B—Tank Sump Fitting

Continued on next page

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N105197 —UN—05AUG13

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

CS12167,0000B02 -19-05APR18-55/107

041118

PN=95

BKK10302, BKK10303, BKK10304, BKK10305

CAUTION: Low-volume pump assembly weighs approximately 22.3 kg (49 lb).

Pump assembly is awkward, two people or lifting device are required for installation.

163.Install Low-Volume Pump Assembly and Strainer—If Equipped: Install low-volume pump assembly (A) to the low-volume tank bracket (B) using cap screws (C and D) and flange lock nuts.

C—Cap Screws, M10 x 30 (2 used) D—Cap Screws, M8 x 30 (3 used)

N116335 —UN—27FEB15

A—Low-Volume Pump Assembly B—Low-Volume Tank Bracket

N116336 —UN—27FEB15

Low-Volume Pump Assembly

CS12167,0000B02 -19-05APR18-56/107

164.Install valve and strainer assembly (A) to mount (B) using cap screws (C) and flange lock nuts.

C—Cap Screws, M8 x 100 (2 used) N116828 —UN—25MAR15

A—Valve and Strainer Assembly B—Mount

Continued on next page

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041118

PN=96

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

A—90° Hose Barb for 1/2 in ID Hose

N110520 —UN—25FEB14

165.Install Check Valves in Mixer: Apply sealant to the hose barb (A) and install in the check valve (B).

B—Check Valve

CS12167,0000B02 -19-05APR18-58/107

166.Remove plug (A) from mixer assembly (B).

167.Apply sealant to check valve assembly (C) and install in mixer. Position check valve assembly as shown.

N110461 —UN—25FEB14

C—Check Valve Assembly

N110462 —UN—25FEB14

A—Plug B—Mixer Assembly

Continued on next page

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041118

PN=97

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

N110521 —UN—25FEB14

168.Low-Volume System—If Equipped: Apply sealant to the hose barb (A) and install in the check valve (B).

169.Apply sealant to check valve (B) and install in fitting (C).

A—Straight Hose Barb for 1/2 in ID Hose B—Check Valve

C—45° Fitting

CS12167,0000B02 -19-05APR18-60/107

170.Remove plug (A) from mixer assembly (B).

171.Apply sealant to check valve assembly (C) and install in mixer. Position check valve assembly as shown.

N110522 —UN—25FEB14

C—Check Valve Assembly

N110523 —UN—25FEB14

A—Plug B—Mixer Assembly

Continued on next page

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041118

PN=98

BKK10302, BKK10303, BKK10304, BKK10305

172.Install Mixer Assembly and Brackets: Remove and retain flange clamps (A) and gaskets (B).

173.Remove and discard fitting (C).

C—Fitting N105189 —UN—05AUG13

A—Flange Clamps B—Gaskets

CS12167,0000B02 -19-05APR18-62/107

174.Install mixer assembly (A) to the suspended center frame (B). Position as shown.

175.Retain mixer assembly with U-bolts (C) and nuts (D).

A—Mixer Assembly B—Suspended Center Frame C—U-Bolt, M8 (2 used)

N105190 —UN—05AUG13

176.Install bracket (E) using U-bolt (F) and nuts.

D—Nut, M8 (6 used) E—Bracket F— U-Bolt, M8

Mixer Assembly CS12167,0000B02 -19-05APR18-63/107

177.Install hose bracket (A) and plate (B) using cap screws (C) and flange lock nuts (D). Position at measurement (E) from right-hand tilt cylinder mount (F).

D—Flange Lock Nut, M12 (4 used) E—Measurement, 936 mm (37 in) F— Right-Hand Tilt Cylinder Mount

N105191 —UN—04MAR14

A—Hose Bracket B—Plate C—Cap Screw, M12 x 140 (4 used)

Continued on next page

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041118

PN=99

BKK10302, BKK10303, BKK10304, BKK10305

178.Install P-clamps (A) on hoses (B) and (C) in shown orientation.

C—Inlet Hose, 1550 mm (61 in)

N110574 —UN—25FEB14

A—P-Clamps, 63.5 mm (2-1/2 in) B—Outlet Hose, 1289 mm (50-3/4 in)

Continued on next page

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041118

PN=100

N105192 —UN—08AUG13

BKK10302, BKK10303, BKK10304, BKK10305

Mixer Plumbing A—Flange Clamp B—Elbow Fitting C—Hose Barb Fitting D—Inlet Hose, 1550 mm (61 in)

E—Band Clamps F— Flange Clamp G—Mixer Assembly Inlet H—Band Clamps I— Outlet Hose, 1289 mm (50-3/4 in)

J— Mixer Assembly Outlet K—Band Clamps L— Barbed Elbow Fitting M—Band Clamps

N—Flange Clamp O—Boom Isolation Valve

179.Loosen flange clamp (A).

184.Route outlet hose (I) through P-clamps as shown.

180.Rotate elbow fitting (B) to position shown.

185.Install outlet hose to the mixer assembly outlet (J) and retain using band clamps (K).

181.Install hose barb fitting (C) to the elbow fitting and retain with the flange clamp (F) and gasket.

186.Install barbed elbow fitting (L) to the outlet hose and retain with band clamps (M).

182.Route inlet hose (D) through P-clamps as shown.

187.Install barbed elbow fitting to boom isolation valve (O) using flange clamp (N) and gasket.

183.Install inlet hose to the hose barb fitting and mixer assembly inlet (G) as shown using band clamps (E) and (H).

Continued on next page

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041118

PN=101

BKK10302, BKK10303, BKK10304, BKK10305

188.Retain P-clamps (A) using cap screws (B) and flange lock nuts.

189.Retain P-clamp (C) using cap screw (D) and flange lock nut.

D—Cap Screw, M10 x 40 E—P-Clamp, 63.5 mm (2-1/2 in) F— Cap Screw, M10 x 40 (3 used)

N110575 —UN—25FEB14

A—P-Clamp, 63.5 mm (2-1/2 in) B—Cap Screws M10 x 30 (2 used) C—P-Clamp, 63.5 mm (2-1/2 in)

N110573 —UN—25FEB14

190.Retain P-clamps (E) using cap screws (F) and flange lock nuts.

Mixer P-Clamps CS12167,0000B02 -19-05APR18-67/107

191.P-clamp Installation: Remove and retain cap screw (A) and nut.

A—Cap Screw

B—P-Clamp, 38.1 mm (1-1/2 in)

Continued on next page

KK43425 (11APR18)

100

N107685 —UN—21FEB14

192.Install P-clamp (B) as shown using previously removed cap screw and nut.

CS12167,0000B02 -19-05APR18-68/107

041118

PN=102

BKK10302, BKK10303, BKK10304, BKK10305

193.Install P-clamps (A) using cap screws (B) and flange lock nuts. Position as shown.

194.Install double P-clamp (C) using cap screw (D) and flange nut. Position as shown.

N107046 —UN—10OCT13

C—Double P-Clamp, 19 mm (3/4 in) D—Cap Screw, M8 x 30

N107233 —UN—10OCT13

A—P-Clamp, 38.1 mm (1-1/2 in) (2 used) B—Cap Screw, M10 x 70

CS12167,0000B02 -19-05APR18-69/107

195.Remove and retain cap screws (A) and nuts.

196.Install P-clamps (B) using previously removed cap screws and nuts. Position as shown.

B—P-Clamps, 38.1 mm (1-1/2 in) (2 used)

N107234 —UN—14OCT13

A—Cap Screws (2 used)

Continued on next page

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041118

PN=103

BKK10302, BKK10303, BKK10304, BKK10305

197.Install bracket (A) to upper mounting tube (B) using U-bolt (C) and flange lock nuts.

199.Install P-clamp (F) using cap screw (G) and flange nut. Position as shown.

200.Install P-clamp (H) using cap screw (I) and flange nut.

Position as shown.

201.Install retainer bracket (J) to lift arm frame (K) using U-bolt (L) and flange lock nuts.

N110775 —UN—04MAR14

198.Install hose support (D) to bracket using cap screws (E) and flange lock nuts.

202.Install hose retainer (M) to the retainer bracket using cap screw (N) and flange lock nut.

NOTE: Install P-clamp (O) to the hose retainer if the low-volume bundle is installed.

N110628 —UN—04MAR14

I— Cap Screw, M8 x 30 J— Retainer Bracket K—Lift Arm Frame L— U-Bolt, M8 x 112 M—Hose Retainer N—Cap Screw, M8 x 60 O—P-Clamp, 19 mm (3/4 in)—Low-Volume Bundle ONLY

N110776 —UN—04MAR14

A—Bracket B—Upper Mounting Tube C—U-Bolt, M10 x 114 D—Hose Support E—Cap Screw, M10 x 25 (2 used) F— P-Clamp, 38.1 mm (1-1/2 in) G—Cap Screw, M8 x 30 H—P-Clamp, 38.1 mm (1-1/2 in)

CS12167,0000B02 -19-05APR18-71/107

203.Remove upper nut (A) from the hose retainer (B).

204.Install P-clamp (C) using previously removed nut.

N110930 —UN—12MAR14

NOTE: Install P-clamp (F) to hose retainer if low-volume bundle is installed.

205.Install hose retainers (D) to lift arm frame using cap screw (E) and flange nut.

A—Nut B—Hose Retainer C—Double P-Clamp, 36.5 mm (1-7/16 in)

D—Hose Retainers E—Cap Screw, M8 x 160 F— P-Clamp, 19 mm (3/4 in)—Low-Volume Bundle ONLY Continued on next page

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041118

PN=104

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: Electrical harness retainers must be removed before installing bracket. After bracket installation, retain the harness to the bracket using provided holes (D).

A—Bracket B—Boom Frame

N116810 —UN—20MAR15

206.Install bracket (A) to the boom frame (B) using cap screws (C) and flange lock nuts.

C—Cap Screws, M8 x 25 and Flange Nuts (2 used) D—Holes for Retaining Electrical Harness

CS12167,0000B02 -19-05APR18-73/107

NOTE: To simplify the text and photos, the following procedure does not call out the installation of hose clamps.

N116451 —UN—03MAR15

Install hose clamps on each hose end and tighten to specification.

Specification Hose Clamps—Torque........................................................ 3.9—4.5 N·m (35—40 lb·in)

Hose-to-Clamp Reference • 1/2 in ID hoses, use 1 in clamps • 3/4 in ID hoses, use 1 in clamps • 1 in ID hoses, use 1-1/2 in clamps

Rinse Tank Connection

207.Models R4030 and R4038 Only: Depending on configuration, remove foam marker fitting (B) or plug (C) from T-fitting (D).

A—Rinse Tank B—Foam Marker Fitting

C—Plug D—T-Fitting CS12167,0000B02 -19-05APR18-74/107

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

A—Pipe Nipple, 3/4 in B—T-Fitting, 3/4 in C—Straight Hose Barb for 3/4 in ID Hose

N116452 —UN—03MAR15

208.Models R4030 and R4038 Only With Foam Marker: Apply sealant to threads and assemble parts (A—E) as shown.

D—Foam Marker Fitting E—T-Fitting

With Foam Marker Continued on next page

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041118

PN=105

BKK10302, BKK10303, BKK10304, BKK10305

209.Models R4030 and R4038 Only Without Foam Marker: Apply sealant to threads and install 90° hose barb (B) to T-fitting (A) as shown.

B—90° Hose Barb for 3/4 in ID Hose N128686 —UN—11APR17

A—T-Fitting

Without Foam Marker CS12167,0000B02 -19-05APR18-76/107

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

N116453 —UN—03MAR15

210.Models R4030 and R4038 Only: Cut hose (A) to 336 mm (13.25 in).

211.Models R4030 and R4038 Only: Install one end of hose (A) to barb fitting (B).

212.Models R4030 and R4038 Only: Assemble straight hose barbs (C) and check valve (D).

IMPORTANT: Proper check valve installation is necessary to prevent contamination of rinse water.

213.Models R4030 and R4038 Only: Install check valve assembly to hose (A), making sure that arrow on valve is pointing away from the rinse tank.

A—Rinse Hose, 3/4 in ID x 336 mm (13.25 in) B—Barb Fitting for 3/4 in ID Hose

C—Straight Hose Barbs for 3/4 in ID Hose D—Check Valve

Continued on next page

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N116454 —UN—04MAR15

NOTE: Arrows on check valve show direction of flow.

CS12167,0000B02 -19-05APR18-77/107

041118

PN=106

BKK10302, BKK10303, BKK10304, BKK10305

214.Models R4030 and R4038 Only: Cut hose (A) to 1329 mm (52.25 in).

C—Rinse Valve Fitting

N116456 —UN—04MAR15

A—Rinse Hose, 3/4 in ID x 1329 mm (52.25 in) B—Check Valve Barb Fitting

N116455 —UN—04MAR15

215.Models R4030 and R4038 Only: Install one end of hose (A) to check valve barb fitting (B) and the other end to rinse valve fitting (C).

Rinse Valve CS12167,0000B02 -19-05APR18-78/107

IMPORTANT: Proper check valve installation is necessary to prevent contamination of rinse water.

N116738 —UN—25MAR15

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

Arrows on check valve show direction of flow.

216.R4045 Only: Assemble parts (A—G) as shown.

A—T-Fitting, 2 in B—Gasket C—Clamp, 2 in D—Adaptor, 2 in flange with 3/4 in NPT port

E—Pipe Nipple, 3/4 in F— Check Valve G—Straight Hose Barb for 3/4 in ID Hose

Continued on next page

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041118

PN=107

N130079 —UN—24APR17

N116729 —UN—25MAR15

BKK10302, BKK10303, BKK10304, BKK10305

217.R4045 Only: Loosen flange clamp (A) and separate rinse hose (B) from manifold (C).

A—Flange Clamp B—Rinse Hose C—Manifold

N116739 —UN—25MAR15

218.R4045 Only: Install T-fitting assembly (D) between rinse hose and manifold using gaskets (E) and flange clamps (F). Align fitting as shown and tighten clamps.

D—T-Fitting Assembly E—Gaskets (2 used) F— Flange Clamps (2 used)

Alignment Shown Continued on next page

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041118

PN=108

BKK10302, BKK10303, BKK10304, BKK10305

219.R4045 Only: Cut hose (A) to 813 mm (32 in).

220.R4045 Only:Install one end of hose (A) to check valve barb fitting (B) and the other end to rinse valve fitting (C).

N116743 —UN—25MAR15

C—Rinse Valve Fitting

N116741 —UN—07MAY15

A—Rinse Hose, 3/4 in ID x 813 mm (32 in) B—Check Valve Barb Fitting

Continued on next page

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041118

PN=109

BKK10302, BKK10303, BKK10304, BKK10305

221.Route hose (A) through P-clamps (B) and install to pump return fitting (C).

222.Route hose (D) through P-clamps (E) and install to pump return fitting (F).

D—B1 Hose, 1/2 in E—P-Clamps F— Pump Return Fitting

N116737 —UN—25MAR15

N116734 —UN—25MAR15

A—A1 Hose, 1/2 in B—P-Clamps C—Pump Return Fitting

CS12167,0000B02 -19-05APR18-82/107

223.Connect hose (A) to the B2 rinse fitting (B).

224.Connect hose (C) to the B2 vent fitting (D).

C—Hose, 1 in D—Vent Fitting N116731 —UN—25MAR15

A—Hose, 1 in B—Rinse Fitting

Hose Routing Tanks B1 and B2 Continued on next page

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041118

PN=110

BKK10302, BKK10303, BKK10304, BKK10305

225.Route vent hose (A) through P-clamps (B) as shown.

B—P-Clamps

N116733 —UN—25MAR15

N116736 —UN—25MAR15

A—Vent Hose, 1 in

Continued on next page

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041118

PN=111

N116732 —UN—25MAR15

BKK10302, BKK10303, BKK10304, BKK10305

226.Route hose (A) through P-clamps (B) as shown and install to T-fitting (E).

227.Route hose (C) through P-clamps (D) as shown and install to T-fitting (E).

228.Route hose (F) through P-clamp (G) as shown and install to rinse/fill valve fitting (H).

N116735 —UN—14MAY15

229.Cut hose (I) to 660 mm (26 in).

230.Route hose (I) through P-clamp (J) as shown. Install one end of hose (I) onto T-fitting (E) and the other to rinse/fill valve fitting (K).

A—Hose, 1 in ID B—P-Clamps C—Hose, 1 in ID D—P-Clamps E—T-Fitting, 1 in F— Hose, 1 in ID

G—P-Clamp H—Rinse/Fill Valve Fitting I— Hose, 1 in ID x 660 mm (26 in) J— P-Clamp K—Rinse/Fill Valve Fitting Continued on next page

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041118

PN=112

BKK10302, BKK10303, BKK10304, BKK10305

231.Cut hose (A) to 862 mm (34 in).

232.Route hose (A) through P-clamps as shown and install to tank fill fitting (B).

233.Install T-fitting (C) as shown.

234.Cut hose (D) to 1070 mm (42 in).

235.Route hose (D) as shown and install to the strainer supply fitting (E).

236.Install other end to the strainer inlet fitting (F).

A—Hose, 1 in ID x 862 mm (34 in) B—Tank Fill Fitting C—T-Fitting, 1 in D—Hose, 3/4 in ID x 1070 mm (42 in)

N107243 —UN—10OCT13

237.Retain hoses using tie bands (G) as shown.

E—Strainer Supply Fitting F— Strainer Inlet Fitting G—Tie Bands (2 used)

CS12167,0000B02 -19-05APR18-86/107

238.Cut hose (A) to 1070 mm (42 in).

239.Route hose (A) through P-clamps (C and D) and install to tank A1 fill fitting (E).

240.Install other end to T-fitting (B).

242.Route hose (F) as shown and install to tank B1 fill fitting (G).

243.Install other end of hose to the strainer inlet fitting (H).

A—Hose, 1 in ID x 1070 mm (42 in) B—T-Fitting C—P-Clamp D—Double P-Clamps (2 used)

E—Tank A1 Fill Fitting F— Hose, 3/4 in ID x 388 mm (15.25 in) G—Tank B1 Fill Fitting H—Strainer Inlet Fitting Continued on next page

KK43425 (11APR18)

111

N116925 —UN—27MAR15

241.Cut hose (F) to 388 mm (15.25 in).

CS12167,0000B02 -19-05APR18-87/107

041118

PN=113

BKK10302, BKK10303, BKK10304, BKK10305

244.Cut hose (A) to 400 mm (15.75 in).

245.Install hose (A) to tank B2 fill fitting (B).

246.Install other end to the fitting (C).

N107245 —UN—10OCT13

247.Cut hose (D) to 692 mm (27.25 in).

248.Route hose (D) as shown and install to T-fitting (E).

249.Install other end to the tank A1/A2 rinse/fill valve fitting (F).

250.Cut hose (G) to 812 mm (32 in).

251.Route hose (G) as shown and install to tank B1 fill fitting (H).

252.Install other end to the tank B1/B2 rinse/fill valve fitting (I).

F— Tank A1/A2 Rinse/Fill Valve Fitting G—Hose, 1 in ID x 812 mm (32 in) H—Tank B1 Fill Fitting I— Tank B1/B2 Rinse/Fill Valve Fitting

N107246 —UN—10OCT13

A—Hose, 1 in ID x 400 mm (15.75 in) B—Tank B2 Fill Fitting C—Fitting D—Hose 1 in ID x 692 mm (27.25 in) E—T-Fitting

Continued on next page

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041118

PN=114

BKK10302, BKK10303, BKK10304, BKK10305

253.Cut hose (A) to 419 mm (16.5 in).

254.Install hose (A) to fitting (B) and strainer fitting (C).

255.Cut hose (D) to 572 mm (22.5 in).

256.Install hose (D) to fitting (E) and strainer fitting (F).

258.Install hose (G) to pump inlet fitting (H) and rinse valve fitting (I).

259.Cut hose (J) to 367 mm (14.5 in).

260.Install hose (J) to fitting (K) and rinse valve fitting (L).

G—Hose, 3/4 in ID x 343 mm (13.5 in) H—Pump Inlet Fitting I— Rinse Valve Fitting J— Hose, 3/4 in ID x 367 mm (14.5 in) K—Fitting L— Rinse Valve Fitting

N116813 —UN—20MAR15

A—Hose, 3/4 in ID x 419 mm (16.5 in) B—Fitting C—Strainer Fitting D—Hose, 3/4 in ID x 572 mm (22.5 in) E—Fitting F— Strainer Fitting

N116814 —UN—23MAR15

257.Cut hose (G) to 343 mm (13.5 in).

Continued on next page

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041118

PN=115

BKK10302, BKK10303, BKK10304, BKK10305

261.Cut hose (A) to 3037 mm (119.5 in).

262.Route mixer supply hose (A) through P-clamps, brackets, and hose retainers (B and C) as shown.

263.Install mixer supply hose (A) to the barbed elbow fitting (D).

NOTE: Ensure that hose has sufficient length for all boom positions.

264.Install to pump output fitting (E).

265.Install check valve assembly to hose (A), making sure that arrow on valve is pointing away from the rinse tank.

D—Barbed Elbow Fitting, 1/2 in NPT x 1/2 in Barb E—Pump Output Fitting

N116811 —UN—20MAR15

N110928 —UN—12MAR14

A—Mixer Supply Hose, 1/2 in ID x 3037 mm (119.5 in) B—Hose Retainers C—Hose Retainer

N116812 —UN—20MAR15

NOTE: Arrows on check valve show direction of flow.

Continued on next page

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041118

PN=116

BKK10302, BKK10303, BKK10304, BKK10305

N116461 —UN—05MAR15

IMPORTANT: There are two different types of hose used in this procedure. Most hoses used in this system are braided. There are some locations where a spiral wound hose is needed. See pictorial legend for the proper hose type, if specified braided hose is not used.

266.Hose Routing—Low-Volume Pump and Tank—If Equipped: Attach rinse hose (A) to rinse fitting (C).

267.Attach return hose (B) to pump return fitting (D).

268.Cut hose (E) to 246 mm (9.5 in).

269.Attach strainer supply hose (E) to the strainer inlet fitting (F) and tank supply fitting (G).

Low-Volume Pump and Tank

270.Cut hose (H) to 345 mm (13.5 in).

271.Attach tank fill hose (H) to fill fitting (I) and tank fill fitting (J).

272.Cut hose (K) to 537 mm (21 in).

H—Tank Fill Hose, 1 in Spiral Wound I— Fill Fitting J— Tank Fill Fitting K—Pump Supply Hose, 3/4 in L— Pump Inlet Fitting M—Rinse Valve Fitting

N116462 —UN—05MAR15

A—Rinse Hose, 1 in B—Return Hose, 1/2 in ID C—Rinse Fitting D—Pump Return Fitting E—Strainer Supply Hose, 3/4 in F— Strainer Inlet Fitting G—Tank Supply Fitting

N116463 —UN—05MAR15

273.Attach pump supply hose (K) to pump inlet fitting (L) and rinse valve fitting (M).

Continued on next page

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041118

PN=117

BKK10302, BKK10303, BKK10304, BKK10305

274.Cut hose (A) to 458 mm (18 in).

275.Attach pump supply hose (A) to the strainer valve fitting (B).

276.Route pump supply hose through P-clamp (C) and install to pump inlet fitting (D).

C—P-Clamp D—Pump Inlet Fitting N116525 —UN—05MAR15

A—Pump Supply Hose, 3/4 in B—Strainer Valve Fitting

Continued on next page

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041118

PN=118

BKK10302, BKK10303, BKK10304, BKK10305

277.Cut hose (B) approximately 203 mm (8 in) from previously installed check valve (A).

278.Install T-fitting (C) as shown.

279.Cut hose (D) to 1575 mm (62 in).

280.Attach low-volume rinse hose (D) to T-fitting (C).

D—Low-Volume Rinse Hose, 3/4 ID x 1575 mm (62 in).

E—Double P-Clamps (3 used) F— Valve Inlet Fitting, 3/4 in

N116526 —UN—05MAR15

N116740 —UN—25MAR15

A—Check Valve B—Rinse Hose C—T-Fitting, 3/4 in

N116742 —UN—25MAR15

281.Route low-volume rinse hose through double P-clamps (E) and install to the valve inlet fitting (F).

Continued on next page

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041118

PN=119

N116531 —UN—06MAR15

N116528 —UN—06MAR15

BKK10302, BKK10303, BKK10304, BKK10305

282.Cut hose (A) to 3444 mm (135.5 in).

283.Attach mixer supply hose (A) to pump outlet fitting (B).

285.Route mixer supply hose through P-clamps (F).

IMPORTANT: Ensure adequate hose length to prevent damage or stress in all boom positions.

286.Install mixer supply hose to the barbed fitting (G).

E—Bracket F— P-Clamps (3 used) G—Barbed Fitting, 1/2 in

N116530 —UN—23MAR15

A—Mixer Supply Hose B—Pump Outlet Fitting, 1/2 in C—P-Clamp D—Double P-Clamps (4 used)

N105203 —UN—05AUG13

284.Route mixer supply hose through P-clamp (C), double P-clamps (D), and bracket (E) as shown.

Continued on next page

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041118

PN=120

BKK10302, BKK10303, BKK10304, BKK10305

CAUTION: Spray system can contain hazardous material which can cause serious injury or death to you or others. Wear protective clothing, eyewear, and gloves.

N105698 —UN—06AUG13

Do not drain solution onto the ground. Drain into a container. Drain solution in an area where people, animals, vegetation, and water supply, cannot be contaminated.

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

287.Install Strainer Drain Valves: Remove and discard plugs (A). Use a suitable container to catch solution in strainers.

N130080 —UN—24APR17

288.Apply sealant to valves (B).

289.Install valves in strainers (C).

A—Plug B—Valve

C—Strainer

Continued on next page

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041118

PN=121

BKK10302, BKK10303, BKK10304, BKK10305

290.Low-Volume Harness Routing—If Equipped: Continue routing DI harness (A) rearward as shown.

291.Retain DI harness to supply hose (B) using tie bands (C).

N105683 —UN—05AUG13

292.Install low-volume harness (D) to the low-volume pump (E).

NOTE: Ensure tie band (G) does not interfere with connector latch.

293.Retain connector (F) as shown using tie band.

IMPORTANT: Verify wires (H) are not under tension. Water or chemical may enter the connection, causing damage.

294.Connect low-volume harness to DI harness.

295.Retain connector (I) to pump bracket using tie bands through holes (J).

F— Connector G—Tie Band H—Wires I— Connector J— Holes

N107961 —UN—21FEB14

A—DI Harness B—Supply Hose C—Tie Bands D—Low-Volume Harness E—Low-Volume Pump

Continued on next page

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041118

PN=122

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: Tail light relocation is required on North American machines only.

296.Install light bracket (A) using cap screws (B) and nuts.

N105686 —UN—28AUG13

297.Disconnect harness connector (C).

298.Remove harness (D) from retainers (E).

299.Remove and retain cap screws (F) and tail light assembly (G).

E—Retainer F— Cap Screw, 2 used G—Tail Light Assembly

N105687 —UN—05AUG13

A—Light Bracket B—Cap Screw, M8 x 25 (2 used) C—Harness Connector D—Light Harness

Continued on next page

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041118

PN=123

BKK10302, BKK10303, BKK10304, BKK10305

300.Install tail light assembly (A) to the light bracket (B) using previously removed cap screws (C).

301.Connect tail light connector (D) to the DI harness connector (E).

302.Retain tail light harness (F) with tie bands as needed.

303.Connect chassis harness (G) to DI harness (H).

E—DI Harness Connector F— Tail Light Harness G—Chassis Harness H—DI Harness

N105688 —UN—05AUG13

N105685 —UN—28AUG13

A—Tail Light Assembly B—Light Bracket C—Cap Screw D—Tail Light Connector

Continued on next page

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041118

PN=124

BKK10302, BKK10303, BKK10304, BKK10305

IMPORTANT: Ensure decal adhesion. Before applying decals, clean all dirt, grease, oil, and moisture from application area. Surface temperature should be greater than 15°C (60°F) for best adhesion.

304.Install Decals: Correctly identify the decal and locate decal placement.

305.Remove paper backing from decal.

306.Press one edge of decal on application area.

N105695 —UN—05AUG13

307.Smooth out air pockets while slowly pressing across the decal to the opposite edge. Verify complete decal adhesion.

308.Install decals (A, B, and C) as shown.

A—Decal A B—Decal B

C—Decal C

N105696 —UN—05AUG13

Decal Placement

Decal Identification Continued on next page

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041118

PN=125

BKK10302, BKK10303, BKK10304, BKK10305

309.Install decals (A and B) as shown. See table to determine the correct decals for your location.

NOTE: Install text-free decal (A) at alternate location shown.

Decal A N203265

Decal B

N105935 —UN—04SEP13

Location North America, English

N409438

North America, French N208394

N409815

North America, Spanish

N204114

N409814

All Others (Text Free)

N409946 (use alternate location)

N409944

NOTE: Complete instructions on downloading and installing Software Payload are given in PC20380 DOWNLOAD SOFTWARE PAYLOAD Installation Instruction.

N105938 —UN—04SEP13

Order software part number KK21835 through JDPoint. Machine model number and serial number are required at time of order. Download of updated software through Service ADVISOR™ Software Delivery System is required.

Direct Injection software is the same for both high and low-volume pumps. Software does not need to be ordered for each pump on the machine.

Alternate Location

310.Download and Install Software Payload: Download Software Payload through Service ADVISOR™ Software Delivery Service.

B—Decal

N105937 —UN—04SEP13

A—Decal

N105936 —UN—04SEP13

If the machine has multiple pumps, the following instructions must be followed for each individual pump to update software on the machine.

Service ADVISOR is a trademark of Deere & Company Continued on next page

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041118

PN=126

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: Disconnect all injection pumps that are not being programmed at this time.

311.Disconnect pump connector (A) from direct injection harness (B).

A—Pump Connector

N111100 —UN—25MAR14

312.Assign the connected pump as Pump #1.

B—Direct Injection Harness

Single Pump, 100 gal System Shown CS12167,0000B02 -19-05APR18-101/107

313.Select a pump for setup on the GreenStar™ 3 2630 Display. a. Select Menu button (A). b. Select pump button (B) of the pump to be set up.

B—Pump Button

N106032 —UN—28AUG13

A—Menu Button

GreenStar is a trademark of Deere & Company CS12167,0000B02 -19-05APR18-102/107

314.Select a pump for setup on the CommandCenter™ display. a. Select Menu button (A).

N133483 —UN—27NOV17

A—Menu Button

CommandCenter is a trademark of Deere & Company Continued on next page

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041118

PN=127

BKK10302, BKK10303, BKK10304, BKK10305

b. Select the applications tab (A). c. Select the ISOBUS VT application (B).

B—ISOBUS VT Application N133484 —UN—27NOV17

A—Applications Tab

CS12167,0000B02 -19-05APR18-104/107

d. Select setup button (A) and select Raven Industries. e. Select pump button (B) of the pump to be set up.

B—Pump Button

N133485 —UN—27NOV17

A—Setup Button

CS12167,0000B02 -19-05APR18-105/107

315.Select Tools softkey (A) from Direct Injection Main Page.

N93500 —UN—23APR12

A—Tools Softkey

Continued on next page

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316.Select Info Tab (A). Product information appears.

317.Select Pump #1 from drop-down menu (B). Pumps #1, #2, and #3 are available.

318.Select the direct injection software, and load it from Service ADVISOR™.

N93830 —UN—22AUG11

NOTE: If all injection pump options and features are not available after programming, then programming was not successful. Perform programming procedure again if necessary to obtain all injection pump options.

319.System Test: Test the DI system with water after installation is complete to ensure that there are no system leaks and that it functions properly.

Refer to the following DI Operation Manual procedures:

• Fill Chemical Tank • Priming Injection Pump • Rinse System • Drain Chemical Tanks

A—Info Tab

B—Drop-Down Menu

• Prepare Direct Injection System for Storage • Shipping Machine During Cold-Weather Months

If machine is going into storage or cold weather:

CS12167,0000B02 -19-05APR18-107/107

Two High-Volume Pumps, 200 gal System Bundle consists of two high-volume pumps (A and B), two 100 gal tank systems (four 50 gal tanks, C, D, E and F), one in-line mixer assembly (G), and necessary installation hardware.

E—Left-Hand Side Inner 50 gal Tank (B1) F— Right-Hand Side Inner 50 gal Tank (B2) G—Mixer Assembly N107026 —UN—10OCT13

A—High-Volume Pump B—High-Volume Pump C—Left-Hand Side Outer 50 gal Tank (A1) D—Right-Hand Side Outer 50 gal Tank (A2)

Continued on next page

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1. Install label (A) on two 50 gallon tank assemblies at locations (C).

2. Mark one tank assembly with a number “1” after the “A” decals, making it “A1”.

N110145 —UN—25FEB14

3. Mark other tank assembly with a number “2” after the “A” decals, making it “A2”.

4. Install label (B) on two 50 gallon tank assemblies at locations (C).

5. Mark one tank assembly with a number “1” after the “B” decals, making it “B1”.

6. Mark other tank assembly with a number “2” after the “B” decals, making it “B2”.

C—Locations

N116549 —UN—16MAR15

A—Label A (2 used per tank) B—Label B (2 used per tank)

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7. Install tank P-clamps—A1: Install P-clamps (B), using cap screws (C), and nuts (D) as shown.

C—Cap Screw, M8 x 20 (3 used) D—Flange Nut, M8 (3 used)

N116098 —UN—19MAR15

A—Tank Assembly A1 B—P-Clamps, 38 mm (1-1/2 in) Diameter

Tank A1 Continued on next page

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8. Install tank P-clamps—A2: Install P-clamps (B), using cap screws and flange nuts (C) as shown.

9. Install P-clamps (D), using cap screws and flange nuts (E) as shown.

10. Install double P-clamp (F) using cap screw, flat washer, and flange nut (G) at location shown.

N116822 —UN—24MAR15

11. Remove and retain flange nuts (H) and install bracket (I).

12. Install P-clamp (J) to bracket with a cap screw and flange nut (K).

G—Cap Screw, M8 x 20, Flat Washer, and Flange Nut H—Flange Nuts I— Bracket J— P-Clamp, 38 mm (1-1/2 in) K—Cap Screw, M10 x 30 and Flange Nut

Tank A2

N116823 —UN—24MAR15

A—Tank Assembly A2 B—P-Clamps, 38 mm (1-1/2 in) (2 used) C—Cap Screws, M8 x 20 and Flange Nuts (2 used) D—P-Clamps, 38 mm (1-1/2 in) (2 used) E—Cap Screws, M10 x 30 and Flange Nuts (2 used) F— Double P-Clamp

Lower P-clamps Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305

13. Install tank P-clamps—B1: Install P-clamps (B and C) using cap screws (D) and flange nuts (E). Position as shown.

14. Remove and retain the nut (F).

15. Install P-clamp (G) using previously removed nut.

Position as shown.

E—Flange Nuts, M8 (2 used) F— Nut G—P-Clamp, 22 mm (7/8 in)

N107952 —UN—25MAR15

N107951 —UN—21FEB14

A—Tank Assembly B1 B—P-Clamp, 22 mm (7/8 in) C—P-Clamp, 38 mm (1-1/2 in) D—Cap Screws, M8 x 20 (2 used)

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16. Remove and retain nuts (A).

17. Install bracket (B) and P-clamp (C) using previously removed nuts.

A—Nuts B—Bracket C—P-Clamp, 38 mm (1-1/2 in)

N116807 —UN—19MAR15

18. Install P-clamp (D) using cap screw (E) and flange lock nut (F). Position as shown.

D—P-Clamp, 38 mm (1-1/2 in) E—Cap Screw, M10 x 30 F— Flange Lock Nut, M10

Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305

19. Install tank P-clamps—B2: Install P-clamps (A) using cap screws and flange nuts (B).

B—Cap Screws, M8 x 20 and Flange Nuts

N116808 —UN—19MAR15

A—P-Clamps, 38 mm (1-1/2 in)

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20. Remove and retain nuts (A).

21. Install bracket (B) using previously removed nuts.

A—Nuts B—Bracket C—P-Clamp, 38 mm (1-1/2 in)

N116809 —UN—20MAR15

22. Install P-clamp (C) using cap screw (D) and flange lock nut (E). Position as shown.

D—Cap Screw, M10 x 30 E—Flange Lock Nut, M10

Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305

NOTE: Loosen or remove tank as necessary to install some P-clamps.

23. Install tank P-clamps—Low-Volume System—If Equipped: Install P-clamps (A) using cap screws and flange lock nuts (B). Position as shown.

24. Install double P-clamp (C) using cap screw and nut (D).

25. Remove and retain cap screw and nut (E).

26. Install double P-clamp (F) using previously removed cap screw and nut.

A—P-Clamps, 22.3 mm (7/8 in) B—Cap Screws, M8 x 20, and Flange Nuts C—Double P-Clamp, 36.5 mm (1-1/2 in) D—Cap Screw, M8 x 20, and Flange Nut

N116102 —UN—19MAR15

27. Install double P-clamp (G) using cap screw, spacer, and flange lock nut (H). Position as shown.

E—Cap Screw and Flange Nut F— Double P-Clamp, 36.5 mm (1-1/2 in) G—Double P-Clamp, 36.5 mm (1-1/2 in) H—Cap Screw, M10 x 45, Spacer, 21 mm (0.82 in), and Flange Lock Nut

Low-Volume P-Clamps CS12167,0000B03 -19-05APR18-9/107

IMPORTANT: Clamp (A) must be installed before installing plug (B) to minimize the chance of the tank splitting.

N116097 —UN—24FEB15

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

28. Install Upper Tank Fittings and Hoses—A1: Install clamp (A) to tank.

29. Apply sealant to plug (B) and install in tank.

30. Apply sealant to hose barb fittings (C and D) and install in tank. Position as shown.

A—Clamp B—Plug, 3/4 in NPT

A1 Upper Fittings

C—Hose Barb Fitting, 1 in 90° D—Hose Barb Fitting, 1 in Barb x 3/4 in NPT 90° Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305

NOTE: To simplify the text and photos, the following procedure does not call out the installation of hose clamps.

Install hose clamps on each hose end and tighten to specification.

Specification Hose Clamps—Torque........................................................ 3.9—4.5 N·m (35—40 lb·in)

N116325 —UN—25FEB15

Hose-to-Clamp Reference • 1/2 in ID hoses, use 1 in clamps • 3/4 in ID hoses, use 1 in clamps • 1 in ID hoses, use 1-1/2 in clamps 31. Cut hose (A) to 1930 mm (76 in).

32. Route through P-clamp (B) and install onto the rinse fitting (C).

33. Cut hose (D) to 2550 mm (100 in).

A1 Upper Hoses

34. Route through P-clamps (E) and install onto the vent fitting (F).

A—Hose, 1 in ID x 1930 mm (76 in) B—P-Clamp C—Rinse Fitting

D—Hose, 1 in ID x 2550 mm (100 in) E—P-Clamps (2 used) F— Vent Fitting CS12167,0000B03 -19-05APR18-11/107

IMPORTANT: Clamp (A) must be installed before installing hose barb fitting (B) to minimize the chance of the tank splitting.

N102977 —UN—27MAR13

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

35. Install Upper Tank Fittings and Hoses—A2: Install clamp (A) to tank.

36. Apply sealant to the hose barb fitting (B) and install in tank.

A2 Upper Fittings

37. Apply sealant to hose barb fittings (C and D) and install in tank. Position as shown.

A—Clamp B—Hose Barb Fitting, 3/4 in NPT x 1/2 in Barb 90° Continued on next page

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C—Hose Barb Fitting, 1 in 90° D—Hose Barb Fitting, 1 in Barb x 3/4 in NPT 90° CS12167,0000B03 -19-05APR18-12/107

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BKK10302, BKK10303, BKK10304, BKK10305

38. Cut hose (A) to 2362 mm (93 in).

39. Route through P-clamps (B) and install onto the vent fitting (C).

40. Cut hose (D) to 2030 mm (80 in).

41. Route through double P-clamp (E) and install onto the tank return fitting (F).

42. Cut hose (G) to 2441 mm (96 in).

A—Hose, 1 in ID x 2362 mm (93 in) B—P-Clamps (2 used) C—Vent Fitting D—Hose, 1/2 in ID x 2030 mm (80 in)

N116326 —UN—25FEB15

43. Route through double P-clamp (E) and install onto the rinse fitting (H).

E—Double P-Clamp F— Tank Return Fitting G—Hose, 1 in ID x 2441 mm (96 in) H—Rinse Fitting

A2 Upper Hoses CS12167,0000B03 -19-05APR18-13/107

IMPORTANT: Clamp (E) must be installed before installing hose barb fitting (F) to minimize the chance of the tank splitting.

N107036 —UN—10OCT13

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

44. Install Upper Tank Fittings and Hoses—B1: Apply sealant to nipple (A) and install in T-fitting (B).

45. Apply sealant to the hose barb fitting (C) and install to T-fitting.

46. Apply sealant to the hose barb fitting (D) and install in T-fitting. Position as shown.

47. Set fitting assembly to the side for later installation.

48. Install clamp (E) to tank.

N107035 —UN—10OCT13

49. Apply sealant to the hose barb fitting (F) and install in the tank as shown.

50. Apply sealant to the hose barb fitting (G) and install in the tank as shown.

51. Apply sealant to fitting assembly (H) and install in the tank as shown.

B1 Upper Fittings A—Nipple, 3/4 in x 1 in B—T-Fitting, 1 in C—Hose Barb Fitting, 1 in NPT x 1 in Barb, Straight D—Hose Barb Fitting, 1 in NPT x 1 in Barb, 90°

E—Clamp F— Hose Barb Fitting, 3/4 in NPT x 1/2 in Barb, 90° G—Hose Barb Fitting, 1 in NPT x 1 in Barb, 90° H—Fitting Assembly Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305

52. Cut hose (A) to 380 mm (15 in) and attach to vent fitting (B).

53. Cut hose (C) to 400 mm (15.75 in) and attach to rinse fitting (D).

54. Cut hose (E) to 2264 mm (89 in).

55. Route hose (E) through P-clamps (F) and install onto the rinse fitting (G).

56. Cut hose (H) to 1847 mm (72.75 in).

A—Hose, 1 in ID x 380 mm (15 in) B—Vent Fitting C—Hose, 1 in ID x 400 mm (15.75 in) D—Rinse Fitting E—Hose, 1 in ID x 2264 mm (89 in)

N116534 —UN—12MAR15

57. Route through P-clamps (I) and install onto the tank return fitting (J).

F— P-Clamps (2 used) G—Rinse Fitting H—Hose, 1/2 in ID x 1847 mm (72.75 in) I— P-Clamps (2 used) J— Tank Return Fitting B1 Upper Hoses

CS12167,0000B03 -19-05APR18-15/107

IMPORTANT: Clamp (E) must be installed before installing plug (F) to minimize the chance of the tank splitting.

N107037 —UN—10OCT13

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

58. Install Upper Tank Fittings and Hoses—B2: Apply sealant to nipple (A) and install in T-fitting (B).

59. Apply sealant to the hose barb fitting (C) and install to T-fitting.

60. Apply sealant to the hose barb fitting (D) and install in T-fitting. Position as shown.

61. Set fitting assembly to the side for later installation.

62. Install clamp (E) to tank.

N107038 —UN—10OCT13

63. Apply sealant to plug (F) and install in the tank as shown.

64. Apply sealant to the hose barb fitting (G) and install in the tank as shown.

65. Apply sealant to fitting assembly (H) and install in the tank as shown.

B2 Upper Fittings A—Nipple, 1 in x 1 in B—T-Fitting, 1 in C—Hose Barb Fitting, 1 in NPT x 1 in Barb, Straight D—Hose Barb Fitting, 1 in NPT x 1 in Barb, 90°

E—Clamp F— Plug G—Hose Barb Fitting, 3/4 in NPT x 1 in Barb, 90° H—Fitting Assembly

Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305

66. Cut hose (A) to 2431 mm (95.75 in).

67. Route through P-clamps (B) and install onto the vent fitting (C).

C—Vent Fitting

N116536 —UN—12MAR15

A—Hose, 1 in ID x 2431 mm (95.75 in) B—P-Clamps (2 used)

B2 Upper Hoses CS12167,0000B03 -19-05APR18-17/107

IMPORTANT: Clamp (A) must be installed before installing hose barb fitting (B) to minimize the chance of the tank splitting.

N116330 —UN—26FEB15

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

68. Install Upper Tank Fittings and Hoses—LowVolume System—If Equipped: Install clamp (A) to tank.

69. Apply sealant to the hose barb fitting (B) and install in tank. Position as shown.

70. Apply sealant to hose barb fittings (C and D) and install in tank. Position as shown.

Low-Volume Upper Fittings A—Clamp B—Hose Barb Fitting, 3/4 in NPT x 1/2 in Barb 90°

Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305

71. Cut hose (A) to 1983 mm (78 in).

72. Route through double P-clamps (C) and install onto the rinse fitting (B).

73. Cut hose (D) to 1628 mm (64 in).

74. Route through double P-clamps (C) and install onto the vent fitting (E).

75. Cut hose (F) to 1400 mm (55 in).

A—Hose, 1 in ID x 1983 mm (78 in) B—Rinse Fitting C—Double P-Clamps (2 used) D—Hose, 1 in ID x 1628 mm (64 in)

N116329 —UN—26FEB15

76. Route through double P-clamps (H) and install onto the tank return fitting (G).

E—Vent Fitting F— Hose, 1/2 in ID x 1400 mm (55 in) G—Tank Return Fitting H—P-Clamps (2 used)

Low-Volume Upper Hoses CS12167,0000B03 -19-05APR18-19/107

77. Install High-Volume Pump: Raise boom to highest position.

79. Remove and discard cap screws and nuts (C) and bracket (D).

80. Remove cap screws and nuts (E). Retain hardware for attaching the rinse valve.

81. Move hose clamp assembly (F) off to the side.

D—Bracket E—Cap Screws and Nuts (2 used) F— Hose Clamp Assembly

N116104 —UN—24FEB15

A—Cap Screws and Nuts (2 used) B—P-Clamps (2 used) C—Cap Screws and Nuts (2 used)

N116537 —UN—12MAR15

78. Remove and retain cap screws and nuts (A) and P-clamps (B).

Continued on next page

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BKK10302, BKK10303, BKK10304, BKK10305

CAUTION: High-volume pump assembly (A) is awkward to handle. Two people are required to install. Plan a safe installation procedure. Use appropriate lifting device to install.

NOTE: As necessary, loosen pump mounting hardware (B) to aid in alignment of assembly mounting holes.

N116821 —UN—24MAR15

High-volume pump assembly weighs approximately 56 kg (123.5 lb).

82. Install high-volume pump assembly (A) to mounting tabs (C).

83. Retain using cap screws (D).

84. Tighten any hardware loosened during installation.

85. Retain vent hoses (F) to high-volume pump assembly using previously removed P-clamps, cap screws, and nuts.

A—High-Volume Pump Assembly B—Pump Mounting Hardware C—Mounting Tabs

D—Cap Screw, M8 x 25 (4 used) E—Check Valves (2 used) F— Vent Hoses

One High-Volume Pump, 200 gal System

N116539 —UN—23MAR15

IMPORTANT: Verify that check valves (E) are stamped 046 and contain a hole in the poppet. Otherwise, contact your John Deere Dealer for a proper replacement. These check valves are necessary for pump priming and are not to be used in a traditional check valve application.

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86. Identify rinse valve ports (A—C) for future reference.

• Rinse water is always connected to port “AUX” (A).

• Chemical is always connected to port “MAIN” (B).

• DI Pump is always connected to port “COMMON” (C).

C—COMMON Port

N118300 —UN—27MAY15

A—AUX Port B—MAIN Port

Continued on next page

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N116543 —UN—07MAY15

N116542 —UN—13MAR15

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

N130081 —UN—25APR17

87. Attach bracket (A) to rinse valve assembly (B) using cap screws and flange nuts (C).

88. Apply sealant to hose barb fittings (D, E, and F) and install in the rinse valve. Position as shown.

89. Attach P-clamp (G) to bracket using cap screw and flange nut (H).

90. Attach rinse valve assembly (I) to bracket assembly using cap screws and flange nuts (J).

91. Apply sealant to hose barb fittings (K, L, and M) and install in the rinse valve. Position as shown.

H—Cap Screw, M8 x 20 and Flange Nut I— Rinse Valve Assembly J— Cap Screws, M8 x 30 and Flange Nuts (2 used) K—Hose Barb Fitting, 3/4 in Barb x 3/4 in NPT 90° L— Hose Barb Fitting, 3/4 in Barb x 3/4 in NPT Straight M—Hose Barb Fitting, 3/4 in Barb x 3/4 in NPT 90°

N130082 —UN—25APR17

A—Bracket B—Rinse Valve Assembly C—Cap Screws, M8 x 30 and Flange Nuts (2 used) D—Hose Barb Fitting, 3/4 in Barb x 3/4 in NPT 90° E—Hose Barb Fitting, 3/4 in Barb x 3/4 in NPT Straight F— Hose Barb Fitting, 3/4 in Barb x 3/4 in NPT 90° G—P-Clamp, 38 mm (1-1/2 in)

Continued on next page

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PN=141

BKK10302, BKK10303, BKK10304, BKK10305

92. Attach rinse valve assembly (A) to front side of frame (B) using previously removed cap screws (C).

93. Install P-clamp (D) and previously removed flange nuts (E).

D—P-Clamp, 38 mm (1-1/2 in) E—Flange Nuts

N116827 —UN—24MAR15

A—Rinse Valve Assembly B—Frame C—Cap Screws

N116826 —UN—24MAR15

View from Rear

CS12167,0000B03 -19-05APR18-24/107

94. Remove nut (A) from the cap screw (B).

95. Remove and discard the hose mount (C).

C—Hose Mount D—Rinse Bracket

N116907 —UN—25MAR15

A—Nut B—Cap Screw

N117990 —UN—27MAY15

96. Move clamp assembly over to rinse bracket (D) and reinstall previously removed nut.

Continued on next page

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041118

PN=142

BKK10302, BKK10303, BKK10304, BKK10305

IMPORTANT: Do not disconnect battery on machines equipped with Final Tier 4 engines until LED (A) has turned off. This indicates that the DEF system purge is complete.

A—LED

N102417 —UN—01MAR13

97. Install Wiring Harness: Rotate handle (B) counterclockwise to disconnect batteries.

B—Handle

Disconnect Switch CS12167,0000B03 -19-05APR18-26/107

98. Install bulkhead connector (A) at shown location.

Retain using nut (B).

B—Nut

N105682 —UN—05AUG13

A—Bulkhead Connector

Bulkhead Connector Continued on next page

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PN=143

BKK10302, BKK10303, BKK10304, BKK10305

N105205 —UN—07AUG13

B

A

Harness Routing Diagram

99. Route direct injection (DI) harness (A) behind cab mount (C).

100.Locate chassis harness (B).

N105809 —UN—08AUG13

IMPORTANT: Avoid rub or pinch points when routing harness to prevent damage.

101.Route DI harness along chassis harness.

102.Route DI harness forward as shown.

IMPORTANT: Use additional tie bands if necessary to prevent harness rub points.

103.Retain DI harness to chassis harness with tie bands as needed.

A—Direct Injection (DI) Harness B—Chassis Harness Continued on next page

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C—Cab Mount

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041118

PN=144

BKK10302, BKK10303, BKK10304, BKK10305

104.Remove and retain the nut (A) and wire (B) from the starter relay (C) in the battery box.

A—Nut B—Wire C—Starter Relay

N105207 —UN—05AUG13

105.Locate chassis harness connector (D) and red wire (E).

D—Chassis Harness Connector E—Red Wire

Starter Relay CS12167,0000B03 -19-05APR18-29/107

106.Install DI relay (A) using cap screw (B) and nut.

NOTE: Wire (F) is to be installed in its previous position on the starter relay.

N105679 —UN—05AUG13

107.Install bus bar (C) to the starter relay and DI relay using nut (D) and previously removed nut (E) and wire.

108.Connect chassis harness connector (I) to the DI relay.

109.Install red wire (G) to bottom stud of the DI relay, retain using nut (H).

110.Remove and retain cap screw (J).

Direct Injection Relay

111.Install DI harness ground (K) as shown using previously removed cap screw.

G—Red Wire H—Nut I— Chassis Harness Connector J— Cap Screw K—DI Harness Ground

N111104 —UN—09APR14

A—DI Relay B—Cap Screw, M6 x 50 C—Bus Bar D—Nut E—Nut, Previously Removed F— Wire

DI Ground Continued on next page

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PN=145

BKK10302, BKK10303, BKK10304, BKK10305

112.Connect DI harness connector (A) to chassis harness (B) at the battery box.

B—Chassis Harness

N105931 —UN—28AUG13

A—DI Harness Connector

CS12167,0000B03 -19-05APR18-31/107

113.Remove and retain cap screws (A) and nuts.

114.Position fuse box (B) as desired to access the rear of box.

Fuse Name

DI Harness Wire Code

N105689 —UN—05AUG13

115.Install DI harness (C) to the fuse box terminals. See table for proper placement.

Fuse Box Location

F111

8722

11

F112

8712

12

F113

8702

13

116.Install fuse box using previously removed cap screws and nuts.

C—DI Harness

N105690 —UN—05AUG13

A—Cap Screws B—Fuse Box

Continued on next page

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041118

PN=146

BKK10302, BKK10303, BKK10304, BKK10305

117.Connect rear bulkhead connector (A) to the front bulkhead connector (B).

B—Front Bulkhead Connector

N105691 —UN—05AUG13

A—Rear Bulkhead Connector

Bulkhead Connectors CS12167,0000B03 -19-05APR18-33/107

B

N105206 —UN—05MAR14

A

Harness Routing Diagram

NOTE: Some parts have been removed to provide clarity.

118.Route DI harness (A) rearward along solution system harness (B). Retain with tie bands as needed.

B—Solution System Harness

N105810 —UN—08AUG13

A—DI Harness

Continued on next page

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041118

PN=147

N110779 —UN—04MAR14

N110781 —UN—04MAR14

BKK10302, BKK10303, BKK10304, BKK10305

Bracket Identification

119.Remove and retain cap screws (A) and flange lock nuts.

N110782 —UN—04MAR14

NOTE: If the boom air purge is not installed on machine, install bracket (C) using two M8 x 20 cap screws (D) and flange lock nuts.

120.Install bracket (C) using previously removed cap screws (A) and flange lock nuts.

A—Cap Screws (2 used) B—Air Purge Valve

C—Bracket D—Cap Screws, M8 x 20 (2 used)

N110780 —UN—04MAR14

Bracket Installed with Air Purge

Bracket Installed without Air Purge Continued on next page

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CS12167,0000B03 -19-05APR18-35/107

041118

PN=148

BKK10302, BKK10303, BKK10304, BKK10305

121.Install harness (A) in P-clamp (B).

122.Install P-clamps (B and C) to bracket as shown using cap screw, washer, and flange lock nut (D).

A—Harness B—P-Clamp, 38.1 mm (1-1/2 in) C—Double P-Clamp, 36.5 mm (1-7/16 in)

D—Cap Screw, M8 x 30, Washer, and Flange Lock Nut E—P-Clamp, 38.1 mm (1-1/2 in) F— Cap Screw, M8 x 30, Washer, and Flange Lock Nut

N116902 —UN—25MAR15

123.Install P-clamps (E) to bracket as shown using cap screw, washer, and flange lock nut (F).

CS12167,0000B03 -19-05APR18-36/107

124.Continue routing DI harness (A) along boom support (B) to the high-volume pump. Use tie bands (C) to retain harness.

C—Tie Bands (6 used)

N116903 —UN—25MAR15

A—DI Harness B—Boom Support

Continued on next page

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041118

PN=149

BKK10302, BKK10303, BKK10304, BKK10305

125.Install high-volume pump harness (A) to high-volume pump assembly (B).

126.Retain connector (C) as shown using supplied tie band (D).

IMPORTANT: Verify wires (E) are not under tension. Water or chemical may enter the connection, causing damage.

127.Connect high-volume pump harness to DI harness (F).

128.Retain connector (G) to solution system harness (H) using tie bands.

E—Wires F— DI Harness G—Connector H—Solution System Harness

N107959 —UN—21FEB14

A—High-Volume Pump Harness B—High-Volume Pump Assembly C—Connector D—Tie Band

N107958 —UN—21FEB14

NOTE: If the low-volume bundle is not installed, coil harness breakout and retain to machine using tie bands.

Continued on next page

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CS12167,0000B03 -19-05APR18-38/107

041118

PN=150

BKK10302, BKK10303, BKK10304, BKK10305

129.Connect CAN connections on machines NOT equipped with ExactApply™. a. Disconnect harness connectors (A and B) on main solution harness (C).

N110777 —UN—04MAR14

b. Disconnect harness connectors (D and E) on DI harness (F). c. Connect harness connectors (A) and (D) together. d. Connect harness connectors (B) and (E) together.

D—DI Harness Connector E—DI Harness Connector F— DI Harness

N110778 —UN—04MAR14

A—Main Solution Harness Connector B—Main Solution Harness Connector C—Main Solution Harness

ExactApply is a trademark of Deere & Company CS12167,0000B03 -19-05APR18-39/107

NOTE: CAN connections are located under the solution system control unit.

A

130.Connect CAN connections on machines EQUIPPED with ExactApply™. a. Disconnect CAN connectors (D, E, F, and G) between main solution harness (A) and the ExactApply™ harness (B). b. Disconnect CAN connectors (H and I) on the DI harness (C).

B

E

D

c. Connect CAN connectors (D and H). d. Connect CAN connectors (I and F).

C

A—Main Solution Harness B—ExactApply™ Harness C—Direct Injection (DI) Harness D—Main Solution Harness CAN Connector E—Main Solution Harness CAN Connector

F— ExactApply™ Harness CAN Connector G—ExactApply™ Harness CAN Connector H—DI Harness CAN Connector I— DI Harness CAN Connector

Continued on next page

KK43425 (11APR18)

149

G

F

H

I

N130202 —UN—03MAY17

e. Connect CAN connectors (E and G).

CS12167,0000B03 -19-05APR18-40/107

041118

PN=151

BKK10302, BKK10303, BKK10304, BKK10305

131.Install Tank Assemblies—Without Low-Volume Kit: Tank placement from left to right is A1, B1, B2, and A2.

C—Tank Assembly B2 D—Tank Assembly A2 N107044 —UN—10OCT13

A—Tank Assembly A1 B—Tank Assembly B1

CS12167,0000B03 -19-05APR18-41/107

CAUTION: Tank assemblies are awkward to handle. Two people are required to install.

Plan a safe installation procedure. Use appropriate lifting device to install.

N116546 —UN—16MAR15

NOTE: Tank assemblies weigh approximately 47 kg (103 lb) each.

132.Loosen cap screws and nuts (A).

A—Cap Screws and Nuts (4 used)

CS12167,0000B03 -19-05APR18-42/107

133.Install tank assembly (A) to upper mounting tube (B).

134.Loosely install cap screws and nuts (G), and clamp bracket (F).

135.Install spacer (C) between tank assembly and lower mounting tube (D).

NOTE: Install spacer cap screws from the front, flange lock nuts to the rear.

N116547 —UN—16MAR15

136.Retain tank assembly and spacer to lower mounting tube with the cap screws and flange lock nuts (E).

137.Tighten hardware (E, G, and H) starting from the bottom and working up.

138.Repeat procedure for the remaining tank assemblies.

A—Tank Assembly B—Upper Mounting Tube C—Spacer D—Lower Mounting Tube

E—Cap Screws, M10 x 100 and Flange Lock Nuts F— Clamp Bracket G—Cap Screws, M10 x 40 and Nuts (2 used) H—Cap Screw and Nut (4 used) Continued on next page

KK43425 (11APR18)

150

A2 Tank Assembly

CS12167,0000B03 -19-05APR18-43/107

041118

PN=152

BKK10302, BKK10303, BKK10304, BKK10305

139.Install Tank Assemblies—With Low-Volume Kit: Tank placement from left to right is Low-Volume, A1, B1, B2, and A2.

D—Tank Assembly B2 E—Tank Assembly A2 N116548 —UN—16MAR15

A—Tank Assembly—LowVolume B—Tank Assembly A1 C—Tank Assembly B1

CS12167,0000B03 -19-05APR18-44/107

NOTE: Tank assemblies weigh approximately 47 kg (103 lb) each.

140.Tanks A2, B1, and B2: Loosen cap screws and nuts (A).

A—Cap Screws and Nuts (4 used) Continued on next page

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151

N116546 —UN—16MAR15

CAUTION: Tank assemblies are awkward to handle. Two people are required to install.

Plan a safe installation procedure. Use appropriate lifting device to install.

CS12167,0000B03 -19-05APR18-45/107

041118

PN=153

BKK10302, BKK10303, BKK10304, BKK10305

141.Tanks A2, B1, and B2: Install tank assembly (A) to upper mounting tube (B).

142.Loosely install cap screws and nuts (G), and clamp bracket (F).

NOTE: Install spacer cap screws from the front, flange lock nuts to the rear.

143.Install spacer (C) between tank assembly and lower mounting tube (D).

N116547 —UN—16MAR15

144.Retain tank assembly and spacer to lower mounting tube with the cap screws and flange lock nuts (E).

145.Tighten hardware (E, G, and H) starting from the bottom and working up.

NOTE: Do not install A1 tank assembly at this time.

146.Repeat procedure for the remaining tank assemblies.

A2 Tank Assembly A—Tank Assembly B—Upper Mounting Tube C—Spacer D—Lower Mounting Tube

E—Cap Screws, M10 x 100 and Flange Lock Nuts (2 used) F— Clamp Bracket G—Cap Screws, M10 x 40 and Nuts (2 used) H—Cap Screw and Nut (4 used) CS12167,0000B03 -19-05APR18-46/107

147.Remove and retain cap screws and nuts (A) from low-volume tank assembly (C).

148.Loosen cap screws and nuts (B).

C—Low-Volume Tank Assembly

N116331 —UN—27FEB15

A—Cap Screws and Nuts (4 used) B—Cap Screws and Nuts (4 used)

Low-Volume Tank Assembly Continued on next page

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CS12167,0000B03 -19-05APR18-47/107

041118

PN=154

BKK10302, BKK10303, BKK10304, BKK10305

149.Remove and retain tank strap nuts (A).

150.Remove tank A1 (B) from the support bracket.

A—Tank Strap Nuts B—Tank A1

N116332 —UN—27FEB15

151.Remove and discard cap screws and nuts (D), and mounting bracket (C).

C—Mounting Bracket D—Cap Screws and Nuts (4 used)

A1 Tank Mounting Bracket CS12167,0000B03 -19-05APR18-48/107

152.Install lifting strap or chain to hole (A) in tank assembly A1.

153.Attach low-volume tank mounting bracket (B) to A1 support (C). Loosely retain with previously removed cap screws and nuts (D).

154.Reinstall tank A1 (E) to support bracket.

D—Cap Screws and Nuts (4 used) E—Tank A1 F— Low-Volume Tank Assembly N116333 —UN—27FEB15

A—Hole B—Mounting Bracket C—A1 Support

Attach Tank Assemblies Continued on next page

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041118

PN=155

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: The combined weight of the A1 assembly and the low-volume assembly is 88.5 kg (195 lb).

155.Slide tank assemblies onto upper mounting tube (A).

156.Install spacers (B) between tank assembly A1 and mounting tube. Retain with cap screws and flange lock nuts (C).

157.Install spacer tubes (E) between low-volume tank assembly and support. Retain with cap screws and flange lock nuts (D).

A—Upper Mounting Tube B—Spacers C—Cap Screws, M10 x 100 and Flange Lock Nuts (2 used)

N116334 —UN—27FEB15

158.Tighten all hardware starting at lower mount and working up.

D—Cap Screw, M10 x 150 and Flange Lock Nut (2 used) E—Spacer Tubes (2 used)

Install Tanks CS12167,0000B03 -19-05APR18-50/107

NOTE: Install tank sump valve assemblies from right to left.

A—Valve Assembly B—Gasket

N102986 —UN—27MAR13

159. Install Tank Sump Valve Assemblies: Install valve assembly (A) to the A2 tank sump using gasket (B) and flange clamp (C). Position as shown.

C—Flange Clamp, 1 in

Tank A2 Sump Valve CS12167,0000B03 -19-05APR18-51/107

160.Install B1 valve assembly (A) to tank assembly B1 (B) using gasket (C) and flange clamp (D). Position as shown.

A—B1 Valve Assembly B—Tank Assembly B1 C—Gasket

N107045 —UN—10OCT13

161.Install B2 valve assembly (E) to tank assembly B2 (F) using gasket and flange clamp. Position as shown.

D—Flange Clamp, 1 in E—B2 Valve Assembly F— Tank Assembly B2

Continued on next page

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041118

PN=156

BKK10302, BKK10303, BKK10304, BKK10305

162.Install valve assembly (A) to the A1 tank sump using gasket (B) and flange clamp (C). Position as shown.

C—Flange Clamp, 1 in

N103020 —UN—27MAR13

A—Valve Assembly B—Gasket

Tank A1 Sump Valve CS12167,0000B03 -19-05APR18-53/107

163.Install Low-Volume Tank Sump Valve and Fittings—Low-Volume System—If Equipped: Apply sealant to low-volume sump valve assembly (A).

164.Install low-volume sump valve assembly (A) to the tank sump fitting (B). Position as shown.

A—Low-Volume Sump Valve Assembly

B—Tank Sump Fitting

Continued on next page

KK43425 (11APR18)

155

N105197 —UN—05AUG13

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

CS12167,0000B03 -19-05APR18-54/107

041118

PN=157

BKK10302, BKK10303, BKK10304, BKK10305

CAUTION: Low-volume pump assembly weighs approximately 22.3 kg (49 lb).

Pump assembly is awkward, two people or lifting device are required for installation.

165.Install Low-Volume Pump Assembly and Strainer—If Equipped: Install low-volume pump assembly (A) to the low-volume tank bracket (B) using cap screws (C and D) and flange lock nuts.

C—Cap Screws, M10 x 30 (2 used) D—Cap Screws, M8 x 30 (3 used)

N116335 —UN—27FEB15

A—Low-Volume Pump Assembly B—Low-Volume Tank Bracket

N116336 —UN—27FEB15

Low-Volume Pump Assembly

CS12167,0000B03 -19-05APR18-55/107

166.Install valve and strainer assembly (A) to mount (B) using cap screws (C) and flange lock nuts.

C—Cap Screws, M8 x 100 (2 used) N116828 —UN—25MAR15

A—Valve and Strainer Assembly B—Mount

Continued on next page

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CS12167,0000B03 -19-05APR18-56/107

041118

PN=158

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

N110460 —UN—25FEB14

167.Install Check Valves in Mixer: Apply sealant to the hose barb (A) and install in the check valve (B).

168.Apply sealant to the hose barb (C) and install in the check valve (D).

169.Apply sealant to check valve (D) and install in fitting (E).

A—90° Hose Barb for 1/2 in ID Hose B—Check Valve C—Straight Hose Barb for 1/2 in ID Hose

D—Check Valve E—45° Fitting

CS12167,0000B03 -19-05APR18-57/107

170.Remove plugs (A) from mixer assembly (B).

171.Apply sealant to check valve assemblies (C and D) and install in mixer. Position check valve assemblies as shown.

N110518 —UN—25FEB14

C—Check Valve Assembly D—Check Valve Assembly

N110519 —UN—05MAR14

A—Plugs B—Mixer Assembly

Continued on next page

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041118

PN=159

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

N110521 —UN—25FEB14

172.Low-Volume System—If Equipped: Apply sealant to the hose barb (A) and install in the check valve (B).

173.Apply sealant to check valve (B) and install in fitting (C).

A—Straight Hose Barb for 1/2 in ID Hose B—Check Valve

C—45° Fitting

CS12167,0000B03 -19-05APR18-59/107

174.Remove plug (A) from mixer assembly (B).

175.Apply sealant to check valve assembly (C) and install in mixer. Position check valve assembly as shown.

N110522 —UN—25FEB14

C—Check Valve Assembly

N110523 —UN—25FEB14

A—Plug B—Mixer Assembly

Continued on next page

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041118

PN=160

BKK10302, BKK10303, BKK10304, BKK10305

176.Install Mixer Assembly and Brackets: Remove and retain flange clamps (A) and gaskets (B).

177.Remove and discard fitting (C).

C—Fitting N105189 —UN—05AUG13

A—Flange Clamps B—Gaskets

CS12167,0000B03 -19-05APR18-61/107

178.Install mixer assembly (A) to the suspended center frame (B). Position as shown.

179.Retain mixer assembly with U-bolts (C) and nuts (D).

A—Mixer Assembly B—Suspended Center Frame C—U-Bolt, M8 (2 used)

N105190 —UN—05AUG13

180.Install bracket (E) using U-bolt (F) and nuts.

D—Nut, M8 (6 used) E—Bracket F— U-Bolt, M8

Mixer Assembly CS12167,0000B03 -19-05APR18-62/107

181.Install hose bracket (A) and plate (B) using cap screws (C) and flange lock nuts (D). Position at measurement (E) from right-hand tilt cylinder mount (F).

D—Flange Lock Nut, M12 (4 used) E—Measurement, 936 mm (37 in) F— Right-Hand Tilt Cylinder Mount

N105191 —UN—04MAR14

A—Hose Bracket B—Plate C—Cap Screw, M12 x 140 (4 used)

Continued on next page

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041118

PN=161

BKK10302, BKK10303, BKK10304, BKK10305

182.Install P-clamps (A) on hoses (B) and (C) in shown orientation.

C—Inlet Hose, 1550 mm (61 in)

N110574 —UN—25FEB14

A—P-Clamps, 63.5 mm (2-1/2 in) B—Outlet Hose, 1289 mm (50-3/4 in)

Continued on next page

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041118

PN=162

N105192 —UN—08AUG13

BKK10302, BKK10303, BKK10304, BKK10305

Mixer Plumbing A—Flange Clamp B—Elbow Fitting C—Hose Barb Fitting D—Inlet Hose, 1550 mm (61 in)

E—Band Clamps F— Flange Clamp G—Mixer Assembly Inlet H—Band Clamps I— Outlet Hose, 1289 mm (50-3/4 in)

J— Mixer Assembly Outlet K—Band Clamps L— Barbed Elbow Fitting M—Band Clamps

N—Flange Clamp O—Boom Isolation Valve

183.Loosen flange clamp (A).

188.Route outlet hose (I) through P-clamps as shown.

184.Rotate elbow fitting (B) to position shown.

189.Install outlet hose to the mixer assembly outlet (J) and retain using band clamps (K).

185.Install hose barb fitting (C) to the elbow fitting and retain with the flange clamp (F) and gasket.

190.Install barbed elbow fitting (L) to the outlet hose and retain with band clamps (M).

186.Route inlet hose (D) through P-clamps as shown.

191.Install barbed elbow fitting to boom isolation valve (O) using flange clamp (N) and gasket.

187.Install inlet hose to the hose barb fitting and mixer assembly inlet (G) as shown using band clamps (E) and (H).

Continued on next page

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041118

PN=163

BKK10302, BKK10303, BKK10304, BKK10305

192.Retain P-clamps (A) using cap screws (B) and flange lock nuts.

193.Retain P-clamp (C) using cap screw (D) and flange lock nut.

D—Cap Screw, M10 x 40 E—P-Clamp, 63.5 mm (2-1/2 in) F— Cap Screw, M10 x 40 (3 used)

N110575 —UN—25FEB14

A—P-Clamp, 63.5 mm (2-1/2 in) B—Cap Screws M10 x 30 (2 used) C—P-Clamp, 63.5 mm (2-1/2 in)

N110573 —UN—25FEB14

194.Retain P-clamps (E) using cap screws (F) and flange lock nuts.

Mixer P-Clamps CS12167,0000B03 -19-05APR18-66/107

195.P-clamp Installation: Remove and retain cap screw (A) and nut.

A—Cap Screw

B—P-Clamp, 38.1 mm (1-1/2 in)

Continued on next page

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162

N116904 —UN—25MAR15

196.Install P-clamp (B) as shown using previously removed cap screw and nut.

CS12167,0000B03 -19-05APR18-67/107

041118

PN=164

BKK10302, BKK10303, BKK10304, BKK10305

197.Install double P-clamp (A) using cap screw (B) and flange nut. Position as shown.

B—Cap Screw, M8 x 30

N116905 —UN—25MAR15

A—Double P-Clamp, 19 mm (3/4 in)

CS12167,0000B03 -19-05APR18-68/107

198.Remove and retain cap screws (A) and nuts.

199.Install P-clamps (B) using previously removed cap screws and nuts. Position as shown.

B—P-Clamps, 38.1 mm (1-1/2 in) (2 used)

N107234 —UN—14OCT13

A—Cap Screws (2 used)

Continued on next page

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041118

PN=165

BKK10302, BKK10303, BKK10304, BKK10305

200.Install bracket (A) to upper mounting tube (B) using U-bolt (C) and flange lock nuts.

202.Install P-clamp (F) using cap screw (G) and flange nut. Position as shown.

203.Install P-clamp (H) using cap screw (I) and flange nut.

Position as shown.

204.Install retainer bracket (J) to lift arm frame (K) using U-bolt (L) and flange lock nuts.

N110775 —UN—04MAR14

201.Install hose support (D) to bracket using cap screws (E) and flange lock nuts.

205.Install hose retainer (M) to the retainer bracket using cap screw (N) and flange lock nut.

NOTE: Install P-clamp (O) to the hose retainer if the low-volume bundle is installed.

N110628 —UN—04MAR14

I— Cap Screw, M8 x 30 J— Retainer Bracket K—Lift Arm Frame L— U-Bolt, M8 x 112 M—Hose Retainer N—Cap Screw, M8 x 60 O—P-Clamp, 19 mm (3/4 in)—Low-Volume Bundle ONLY

N110776 —UN—04MAR14

A—Bracket B—Upper Mounting Tube C—U-Bolt, M10 x 114 D—Hose Support E—Cap Screw, M10 x 25 (2 used) F— P-Clamp, 38.1 mm (1-1/2 in) G—Cap Screw, M8 x 30 H—P-Clamp, 38.1 mm (1-1/2 in)

CS12167,0000B03 -19-05APR18-70/107

206.Remove upper nut (A) from the hose retainer (B).

207.Install P-clamp (C) using previously removed nut.

N110930 —UN—12MAR14

NOTE: Install P-clamp (F) to hose retainer if low-volume bundle is installed.

208.Install hose retainers (D) to lift arm frame using cap screw (E) and flange nut.

A—Nut B—Hose Retainer C—Double P-Clamp, 36.5 mm (1-7/16 in)

D—Hose Retainers E—Cap Screw, M8 x 160 F— P-Clamp, 19 mm (3/4 in)—Low-Volume Bundle ONLY Continued on next page

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041118

PN=166

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: Electrical harness retainers must be removed before installing bracket. After bracket installation, retain the harness to the bracket using provided holes (D).

A—Bracket B—Boom Frame

N116810 —UN—20MAR15

209.Install bracket (A) to the boom frame (B) using cap screws (C) and flange lock nuts.

C—Cap Screws, M8 x 25 and Flange Nuts (2 used) D—Holes for Retaining Electrical Harness

CS12167,0000B03 -19-05APR18-72/107

NOTE: To simplify the text and photos, the following procedure does not call out the installation of hose clamps.

N116451 —UN—03MAR15

Install hose clamps on each hose end and tighten to specification.

Specification Hose Clamps—Torque........................................................ 3.9—4.5 N·m (35—40 lb·in)

Hose-to-Clamp Reference • 1/2 in ID hoses, use 1 in clamps • 3/4 in ID hoses, use 1 in clamps • 1 in ID hoses, use 1-1/2 in clamps

Rinse Tank Connection

210.Models R4030 and R4038 Only: Depending on configuration, remove foam marker fitting (B) or plug (C) from T-fitting (D).

A—Rinse Tank B—Foam Marker Fitting

C—Plug D—T-Fitting CS12167,0000B03 -19-05APR18-73/107

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

A—Pipe Nipple, 3/4 in B—T-Fitting, 3/4 in C—Straight Hose Barb for 3/4 in ID Hose

N116452 —UN—03MAR15

211.Models R4030 and R4038 Only With Foam Marker: Apply sealant to threads and assemble parts (A—E) as shown.

D—Foam Marker Fitting E—T-Fitting

With Foam Marker Continued on next page

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041118

PN=167

BKK10302, BKK10303, BKK10304, BKK10305

212.Models R4030 and R4038 Only Without Foam Marker: Apply sealant to threads and install 90° hose barb (B) to T-fitting (A) as shown.

B—90° Hose Barb for 3/4 in ID Hose N128686 —UN—11APR17

A—T-Fitting

Without Foam Marker CS12167,0000B03 -19-05APR18-75/107

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

N116453 —UN—03MAR15

213.Models R4030 and R4038 Only: Cut hose (A) to 336 mm (13.25 in).

214.Models R4030 and R4038 Only: Install one end of hose (A) to barb fitting (B).

215.Models R4030 and R4038 Only: Assemble straight hose barbs (C) and check valve (D).

IMPORTANT: Proper check valve installation is necessary to prevent contamination of rinse water.

216.Models R4030 and R4038 Only: Install check valve assembly to hose (A), making sure that arrow on valve is pointing away from the rinse tank.

A—Rinse Hose, 3/4 in ID x 336 mm (13.25 in) B—Barb Fitting for 3/4 in ID Hose

C—Straight Hose Barbs for 3/4 in ID Hose D—Check Valve

Continued on next page

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NOTE: Arrows on check valve show direction of flow.

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PN=168

BKK10302, BKK10303, BKK10304, BKK10305

217.Models R4030 and R4038 Only: Cut hose (A) to 1329 mm (52.25 in).

C—Rinse Valve Fitting

N116456 —UN—04MAR15

A—Rinse Hose, 3/4 in ID x 1329 mm (52.25 in) B—Check Valve Barb Fitting

N116455 —UN—04MAR15

218.Models R4030 and R4038 Only: Install one end of hose (A) to check valve barb fitting (B) and the other end to rinse valve fitting (C).

Rinse Valve CS12167,0000B03 -19-05APR18-77/107

IMPORTANT: Proper check valve installation is necessary to prevent contamination of rinse water.

N116738 —UN—25MAR15

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

Arrows on check valve show direction of flow.

219.R4045 Only: Assemble parts (A—G) as shown.

A—T-Fitting, 2 in B—Gasket C—Clamp, 2 in D—Adaptor, 2 in flange with 3/4 in NPT port

E—Pipe Nipple, 3/4 in F— Check Valve G—Straight Hose Barb for 3/4 in ID Hose

Continued on next page

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041118

PN=169

N130079 —UN—24APR17

N116729 —UN—25MAR15

BKK10302, BKK10303, BKK10304, BKK10305

220.R4045 Only: Loosen flange clamp (A) and separate rinse hose (B) from manifold (C).

A—Flange Clamp B—Rinse Hose C—Manifold

N116739 —UN—25MAR15

221.R4045 Only: Install T-fitting assembly (D) between rinse hose and manifold using gaskets (E) and flange clamps (F). Align fitting as shown and tighten clamps.

D—T-Fitting Assembly E—Gaskets (2 used) F— Flange Clamps (2 used)

Alignment Shown Continued on next page

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041118

PN=170

BKK10302, BKK10303, BKK10304, BKK10305

222.R4045 Only: Cut hose (A) to 660 mm (26 in).

223.R4045 Only: Install one end of hose (A) to check valve barb fitting (B) and the other end to T-fitting (C).

N116743 —UN—25MAR15

224.R4045 Only: Cut hoses (D) to 275 mm (10.75 in).

225.R4045 Only: Install one end of hoses (D) to T-fitting (C) and the other end to rinse valve fittings (E).

D—Hoses, 3/4 in ID x 275 mm (10.75 in) E—Rinse Valve Fittings

N116913 —UN—25MAR15

A—Rinse Hose, 3/4 in ID x 660 mm (26 in) B—Check Valve Barb Fitting C—T-Fitting, 3/4 in

Continued on next page

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041118

PN=171

BKK10302, BKK10303, BKK10304, BKK10305

226.Route hose (A) through P-clamps (B) and install to T-fitting (C).

227.Route hose (D) through P-clamps (E) and install to pump return fitting (F).

D—Hose, 1/2 in ID E—P-Clamps F— Pump Return Fitting

N116908 —UN—25MAR15

N116911 —UN—25MAR15

A—Hose, 1 in ID B—P-Clamps C—T-Fitting

Continued on next page

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041118

PN=172

BKK10302, BKK10303, BKK10304, BKK10305

228.Connect hose (A) to the B2 vent fitting (B).

229.Connect hose (C) to the B2 rinse fitting (D).

230.Route vent hose (E) through P-clamps (F) as shown.

D—Rinse Fitting E—Vent Hose, 1 in F— P-Clamps

N116915 —UN—26MAR15

A—Hose, 1 in B—Vent Fitting C—Hose, 1 in

N116916 —UN—26MAR15

Hose Routing Tanks B1 and B2

Continued on next page

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041118

PN=173

BKK10302, BKK10303, BKK10304, BKK10305

231.Route hose (A) through double P-clamps (B), P-clamp (C), and install to pump return fitting (D).

232.Route hose (E) through double P-clamps (B), P-clamp (F), and install to T-fitting (G).

233.Cut hose (H) to 617 mm (24.25 in).

234.Route hose (H) through P-clamp (I) as shown. Install one end of hose onto T-fitting (G) and the other to rinse/fill valve fitting (J).

F— P-Clamp G—T-Fitting, 1 in H—Hose, 1 in ID x 617 mm (24.25 in) I— P-Clamp J— Rinse/Fill Valve Fitting

N116914 —UN—26MAR15

A—Hose, 1/2 in ID B—Double P-Clamps (2 used) C—P-Clamp D—Pump Return Fitting E—Hose, 1 in ID

N116912 —UN—25MAR15

Hose Routing Tank A2

CS12167,0000B03 -19-05APR18-83/107

235.Cut hose (A) to 862 mm (34 in).

236.Route hose (A) through P-clamps (C) as shown and install to tank fill fitting (B).

237.Install other end of hose to T-fitting (D).

239.Route hose (E) as shown and install to the strainer supply fitting (F).

240.Install other end of hose to the strainer inlet fitting (G).

241.Retain hoses using tie bands (H) as shown.

A—Hose, 1 in ID x 862 mm (34 in) B—Tank Fill Fitting C—P-Clamps (2 used) D—T-Fitting, 1 in

E—Hose, 3/4 in ID x 1117 mm (44 in) F— Strainer Supply Fitting G—Strainer Inlet Fitting H—Tie Bands (2 used) Continued on next page

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N116918 —UN—26MAR15

238.Cut hose (E) to 1117 mm (44 in).

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041118

PN=174

BKK10302, BKK10303, BKK10304, BKK10305

242.Cut hose (A) to 1070 mm (42 in).

243.Route hose (A) through P-clamps (C and D) and install to tank fill fitting (B).

A—Hose, 1 in ID x 1070 mm (42 in) B—Tank Fill Fitting C—Double P-Clamps (2 used)

N116919 —UN—26MAR15

244.Install other end to T-fitting (E).

D—P-Clamp E—T-Fitting

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245.Cut hose (A) to 400 mm (15.75 in).

246.Install hose (A) to tank B2 fill fitting (B) and B1 fitting (C).

248.Route hose (D) as shown and install to tank B1 fill fitting (E).

249.Install other end of hose to the strainer inlet fitting (F).

A—Hose, 1 in ID x 400 mm (15.75 in) B—Tank B2 Fill Fitting C—Tank B1 Fitting

D—Hose, 3/4 in ID x 388 mm (15.25 in) E—Tank B1 Fill Fitting F— Strainer Inlet Fitting

N116917 —UN—26MAR15

247.Cut hose (D) to 388 mm (15.25 in).

CS12167,0000B03 -19-05APR18-86/107

250.Cut hose (A) to 807 mm (31.75 in).

251.Install hose (A) to tank B1 fill fitting (B).

252.Install other end of hose to tank B1/B2 rinse/fill valve fitting (C).

253.Cut hose (D) to 692 mm (27.25 in).

255.Install other end of hose to tank A1/A2 rinse/fill valve fitting (F).

A—Hose 1 in ID x 807 mm (31.75 in) B—Tank B1 Fill Fitting C—Tank B1/B2 Rinse/Fill Valve Fitting

D—Hose 1 in ID x 692 mm (27.25 in) E—T-Fitting F— Tank A1/A2 Rinse/Fill Valve Fitting Continued on next page

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N116920 —UN—26MAR15

254.Route hose (D) as shown and install to T-fitting (E).

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041118

PN=175

BKK10302, BKK10303, BKK10304, BKK10305

256.Cut hose (A) to 365 mm (14.5 in).

257.Install hose (A) to pump inlet fitting (B) and rinse valve fitting (C).

258.Cut Spiral Wound hose (D) to 532 mm (21 in).

260.Cut Spiral Wound hose (G) to 532 mm (21 in).

261.Install hose (G) to the strainer fitting (H) and rinse valve fitting (I).

262.Cut hose (J) to 343 mm (13.5 in).

263.Install hose (J) to pump inlet fitting (K) and rinse valve fitting (L).

A—Hose, 3/4 in ID x 365 mm (14.5 in) B—Pump Inlet Fitting C—Rinse Valve Fitting D—Hose, 3/4 in ID x 532 mm (21 in) Spiral Wound E—Strainer Fitting F— Rinse Valve Fitting

G—Hose, 3/4 in ID x 532 mm (21 in) Spiral Wound H—Strainer Fitting I— Rinse Valve Fitting J— Hose, 3/4 in ID x 343 mm (13.5 in) K—Pump Inlet Fitting L— Rinse Valve Fitting Continued on next page

KK43425 (11APR18)

N116921 —UN—26MAR15

259.Install hose (D) to the strainer fitting (E) and rinse valve fitting (F).

174

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041118

PN=176

BKK10302, BKK10303, BKK10304, BKK10305

264.Cut hose (A) to 3123 mm (123 in).

265.Route mixer supply hose (A) through P-clamps, brackets, and hose retainers (B and C) as shown.

266.Install mixer supply hose (A) to the barbed elbow fitting (D).

267.Install mixer supply hose to pump output fitting (E).

268.Install check valve assembly to hose (A), making sure that arrow on valve is pointing away from the rinse tank.

D—Barbed Elbow Fitting, 1/2 in NPT x 1/2 in Barb E—Pump Output Fitting

N116923 —UN—27MAR15

N110927 —UN—12MAR14

A—Mixer Supply Hose, 1/2 in ID x 3123 mm (123 in) B—Hose Retainers C—Hose Retainer

N116924 —UN—27MAR15

NOTE: Arrows on check valve show direction of flow.

Continued on next page

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041118

PN=177

BKK10302, BKK10303, BKK10304, BKK10305

269.Cut hose (A) to 3037 mm (119.5 in).

270.Route mixer supply hose (A) through P-clamps, brackets, and hose retainers (B and C) as shown.

271.Install mixer supply hose (A) to the barbed elbow fitting (D).

272.Install mixer supply hose to pump output fitting (E).

NOTE: Arrows on check valve show direction of flow.

D—Barbed Elbow Fitting, 1/2 in NPT x 1/2 in Barb E—Pump Output Fitting

N110565 —UN—25FEB14

N110929 —UN—12MAR14

A—Mixer Supply Hose, 1/2 in ID x 3037 mm (119.5 in) B—Hose Retainers C—Hose Retainer

N110564 —UN—25FEB14

273.Install check valve assembly to hose (A), making sure that arrow on valve is pointing away from the rinse tank.

Continued on next page

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041118

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BKK10302, BKK10303, BKK10304, BKK10305

N116461 —UN—05MAR15

IMPORTANT: There are two different types of hose used in this procedure. Most hoses used in this system are braided. There are some locations where spiral a wound hose is needed. See pictorial legend for the proper hose type, if the specified braided hose is not used.

274.Hose Routing—Low-Volume Pump and Tank—If Equipped: Attach rinse hose (A) to rinse fitting (C).

275.Attach return hose (B) to pump return fitting (D).

276.Cut hose (E) to 246 mm (9.5 in).

277.Attach strainer supply hose (E) to the strainer inlet fitting (F) and tank supply fitting (G).

Low-Volume Pump and Tank

278.Cut hose (H) to 345 mm (13.5 in).

279.Attach tank fill hose (H) to fill fitting (I) and tank fill fitting (J).

280.Cut hose (K) to 537 mm (21 in).

H—Tank Fill Hose, 1 in Spiral Wound I— Fill Fitting J— Tank Fill Fitting K—Pump Supply Hose, 3/4 in L— Pump Inlet Fitting M—Rinse Valve Fitting

N116462 —UN—05MAR15

A—Rinse Hose, 1 in B—Return Hose, 1/2 in C—Rinse Fitting D—Pump Return Fitting E—Strainer Supply Hose, 3/4 in F— Strainer Inlet Fitting G—Tank Supply Fitting

N116463 —UN—05MAR15

281.Attach pump supply hose (K) to pump inlet fitting (L) and rinse valve fitting (M).

Continued on next page

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PN=179

BKK10302, BKK10303, BKK10304, BKK10305

282.Cut hose (A) to 458 mm (18 in).

283.Attach pump supply hose (A) to the strainer valve fitting (B).

284.Route pump supply hose through P-clamp (C) and install to pump inlet fitting (D).

C—P-Clamp D—Pump Inlet Fitting N116525 —UN—05MAR15

A—Pump Supply Hose, 3/4 in B—Strainer Valve Fitting

Continued on next page

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041118

PN=180

BKK10302, BKK10303, BKK10304, BKK10305

285.Cut hose (B) approximately 203 mm (8 in) from previously installed check valve (A).

286.Install T-fitting (C) as shown.

287.Cut hose (D) to 1575 mm (62 in).

288.Attach low-volume rinse hose (D) to T-fitting (C).

D—Low-Volume Rinse Hose, 3/4 ID x 1575 mm (62 in).

E—Double P-Clamps (3 used) F— Valve Inlet Fitting, 3/4 in

N116526 —UN—05MAR15

N116740 —UN—25MAR15

A—Check Valve B—Rinse Hose C—T-Fitting, 3/4 in

N116742 —UN—25MAR15

289.Route low-volume rinse hose through double P-clamps (E) and install to the valve inlet fitting (F).

Continued on next page

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041118

PN=181

N116531 —UN—06MAR15

N116528 —UN—06MAR15

BKK10302, BKK10303, BKK10304, BKK10305

290.Cut hose (A) to 3444 mm (135.5 in).

291.Attach mixer supply hose (A) to pump outlet fitting (B).

293.Route mixer supply hose through P-clamps (F).

IMPORTANT: Ensure adequate hose length to prevent damage or stress in all boom positions.

294.Install mixer supply hose to the barbed fitting (G).

E—Bracket F— P-Clamps (3 used) G—Barbed Fitting, 1/2 in

N116530 —UN—23MAR15

A—Mixer Supply Hose B—Pump Outlet Fitting, 1/2 in C—P-Clamp D—Double P-Clamps (4 used)

N105203 —UN—05AUG13

292.Route mixer supply hose through P-clamp (C), double P-clamps (D), and bracket (E) as shown.

Continued on next page

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041118

PN=182

BKK10302, BKK10303, BKK10304, BKK10305

CAUTION: Spray system can contain hazardous material which can cause serious injury or death to you or others. Wear protective clothing, eyewear, and gloves.

N105698 —UN—06AUG13

Do not drain solution onto the ground. Drain into a container. Drain solution in an area where people, animals, vegetation, and water supply, cannot be contaminated.

NOTE: To prevent leaks, apply Clear Silicone Sealant (PM37463 U.S.) (PM38617 Canada) to all threaded fittings.

295.Install Strainer Drain Valves: Remove and discard plugs (A). Use a suitable container to catch solution in strainers.

N130080 —UN—24APR17

296.Apply sealant to valves (B).

297.Install valves in strainers (C).

A—Plug B—Valve

C—Strainer

Continued on next page

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041118

PN=183

BKK10302, BKK10303, BKK10304, BKK10305

298.Low-Volume Harness Routing—If Equipped: Continue routing DI harness (A) rearward as shown.

299.Retain DI harness to supply hose (B) using tie bands (C).

N105683 —UN—05AUG13

300.Install low-volume harness (D) to the low-volume pump (E).

NOTE: Ensure tie band (G) does not interfere with connector latch.

301.Retain connector (F) as shown using tie band.

IMPORTANT: Verify wires (H) are not under tension. Water or chemical may enter the connection, causing damage.

302.Connect low-volume harness to DI harness.

303.Retain connector (I) to pump bracket using tie bands through holes (J).

F— Connector G—Tie Band H—Wires I— Connector J— Holes

N107961 —UN—21FEB14

A—DI Harness B—Supply Hose C—Tie Bands D—Low-Volume Harness E—Low-Volume Pump

Continued on next page

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PN=184

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: Tail light relocation is required on North American machines only.

304.Install light bracket (A) using cap screws (B) and nuts.

N105686 —UN—28AUG13

305.Disconnect harness connector (C).

306.Remove harness (D) from retainers (E).

307.Remove and retain cap screws (F) and tail light assembly (G).

E—Retainer F— Cap Screw, 2 used G—Tail Light Assembly

N105687 —UN—05AUG13

A—Light Bracket B—Cap Screw, M8 x 25 (2 used) C—Harness Connector D—Light Harness

Continued on next page

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041118

PN=185

BKK10302, BKK10303, BKK10304, BKK10305

308.Install tail light assembly (A) to the light bracket (B) using previously removed cap screws (C).

309.Connect tail light connector (D) to the DI harness connector (E).

310.Retain tail light harness (F) with tie bands as needed.

311.Connect chassis harness (G) to DI harness (H).

E—DI Harness Connector F— Tail Light Harness G—Chassis Harness H—DI Harness

N105688 —UN—05AUG13

N105685 —UN—28AUG13

A—Tail Light Assembly B—Light Bracket C—Cap Screw D—Tail Light Connector

Continued on next page

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041118

PN=186

BKK10302, BKK10303, BKK10304, BKK10305

IMPORTANT: Ensure decal adhesion. Before applying decals, clean all dirt, grease, oil, and moisture from application area. Surface temperature should be greater than 15°C (60°F) for best adhesion.

312.Install Decals: Correctly identify the decal and locate decal placement.

313.Remove paper backing from decal.

314.Press one edge of decal on application area.

N105695 —UN—05AUG13

315.Smooth out air pockets while slowly pressing across the decal to the opposite edge. Verify complete decal adhesion.

316.Install decals (A, B, and C) as shown.

A—Decal A B—Decal B

C—Decal C

N105696 —UN—05AUG13

Decal Placement

Decal Identification Continued on next page

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PN=187

BKK10302, BKK10303, BKK10304, BKK10305

317.Install decals (A and B) as shown. See table to determine the correct decals for your location.

NOTE: Install text-free decal (A) at alternate location shown.

Decal A N203265

Decal B

N105935 —UN—04SEP13

Location North America, English

N409438

North America, French N208394

N409815

North America, Spanish

N204114

N409814

All Others (Text Free)

N409946 (use alternate location)

N409944

NOTE: Complete instructions on downloading and installing Software Payload are given in PC20380 DOWNLOAD SOFTWARE PAYLOAD Installation Instruction.

N105938 —UN—04SEP13

Order software part number KK21835 through JDPoint. Machine model number and serial number are required at time of order. Download of updated software through Service ADVISOR™ Software Delivery System is required.

Direct Injection software is the same for both high and low-volume pumps. Software does not need to be ordered for each pump on the machine.

Alternate Location

318.Download and Install Software Payload: Download Software Payload through Service ADVISOR™ Software Delivery Service.

B—Decal

N105937 —UN—04SEP13

A—Decal

N105936 —UN—04SEP13

If the machine has multiple pumps, the following instructions must be followed for each individual pump to update software on the machine.

Service ADVISOR is a trademark of Deere & Company Continued on next page

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PN=188

BKK10302, BKK10303, BKK10304, BKK10305

NOTE: Disconnect all injection pumps that are not being programmed at this time.

319.Disconnect pump connector (A) from direct injection harness (B).

A—Pump Connector

N111100 —UN—25MAR14

320.Assign the connected pump as Pump #1.

B—Direct Injection Harness

Single Pump, 100 gal System Shown CS12167,0000B03 -19-05APR18-101/107

321.Select a pump for setup on the GreenStar™ 3 2630 Display. a. Select Menu button (A). b. Select pump button (B) of the pump to be set up.

B—Pump Button

N106032 —UN—28AUG13

A—Menu Button

GreenStar is a trademark of Deere & Company CS12167,0000B03 -19-05APR18-102/107

322.Select a pump for setup on the CommandCenter™ display. a. Select Menu button (A).

N133483 —UN—27NOV17

A—Menu Button

CommandCenter is a trademark of Deere & Company Continued on next page

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PN=189

BKK10302, BKK10303, BKK10304, BKK10305

b. Select the applications tab (A). c. Select the ISOBUS VT application (B).

B—ISOBUS VT Application N133484 —UN—27NOV17

A—Applications Tab

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d. Select setup button (A) and select Raven Industries. e. Select pump button (B) of the pump to be set up.

B—Pump Button

N133485 —UN—27NOV17

A—Setup Button

CS12167,0000B03 -19-05APR18-105/107

323.Select Tools softkey (A) from Direct Injection Main Page.

N93500 —UN—23APR12

A—Tools Softkey

Continued on next page

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041118

PN=190

BKK10302, BKK10303, BKK10304, BKK10305

324.Select Info Tab (A). Product information appears.

325.Select Pump #1 from drop-down menu (B). Pumps #1, #2, and #3 are available.

326.Select the direct injection software, and load it from Service ADVISOR™.

N93830 —UN—22AUG11

NOTE: If all injection pump options and features are not available after programming, then programming was not successful. Perform programming procedure again if necessary to obtain all injection pump options.

327.System Test: Test the DI system with water after installation is complete to ensure that there are no system leaks and that it functions properly.

Refer to the following DI Operation Manual procedures:

• Fill Chemical Tank • Priming Injection Pump • Rinse System • Drain Chemical Tanks

A—Info Tab

B—Drop-Down Menu

• Prepare Direct Injection System for Storage • Shipping Machine During Cold-Weather Months

If machine is going into storage or cold weather:

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189

041118

PN=191

BKK10302, BKK10303, BKK10304, BKK10305

KK43425 (11APR18)

190

041118

PN=192