JOHN DEERE 5430I DEMOUNTABLE SELF-PROPELLED CROP SPRAYER TM402319 PDF

5430i Chemical Application Vehicle and Demountable Crop Sprayer Diagnostic

DIAGNOSIS AND TESTS MANUAL Self-Propelled Sprayers models 5430i TM402319 20 JUN 14 (ENGLISH)

For complete service information also see: 5430i Chemical Application Vehicle and Demountable Crop Sprayer Repair

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Pinted by Belgreen

TM402319-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD Section 210 - GENERAL INFORMATION Group 05 - Safety Group 10 - General References Section 211 - DIAGNOSTIC TROUBLE CODES (DTC) Group 5A - ECU - Control Unit Group 5B - BHC - Boom Hydraulic Control Unit Group 5C - CLC - Control Unit Group 5D - CCU - Control Unit Group 5E - SRC - Control Unit Group 5F - ACU - Armrest Control Unit Group 5G - ITC - StarFire Group 5H - SSU - AutoTrac Control Unit Section 212 - OBSERVABLE SYMPTOMS Group 220 - Engine Group 230 - Air Intake and Cooling Group 240 - Electrical System Group 250 - Power Train Group 260 - Brakes Group 270 - Hydraulics Group 275 - Tread Adjust Group 280 - Steering Group 290 - Cab — Air Conditioning and Heating Group 300 - Solution System Group 320 - Pneumatic System Section 220 - ENGINE Group 05 - General Information Group 15 - Engine Diagnostics Section 230 - AIR INTAKE AND COOLING SYSTEMS Group 05 - General Information Group 15A - Air Intake System Group 15B - Intercooler and Hydraulic Oil Cooling System Group 15C - Engine Cooling System Group 20 - Component Location Section 240 - ELECTRICAL SYSTEM Group 05A - Electrical Schematics Overview Group 05B - Component Identification Group 10A - Accessing Diagnostic Codes and Addresses Group 10B - Diagnostic Addresses Group 10C - GS2 Display Diagnostic Information Group 15A - Air Seat Group 15B - Air Conditioning and Heating Group 15C - Air Filter Restriction Group 15D - Auxiliary Power Group 15E - Boom Fold/Unfold Group 15F - Boom Raise and Lower Group 15G - Boom Return to Height Group 15H - Boom Tilt Group 15I - BoomTrac — Automatic Boom Leveling Group 15J - Boom Variable Geometry Group 15K - CAN Bus Group 15L - Charging <- Go to Global Table of contents

TM402319-DIAGNOSIS AND TESTS MANUAL

TM402319-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Group 15M - Control Module Power — CLC Group 15N - Control Module Power — SCS-LC Group 15O - Control Module Power — SV-LC Group 15P - Control Module Power — TA-LC Group 15Q - Control Unit Power — ACU Group 15R - Control Unit Power — BHC Group 15S - Control Unit Power — CCU Group 15T - Control Unit Power — ECU Group 15U - Control Unit Power — SRC Group 15V - Control Unit Power — SSU Group 15W - Dome Light Group 15X - Electric Fuel Pump Group 15Y - Engine and Fuel Control Group 15Z - Engine Sensors Group 15AA - Fuel Level Sensor Group 15AB - GreenStar Display Group 15AC - GreenStar GPS Receiver Group 15AD - Horn Group 15AE - Hydraulic Oil Cooler Fan Group 15AF - Hydraulic Oil Temperature Group 15AG - Hydrostatic Boost Group 15AH - Ladder Electrical Group 15AI - Lights - Alert (Caution and Stop) Group 15AJ - Lights - Beacon Group 15AK - Lights - Delay (Egress) Group 15AL - Lights - Field Lights Group 15AM - Lights - Park Lights Group 15AN - Lights - Road Group 15AO - Lights - Trailer Group 15AP - Lights - Warning and Turn Signal Group 15AQ - Multi-Function Lever Group 15AR - Multi-Function Lever Position Group 15AS - Operator Presence Switch Group 15AT - Park (Secondary) Brake Group 15AU - Power Supply Group 15AV - Power Mirror Group 15AW - Radio Group 15AX - Slip Control Group 15AY - Solution Control System Group 15AZ - Solution Pressure System Group 15BA - Solution Pump Oil Level Group 15BB - Solution Pump Speed Group 15BC - Solution Quick Fill System Group 15BD - Solution Tank Level Group 15BE - Solution Transfer System Group 15BF - Speed Range Group 15BG - Spray Valve Control Group 15BH - Starting Aid (Glow Plugs) Group 15BI - Starting System Group 15BJ - AutoTrac Steering Group 15BK - Steering — Four-Wheel Steering Group 15BL - Steering - Secondary Group 15BM - Throttle

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TM402319-DIAGNOSIS AND TESTS MANUAL

TM402319-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Group 15BN - Trailer Brake Group 15BO - Tread Adjust Group 15BP - Wheel Speed Sensor Group 15BQ - Wiper Group 20 - Connector Information Section 250 - POWER TRAIN Group 05A - General Information Group 05B - Component Identification Group 10 - Test Procedures and Adjustments Group 15A - Final Drive Group 15B - Hydrostatic Drive Group 15C - Hydrostatic Pump Boost Group 15D - Slip Control Group 20 - Power Train Components Location Section 260 - BRAKES Group 05A - General Information Group 05B - Component Identification Group 10 - Tests Group 15A - Secondary Brake Group 15B - Service Brake Group 15C - Trailer Brake Section 270 - HYDRAULIC SYSTEM Group 05A - General Information Group 05B - Component Identification Group 10 - Test Procedures Group 15A - Basic Hydraulic System Group 15B - Boom Fold Hydraulic System Group 15C - Boom Raise Hydraulic System Group 15D - Boom Tilt Hydraulic System Group 15E - Boom Variable Geometry Hydraulic System Group 15F - Diaphragm Solution Pump Hydraulic System Group 15G - Ladder Hydraulic System Group 15H - Pressure Washer Hydraulic Group 15I - Quick Fill Pump Motor Hydraulic System Group 20 - Hydraulic Components Location Group 50 - Diagnostic Tests and Adjustments Section 275 - TREAD ADJUST SYSTEM Group 05A - General Information Group 05B - Component Identification Group 15 - Hydraulic Tread Adjust Group 20 - Component Location Section 280 - STEERING SYSTEM Group 05A - General Information Group 05B - Component Identification Group 15A - Steering Hydraulic System Group 15B - Secondary Steering System Group 20 - Component Location Section 290 - OPERATOR′S CAB Group 10 - Operational Checks Group 15 - Tests and Adjustments Group 20A - Heating and Ventilation Group 20B - Air Conditioning System Section 300 - SOLUTION SYSTEM

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TM402319-DIAGNOSIS AND TESTS MANUAL

TM402319-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Group 05 - General Information Group 15A - Solution System — Overall Description Group 15B - Solution System — Spraying Group 15C - Solution System — Agitation Group 15D - Solution System — Rinse Group 15E - Solution System — Eductor Group 15F - Solution System — Load with Diaphragm Pump Group 15G - Solution System — Load with Quick Fill Pump Group 20 - Component Location Section 320 - PNEUMATIC SYSTEM Group 05 - General Information Group 15A - Air System Group 15B - Air Suspension Diagnostics Group 15C - Boom Air Controls Group 20 - Air Suspension Component Location Section 399 - SERVICE TOOLS Group 10 - Service Tools and Kits

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TM402319-DIAGNOSIS AND TESTS MANUAL

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

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TM402319-DIAGNOSIS AND TESTS MANUAL

GENERAL INFORMATION

(g) by Belgreen v2.0

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

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

CAUTION:

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

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

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

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

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

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

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Section 210 page 1

TM402319-DIAGNOSIS AND TESTS MANUAL

TM402319-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Section 210 - GENERAL INFORMATION Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Perform Service Safely ......................................................................................................................... 1 Wait Before Opening High-Pressure Fuel System ................................................................................. 2 Service Accumulator Systems Safely .................................................................................................... 2 Handle Fluids Safely—Avoid Fires ......................................................................................................... 3 Prevent Battery Explosions ................................................................................................................... 3 Prepare for Emergencies ...................................................................................................................... 4 Protect Against High Pressure Spray .................................................................................................... 4 Prevent Acid Burns ............................................................................................................................... 6 Wear Protective Clothing ...................................................................................................................... 7 Handle Agricultural Chemicals Safely ................................................................................................... 7 Service and Operate Chemical Sprayers Safely .................................................................................... 8 Avoid Contact with Agricultural Chemicals ........................................................................................... 9 Clean Vehicle of Hazardous Pesticides ............................................................................................... 10 Support Machine Properly .................................................................................................................. 10 Service Machines Safely ..................................................................................................................... 11 Practice Safe Maintenance ................................................................................................................. 12 Avoid Harmful Asbestos Dust ............................................................................................................. 12 Work In Ventilated Area ...................................................................................................................... 13 Work in Clean Area ............................................................................................................................. 13 Remove Paint Before Welding or Heating ........................................................................................... 14 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 15 Avoid High-Pressure Fluids ................................................................................................................. 15 Service Tires Safely ............................................................................................................................ 17 Service Cooling System Safely ........................................................................................................... 17 Illuminate Work Area Safely ............................................................................................................... 18 Replace Safety Signs .......................................................................................................................... 18 Use Proper Lifting Equipment ............................................................................................................. 19 Use Proper Tools ................................................................................................................................. 19 Construct Dealer-Made Tools Safely ................................................................................................... 19 Dispose of Waste Properly .................................................................................................................. 20 Live With Safety ................................................................................................................................. 20 Group 10 - General References ............................................................................................................ 22 General Information - Inch Bolt and Cap Screws, Torque Values ........................................................ 22 General Information - Metric Bolt and Cap Screws, Torque Values ..................................................... 23 General Information - Hydraulic System Inch Fittings, Torque Values ................................................ 24 General Information - Hydraulic System Metric Fittings, Torque Values ............................................. 25 General Information - Electrical System, Component Identification Table .......................................... 26 General Information - Electrical System, How to Read a Diagnostic Schematic ................................. 27 General Information - Electrical System, Symbols in Schematic, Wiring and Harness Diagrams ....... 29 General Information - Electrical System, Troubleshooting Unsolved Problems .................................. 30 General Information - Electrical System, Worksheet for Circuit/Harness Test .................................... 32 General Information - Electrical System, Visual Check ....................................................................... 33 Types of fault ...................................................................................................................................... 34 General Information - Electrical System, Seven-Step Test Procedure ................................................ 37 General Information - Hydraulic System, Symbols in Circuit Diagrams .............................................. 38

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TM402319-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.

Perform Service Safely

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Section 210 page 1

TM402319-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL INFORMATION

Group 05: Safety

Danger During the assembly, test and adjustments procedures, it may be necessary to operate drives and hydraulic systems. Stay clear of machine elements when folding, unfolding, raising or lowering booms and during operation of hydraulic motors.

Practice good communication with other service technicians. Be aware of their actions and alert them to potential hazards.

Never lubricate, service or adjust machine while it is running. Keep hands, feet and clothing away from power-driven or hydraulically operated parts. If it is necessary to inspect the machine while it is in operation, be alert to moving parts in the immediate area.

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, wait a minimum of 15 minutes after engine is stopped.

Service Accumulator Systems Safely

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Section 210 page 2

TM402319-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL INFORMATION

Group 05: Safety

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

Relieve pressure from the pressurized system before removing accumulator.

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

Accumulators cannot be repaired.

Handle Fluids Safely—Avoid Fires

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

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

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

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

Prevent Battery Explosions

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Section 210 page 3

TM402319-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL INFORMATION

Group 05: Safety

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

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

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

Prepare for Emergencies

First Aid Kit Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

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

Protect Against High Pressure Spray

High Pressure Spray <- Go to Section TOC

Section 210 page 4

TM402319-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL INFORMATION

Group 05: Safety

Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body. If an accident occurs, see a doctor immediately. Any high pressure spray 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 from Deere & Company Medical Department in Moline, Illinois, U.S.A.

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Section 210 page 5

TM402319-DIAGNOSIS AND TESTS MANUAL

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