JOHN DEERE R4030 SELF-PROPELLED SPRAYER TM115819 SERVICE MANUAL

R4030, R4038, R4045 SelfPropelled Sprayer Diagnostic

DIAGNOSIS AND TESTS MANUAL R4030, R4038 & R4045 Self-Propelled Sprayers TM115819 04 DEC 15 (ENGLISH)

For complete service information also see: DN456 and DN485 Dry Spinner Spreader

TM128419

R4045 Self-Propelled Sprayer Repair

TM116119

R4030 and R4038 Self-Propelled Sprayer Repair

TM115919

JDLink (MTG) Technical Manual

TM114519

GreenStar 3 2630 Display Technical Solutions Manual

TM112219

JDPS Master Tool Manual

TM111119

Alternators and Starting Motors

CTM77

CTM441 - Machine Connection Information

CTM441

120 Series Hydraulic Cylinders

CTM12051

PowerTech 6068 OEM Diesel Engines (Final Tier 4/Stage IV platform) Level 33 ECU

9

6090 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV platform) 6090 PowerTech Diesel Engines (Stage II Emissions) Level 24 ECU 6068 PowerTech Diesel Engine (Stage II platform) Level 24 ECU

CTM12001 9 CTM11771 9 CTM11541 9 CTM11471 9

John Deere Agriculture

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TM115819-DIAGNOSIS AND TESTS MANUAL

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Table of contents FOREWORD Section 210 - GENERAL INFORMATION Group 05 - Safety Group 10 - General References Group 15 - Diagnostic and Testing Procedures Section 211 - DIAGNOSTIC TROUBLE CODES Group 1 - Dry Spinner Spreader - DRC — Diagnostic Trouble Codes Group 2 - ASM — Diagnostic Trouble Codes Group 3 - ASU — Diagnostic Trouble Codes Group 4 - ATC — Diagnostic Trouble Codes Group 5A - BH1 — Diagnostic Trouble Codes Group 5B - BH2 — Diagnostic Trouble Codes Group 6 - CC1 — Diagnostic Trouble Codes Group 7 - CC2 — Diagnostic Trouble Codes Group 8 - CLC — Diagnostic Trouble Codes Group 9 - CSM — Diagnostic Trouble Codes Group 10A - ECU — Level 24 — Diagnostic Trouble Codes Group 10B - ECU — Level 33— Diagnostic Trouble Codes Group 11 - EIC — Diagnostic Trouble Codes Group 12 - FCC — Diagnostic Trouble Codes Group 13 - iTC — Diagnostic Trouble Codes Group 14 - JDL — Diagnostic Trouble Codes Group 15 - LCC — Diagnostic Trouble Codes Group 16 - OIC — Diagnostic Trouble Codes Group 17 - PDU — Diagnostic Trouble Codes Group 18 - RG3 — Diagnostic Trouble Codes Group 19 - RLC — Diagnostic Trouble Codes Group 20A - SR1 — Diagnostic Trouble Codes Group 20B - SR2 — Diagnostic Trouble Codes Group 21 - TEC — Diagnostic Trouble Codes Group 22 - TEI — Diagnostic Trouble Codes Group 23 - VLC — Diagnostic Trouble Codes Group 24 - VTi — Diagnostic Trouble Codes Group 25 - XMC — Diagnostic Trouble Codes Group 26 - XSC — Diagnostic Trouble Codes Section 212 - OBSERVABLE SYMPTOM AND SYSTEM DIAGNOSTICS Group 40 - Electrical Group 45 - Electronic Control Units Group 50 - Drivetrain Group 60 - Steering and Brakes Group 70 - Hydraulics and Pneumatics Group 80 - Solution System Group 90 - Heating, Ventilation, and Air Conditioning Group 140 - Dry Application System — Electrical Group 145 - Dry Application System — Control Unit Group 170 - Dry Application System — Hydraulics Section 220 - ENGINE Group 05 - General Information Group 10 - Engine Systems Section 230 - FUEL, AIR INTAKE, EXHAUST AND COOLING Group 05 - General Information Group 10 - Fuel, Air Intake, Exhaust and Cooling Systems <- Go to Global Table of contents

TM115819-DIAGNOSIS AND TESTS MANUAL

TM115819-DIAGNOSIS AND TESTS MANUAL

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Section 240 - ELECTRICAL Group 05 - General Information Group 20A - Theory of Operation—Application System Group 20B - Theory of Operation—Boom Group 20C - Theory of Operation—Cab Group 20D - Theory of Operation—CAN Bus Group 20E - Theory of Operation—Engine Group 20F - Theory of Operation—GreenStar Group 20G - Theory of Operation—Hydraulic Electrical Group 20H - Theory of Operation—Lighting Group 20I - Theory of Operation—Power Train Group 20J - Theory of Operation — Starting-Charging-Power Distribution Group 30A - Schematic—Application System Group 30B - Schematic—Boom Group 30C - Schematic—Cab Group 30D - Schematic—CAN Bus Group 30E - Schematic—Engine Group 30F - Schematic—GreenStar Group 30G - Schematic—Hydraulic Electrical Group 30H - Schematic—Lighting Group 30I - Schematic—Power Train Group 30J - Schematic—Starting, Charging and Power Distribution Group 50A - Diagnostics—Application System Group 50B - Diagnostics—Boom Group 50C - Diagnostics—Cab Group 50D - Diagnostics—CAN Bus Group 50F - Diagnostics—GreenStar Group 50G - Diagnostics—Hydraulic Electrical Group 50H - Diagnostics—Lighting Group 50I - Diagnostics—Power Train Group 50J - Diagnostics—Starting, Charging and Power Distribution Section 245 - ELECTRONIC CONTROL UNITS Group 05 - General Information Group 10B - Control Unit Addresses Group 10C - Programming Electronic Control Units Group 20 - Theory of Operation Group 30 - Schematic Section 249 - ELECTRICAL COMPONENT INFORMATION Group 40A - Electrical Assemblies Group 40B - Sensors Group 40D - Diodes Group 40E - Lights Group 40F - Fuses Group 40G - Charging Group 40H - Monitoring Devices Group 40K - Relays Group 40M - Motors Group 40R - Resistors Group 40S - Switches Group 40X - Interconnects and Ground Points Group 40Y - Electronically Actuated Mechanical Devices Section 250 - DRIVETRAIN Group 05 - General Information

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TM115819-DIAGNOSIS AND TESTS MANUAL

TM115819-DIAGNOSIS AND TESTS MANUAL

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Group 20 - Theory of Operation Group 30 - Schematic Group 50 - Diagnostic Tests and Adjustments Section 259 - DRIVETRAIN COMPONENT INFORMATION Group 40B - Sensor and Gauge Group 40C - Cylinder Group 40F - Filter Group 40G - Assembly Group Group 40H - Oil Cooler Group 40M - Motor Group 40P - Pump Group 40R - Reservoir Group 40V - Hydraulic Valve Group 40X - Coupler or Diagnostic Coupler Group 40Y - Solenoid Section 260 - STEERING, BRAKES AND TREAD ADJUST Group 20 - Theory of Operation Group 30 - Schematic Group 50 - Diagnostic Tests and Adjustments Section 260A - STEERING Group 20 - Theory of Operation Group 30 - Schematic Group 50 - Diagnostic Tests and Adjustments Section 260B - PARK BRAKE Group 20 - Theory of Operation Group 30 - Schematic Group 50 - Diagnostic Tests and Adjustments Section 260C - SERVICE BRAKES Group 20 - Theory of Operation Group 30 - Schematic Group 50 - Diagnostic Tests and Adjustments Section 269 - STEERING AND BRAKES COMPONENT INFORMATION Group 40C - Cylinder Group 40D - Check Valve Group 40F - Filter Group 40G - Assembly Group Group 40O - Orifice Group 40P - Pump Group 40V - Valve Group 40X - Coupler or Diagnostic Receptacle Group 40Y - Solenoid Section 270 - HYDRAULICS AND PNEUMATICS Group 05 - General Information Group 10 - Test Procedures and Adjustments Group 20A - Theory of Operation—Air Dryer System Group 20B - Theory of Operation—Application System Group 20C - Theory of Operation—Basic Hydraulic System Group 20D - Theory of Operation—Boom Group 30A - Schematic—Application System Group 30B - Schematic—Basic Hydraulic System Group 30C - Schematic—Boom Group 50A - Diagnostics—Air Dryer System Group 50B - Diagnostics—Application System

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TM115819-DIAGNOSIS AND TESTS MANUAL

TM115819-DIAGNOSIS AND TESTS MANUAL

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Group 50C - Diagnostics—Basic Hydraulic System Group 50D - Diagnostics—Boom Section 279 - HYDRAULICS COMPONENT INFORMATION Group 40A - Accumulators Group 40B - Sensors or Gauges Group 40C - Cylinder, Actuator, or Piston Group 40D - Check Valve Group 40F - Filter Group 40G - Valve Block, Assembly, or Gearcase Group 40O - Orifice Group 40P - Pump Group 40V - Valve Group 40X - Coupler or Diagnostic Receptacle Group 40Y - Solenoid Valve Section 280 - SOLUTION SYSTEM Group 20 - Theory of Operation Group 30 - Schematic Group 50 - Diagnostics Section 289 - SOLUTION SYSTEM COMPONENT INFORMATION Group 05 - General Information Group 40A - Accumulators Group 40B - Sensors Group 40D - Check Valves Group 40F - Filters Group 40G - Valve Block, Assembly, or Gearcase Group 40M - Motors Group 40O - Orifices Group 40P - Pumps Group 40R - Reservoirs Group 40V - Valves Group 40X - Diagnostic Receptacle or Coupler Section 290 - HEATING, VENTILATING, AND AIR CONDITIONING SYSTEM Group 20 - Theory of Operation — HVAC Group 30 - Schematic — HVAC Group 50 - Diagnostics — HVAC Section 300 - SPECIAL TOOLS Group 10 - Service Tools and Kits Section 340 - DRY SPINNER SPREADER - ELECTRICAL Group 05 - General Information Group 20A - Application System Theory of Operation Group 20B - CAN Bus Theory of Operation Group 20C - Lighting Theory of Operation Group 30A - Application System Schematic Group 30B - CAN Bus Schematic Group 30C - Lighting Schematic Group 50A - Application System Diagnostic Group 50B - CAN Bus Diagnostic Group 50C - Lighting Diagnostic Group 50D - Diagnostic Tests and Adjustments Section 345 - DRY SPINNER SPREADER - ELECTRONIC CONTROL UNITS Group 05 - General Information Group 20 - Theory of Operation Group 30 - Schematic

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TM115819-DIAGNOSIS AND TESTS MANUAL

TM115819-DIAGNOSIS AND TESTS MANUAL

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Group 50 - Diagnostic Group 50A - Diagnostic Tests and Adjustments Group 50B - DRC Addresses Section 349 - DRY SPINNER SPREADER - ELECTRICAL COMPONENT INFORMATION Group 40A - Electrical Assemblies Group 40B - Sensors Group 40E - Lights Group 40M - Motors Group 40X - Interconnects and Ground Points Group 40Y - Electronically Actuated Mechanical Devices Section 370 - DRY SPINNER SPREADER - HYDRAULIC Group 05 - General Information Group 20 - Theory of Operation Group 30 - Schematic Group 50 - Diagnostic Section 379 - DRY SPINNER SPREADER - HYDRAULIC COMPONENT INFORMATION Group 40M - Motors Group 40V - Valves Group 40Y - Solenoid Valve

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TM115819-DIAGNOSIS AND TESTS MANUAL

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

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TM115819-DIAGNOSIS AND TESTS MANUAL

GENERAL INFORMATION

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Foreword The diagnostic technical manual is written for an experienced technician. Essential tools required to perform certain type of work are identified in Section 300, and are recommended for use.

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

CAUTION: This is the safety-alert symbol. When the symbol is shown on the equipment or in a manual, be alert to the potential for personal injury.

Diagnostic technical manuals are comprised of general information, checks, theory of operation, schematic and diagnostic procedures. Sections in a diagnostic technical manual help quickly identify the likely cause of routine failures. Component sections include images of the component or connector and location on the equipment.

The diagnostic technical manual references component manuals and repair technical manuals. Repair technical manuals are organized for various components requiring service instruction.

Both diagnostic and repair technical manuals are concise guides for specific equipment. They are on-the-job instructions containing vital information to diagnose, analyze, test, and repair the equipment.

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Section 210 page 1

TM115819-DIAGNOSIS AND TESTS MANUAL

TM115819-DIAGNOSIS AND TESTS MANUAL

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Section 210 - GENERAL INFORMATION Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 1 Avoid High-Pressure Fluids ................................................................................................................... 2 Park Machine Safely ............................................................................................................................. 2 Wait Before Opening High-Pressure Fuel System ................................................................................. 3 Clean Exhaust Filter Safely ................................................................................................................... 3 Exhaust Filter Cleaning ......................................................................................................................... 5 Service Accumulator Systems Safely .................................................................................................... 6 Handle Fluids Safely—Avoid Fires ......................................................................................................... 6 Prevent Battery Explosions ................................................................................................................... 7 Prepare for Emergencies ...................................................................................................................... 7 Protect Against High Pressure Spray .................................................................................................... 8 Prevent Acid Burns ............................................................................................................................... 9 Wear Protective Clothing .................................................................................................................... 10 Protect Against Noise ......................................................................................................................... 10 Handle Agricultural Chemicals Safely ................................................................................................. 10 Service and Operate Chemical Sprayers Safely .................................................................................. 11 Avoid Contact with Agricultural Chemicals ......................................................................................... 12 Clean Vehicle of Hazardous Pesticides ............................................................................................... 13 Support Machine Properly .................................................................................................................. 14 Service Machines Safely ..................................................................................................................... 14 Practice Safe Maintenance ................................................................................................................. 15 Avoid Harmful Asbestos Dust ............................................................................................................. 15 Work In Ventilated Area ...................................................................................................................... 16 Work in Clean Area ............................................................................................................................. 16 Precautions for Welding ...................................................................................................................... 18 Remove Paint Before Welding or Heating ........................................................................................... 19 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 20 Service Tires Safely ............................................................................................................................ 21 Service Cooling System Safely ........................................................................................................... 21 Illuminate Work Area Safely ............................................................................................................... 22 Replace Safety Signs .......................................................................................................................... 22 Use Proper Lifting Equipment ............................................................................................................. 23 Use Proper Tools ................................................................................................................................. 23 Construct Dealer-Made Tools Safely ................................................................................................... 23 Decommissioning: Proper Recycling and Disposal of Fluids and Components ................................... 24 Live With Safety ................................................................................................................................. 25 Group 10 - General References ............................................................................................................ 26 Trademarks ........................................................................................................................................ 26 Glossary of Terms ............................................................................................................................... 28 Machine Specifications ....................................................................................................................... 29 Dimensions—All Machines .................................................................................................................. 35 Standard Machine Dimensions ........................................................................................................... 36 Identification Numbers ....................................................................................................................... 37 Sealants and Adhesives Cross-Reference Chart ................................................................................. 40 Face Seal Fittings Assembly and Installation—All Pressure Applications ............................................ 41 Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures ............................. 42 Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications ................. 43

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TM115819-DIAGNOSIS AND TESTS MANUAL

TM115819-DIAGNOSIS AND TESTS MANUAL

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SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures ................................. 44 SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications ..................... 45 Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications ................................. 45 SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications ............................. 47 SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications .................................... 48 External Hexagon Port Plug Torque Chart .......................................................................................... 49 Unified Inch Bolt and Screw Torque Values ........................................................................................ 50 Metric Bolt and Screw Torque Values ................................................................................................. 51 Servicing and Connecting Snap to Connect STC Fittings .................................................................... 52 Group 15 - Diagnostic and Testing Procedures ................................................................................ 54 Troubleshooting .................................................................................................................................. 54

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TM115819-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL INFORMATION

Group 05: Safety

Group 05 - Safety Recognize Safety Information

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

Follow recommended precautions and safe operating practices.

Understand Signal Words

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

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

CAUTION also calls attention to safety messages in this manual.

Follow Safety Instructions

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Section 210 page 1

TM115819-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL INFORMATION

Group 05: Safety

Safety Messages Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition.

Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator′s manual.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

Avoid High-Pressure Fluids

High Pressure 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.

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Section 210 page 2

TM115819-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL INFORMATION

Group 05: Safety

Park Machine Safely

Remove the Key Before working on the machine: 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.

Wait Before Opening High-Pressure Fuel System

High-Pressure Fuel Lines High-pressure fluid remaining in fuel lines can cause serious injury. Only technicians familiar with this type of system should perform repairs. Before disconnecting fuel lines, sensors, or any other components between the high-pressure fuel pump and nozzles on engines with High-Pressure Common Rail (HPCR) fuel system, confirm that the fuel pressure is relieved.

Clean Exhaust Filter Safely

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Section 210 page 3

TM115819-DIAGNOSIS AND TESTS MANUAL

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