REPAIR MANUAL - JOHN DEERE 4730 SELF-PROPELLED SPRAYERS (PIN PREFIX 1NW) TM802519

4730 Self-Propelled Sprayer Repair

REPAIR MANUAL Self-Propelled Sprayers Brazil models 4730 TM802519 06 SEP 13 (ENGLISH)

For complete service information also see: 4730 Self-Propelled Sprayer Diagnosis and Tests

TM80241

GreenStar 3 2630 Display Technical Solutions Manual

9

PowerTech 4045, 6068 Diesel Engine Level 14 Electronic Fuel System with the Denso High Pressure Common Rail (HPCR) Level 14 ECU

TM11221

PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine)

9 CTM320 CTM104

John Deere Agriculture

Pinted by Belgreen

4730 Self-Propelled Sprayer Repair

(g) by Belgreen v2.5

Table of contents FOREWORD Section 10 - GENERAL INFORMATION Group 05 - Safety Group 10 - General Information Group 15 - Fuels and Lubricants Section 20 - ENGINE Group 00 - Component Removal and Installation Section 30 - FUEL, AIR INTAKE, AND COOLING SYSTEMS Group 10 - Diesel Fuel System Group 15 - Air Intake System Group 20 - Engine Cooling System Group 25 - Oil and Fuel Coolers and Air Conditioning Condenser Section 40 - ELECTRICAL Group 05 - Batteries Group 10 - Connector Repair Group 15 - Charging Circuit Group 20 - Starting Circuit Group 25 - Switches and Relays Group 30 - Monitoring Systems and Sensors Group 32 - Engine Control System Group 35 - Lights Group 40 - Convenience and Accessory Components Group 45 - Wiring Harness Routing Group 50 - Boom Trac Pro System Section 50 - POWER TRAIN REPAIR Group 05 - Remove and Install Hydrostatic Components Group 10 - Hydrostatic Drive Repair Group 15 - Planetary Hub Repair Section 60 - STEERING AND BRAKES Group 05 - Steering Column Group 10 - Steering Valve Group 12 - AutoTrac™ Steering System Group 15 - Steering Cylinder Group 20 - Service Brakes Group 25 - Park Brakes Section 61 - SUSPENSION AND TREAD ADJUST REPAIR Group 05 - Suspension Group 10 - Tread Adjust Valves Group 15 - Tread Adjust Cylinders Group 20 - Tread Adjust Shim Pads Section 70 - HYDRAULIC SYSTEM Group 05 - Hydraulic Pump Group 10 - Hydraulic Valves Group 15 - Boom Hydraulic Cylinders Group 20 - Hydraulic Oil Cooler Group 25 - Hydraulic Reservoir Group 30 - Accumulator Group 35 - Retractable Ladder Section 80 - SOLUTION SPRAY SYSTEM Group 05 - Nozzle Repair Group 10 - Solution Tank Group 15 - Solution Pump <- Go to Global Table of contents

4730 Self-Propelled Sprayer Repair

4730 Self-Propelled Sprayer Repair

(g) by Belgreen v2.5

Group 20 - Solution Control Valves Group 25 - Rinse Tank Group 30A - Stainless Steel Eductor Group 30B - Plastic Eductor Section 81 - ON BOARD AIR SYSTEM Group 05 - Component Removal Group 10 - Air Dryer Section 90 - OPERATOR STATION Group 05 - Component Removal and Installation Group 10 - Controls Group 15 - Air Conditioning System Group 20 - Heating System Group 25 - Air Suspension Seat Group 30 - Cab Door and Windshield Section 100 - BOOM REPAIR Group 05 - Boom Repair Section 199 - DEALER FABRICATED TOOLS Group 05 - Dealer Fabricated Tools

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4730 Self-Propelled Sprayer Repair

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 10 page 1

4730 Self-Propelled Sprayer Repair

4730 Self-Propelled Sprayer Repair

(g) by Belgreen v2.5

Section 10 - 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 Park Machine Safely ............................................................................................................................. 3 Servicing Electronic Control Units ......................................................................................................... 3 Welding Near Electronic Control Units .................................................................................................. 5 Keep Electronic Control Unit Connectors Clean .................................................................................... 5 Handle Fluids Safely—Avoid Fires ......................................................................................................... 6 Prevent Battery Explosions ................................................................................................................... 6 Prepare for Emergencies ...................................................................................................................... 7 Protect Against High Pressure Spray .................................................................................................... 7 Prevent Acid Burns ............................................................................................................................... 8 Wear Protective Clothing ...................................................................................................................... 9 Handle Agricultural Chemicals Safely ................................................................................................... 9 Avoid Contact with Agricultural Chemicals ......................................................................................... 10 Clean Vehicle of Hazardous Pesticides ............................................................................................... 11 Decontaminate Spray Equipment ....................................................................................................... 11 Support Machine Properly .................................................................................................................. 12 Service Machines Safely ..................................................................................................................... 12 Practice Safe Maintenance ................................................................................................................. 14 Avoid Harmful Asbestos Dust ............................................................................................................. 14 Work In Ventilated Area ...................................................................................................................... 15 Work in Clean Area ............................................................................................................................. 15 Remove Paint Before Welding or Heating ........................................................................................... 16 Precautions for Welding ...................................................................................................................... 17 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 19 Avoid High-Pressure Fluids ................................................................................................................. 19 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 Dispose of Waste Properly .................................................................................................................. 24 Handle Electronic Components and Brackets Safely .......................................................................... 24 Live With Safety ................................................................................................................................. 25 Group 10 - General Information ........................................................................................................... 26 Machine Specification ......................................................................................................................... 26 Dimensions ......................................................................................................................................... 31 Dimensions—All Machines .................................................................................................................. 32 Identification Numbers ....................................................................................................................... 33 Sealants and Adhesives Cross-Reference Chart ................................................................................. 36 Face Seal Fittings Assembly and Installation—All Pressure Applications ............................................ 36 Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures ............................. 38 Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications ................. 39 SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures ................................. 40

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4730 Self-Propelled Sprayer Repair

4730 Self-Propelled Sprayer Repair

(g) by Belgreen v2.5

SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications ..................... 41 Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications ................................. 41 SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications ............................. 43 SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications .................................... 44 External Hexagon Port Plug Torque Chart .......................................................................................... 45 Identifying Zinc-Flake Coated Fasteners ............................................................................................ 45 Metric Bolt and Screw Torque Values ................................................................................................. 47 Unified Inch Bolt and Screw Torque Values ........................................................................................ 48 Glossary of Terms ............................................................................................................................... 49 Preparing and Painting Sprayer Components ..................................................................................... 50 Programming Control Units ................................................................................................................ 51 Group 15 - Fuels and Lubricants ......................................................................................................... 53 Diesel Fuel .......................................................................................................................................... 53 Testing Diesel Fuel ............................................................................................................................. 53 Handling and Storing Diesel Fuel ........................................................................................................ 53 Lubricity of Diesel Fuel ....................................................................................................................... 54 Diesel Engine Coolant (engine with wet sleeve cylinder liners) .......................................................... 55 Testing Diesel Engine Coolant ............................................................................................................ 56 Supplemental Coolant Additives ......................................................................................................... 56 Operating in Warm Temperature Climates ......................................................................................... 57 Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER ..................................................................................................................................................... 58 Diesel Engine Break-In Oil .................................................................................................................. 60 Diesel Engine Oil ................................................................................................................................ 61 Extended Diesel Engine Oil Service Intervals ..................................................................................... 62 Hydrostatic and Hydraulic Drive Oil .................................................................................................... 63 Planetary Hub Oil ................................................................................................................................ 64 Grease ................................................................................................................................................ 65 Suspension and Steering Grease ........................................................................................................ 65 Alternative and Synthetic Lubricants .................................................................................................. 65 Lubricant Storage ............................................................................................................................... 66

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4730 Self-Propelled Sprayer Repair

Section 10 - 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 10 page 1

4730 Self-Propelled Sprayer Repair

Section 10 - 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 10 page 2

4730 Self-Propelled Sprayer Repair

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Section 10 - 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.

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.

Servicing Electronic Control Units

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Section 10 page 3

4730 Self-Propelled Sprayer Repair

Section 10 - GENERAL INFORMATION

Group 05: Safety

Electronic Control Unit [1] IMPORTANT: Do not open control unit and do not clean with a high pressure spray. Moisture, dirt and other contaminants may cause permanent damage.

Control units are not repairable; replace only if indicated in the diagnostic procedure.

[2] - Since control units are the components LEAST likely to fail, isolate failure before replacing by completing the diagnostic procedure.

[3] - The wiring harness terminals and connectors for electronic control units are repairable.

[4] IMPORTANT: Misleading diagnostic messages and poor performance may occur if an electronic control unit is not programmed identical to the original controller.

Before putting back into service, verify the control unit is programmed identical to the original controller.

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Section 10 page 4

4730 Self-Propelled Sprayer Repair

Section 10 - GENERAL INFORMATION

Group 05: Safety

Welding Near Electronic Control Units

Welding Graphic [1] IMPORTANT: Do not jump-start engines with arc welding equipment. Currents and voltages are too high and may cause permanent damage.

Disconnect the negative (-) battery cable(s).

[2] - Disconnect the positive (+) battery cable(s).

[3] - Connect the positive and negative cables together. Do not attach to vehicle frame.

[4] - Clear or move any wiring harness sections away from welding area.

[5] - Connect welder ground close to welding point and away from control units.

[6] - After welding, reverse Steps 1—5.

Keep Electronic Control Unit Connectors Clean [1] IMPORTANT: Keep terminals clean and free of foreign debris. Moisture, dirt and other contaminants may cause the terminals to erode over time and not make a good electrical connection.

If a connector is not in use, put on the proper dust cap or an appropriate seal to protect it from foreign debris and moisture.

[2] IMPORTANT: Do not probe through the wire insulation or through the back of the connector. Do not insert items such as paper clips or wires into connector terminals. <- Go to Section TOC

Section 10 page 5

4730 Self-Propelled Sprayer Repair

Section 10 - GENERAL INFORMATION

Group 05: Safety

Make measurements on a connector terminal using JDG10466 Flex Probe Kit in SERVICEGARD. Flex Probe Kit JDG10466 Measure connector terminal.

[3] - Observe the locking mechanism of the connector when disconnecting and reconnecting.

[4] - Do not pull on wires to disconnect.

[5] - Before reconnecting: Look for bent terminals; do not force connectors into each other.

Replace any terminal where corrosion exists.

Clean the connector of any foreign debris.

Dry the connector of any moisture.

[6] - When reconnecting, make sure seals around the connector pairs are functional.

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

Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. <- Go to Section TOC

Section 10 page 6

4730 Self-Propelled Sprayer Repair

Section 10 - GENERAL INFORMATION

Group 05: Safety

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 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 10 page 7

4730 Self-Propelled Sprayer Repair

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Section 10 - GENERAL INFORMATION

Group 05: Safety

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

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Section 10 page 13

4730 Self-Propelled Sprayer Repair

Section 10 - GENERAL INFORMATION

Group 05: Safety

Prevent Acid Burns

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

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

2.Wearing eye protection and rubber gloves.

3.Avoiding breathing fumes when electrolyte is added.

4.Avoiding spilling or dripping electrolyte.

5.Use proper jump start procedure.

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

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

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

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

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

3.Get medical attention immediately.

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Section 10 page 8

4730 Self-Propelled Sprayer Repair

Section 10 - GENERAL INFORMATION

Group 05: Safety

Wear Protective Clothing

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

Prolonged exposure to loud noise can cause impairment or loss of hearing.

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

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

Handle Agricultural Chemicals Safely

Safety

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Section 10 page 9

4730 Self-Propelled Sprayer Repair

Section 10 - GENERAL INFORMATION

Group 05: Safety

Safety Chemicals used in agricultural applications such as fungicides, herbicides, insecticides, pesticides, rodenticides, and fertilizers can be harmful to your health or the environment if not used carefully.

Always follow all label directions for effective, safe, and legal use of agricultural chemicals.

Reduce risk of exposure and injury: Wear appropriate personal protective equipment as recommended by the manufacturer. In the absence of manufacturer′s instructions, follow these general guidelines: Chemicals labeled′Danger′ : Most toxic. Generally require use of goggles, respirator, gloves, and skin protection.

Chemicals labeled′Warning′ : Less toxic. Generally require use of goggles, gloves, and skin protections.

Chemicals labeled′Caution′ : Least toxic. Generally require use of gloves and skin protection.

Avoid inhaling vapor, aerosol or dust.

Always have soap, water, and towel available when working with chemicals. If chemical contacts skin, hands, or face, wash immediately with soap and water. If chemical gets into eyes, flush immediately with water.

Wash hands and face after using chemicals and before eating, drinking, smoking, or urination.

Do not smoke or eat while applying chemicals.

After handling chemicals, always bathe or shower and change clothes. Wash clothing before wearing again.

Seek medical attention immediately if illness occurs during or shortly after use of chemicals.

Keep chemicals in original containers. Do not transfer chemicals to unmarked containers or to containers used for food or drink.

Store chemicals in a secure, locked area away from human or livestock food. Keep children away.

Always dispose of containers properly. Triple rinse empty containers and puncture or crush containers and dispose of properly.

Avoid Contact with Agricultural Chemicals

Harmful Pesticides

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Section 10 page 10

4730 Self-Propelled Sprayer Repair

Section 10 - GENERAL INFORMATION

Group 05: Safety

Pesticide Use CAUTION: This enclosed cab does not protect against inhaling vapor, aerosol or dust.

[1] - When operating in an environment where pesticides are present, wear a long-sleeved shirt, long-legged pants, shoes, and socks.

[2] - If pesticide use instructions require respiratory protection, wear an appropriate respirator inside the cab.

[3] - Wear personal protective equipment as required by the pesticide use instructions when leaving the enclosed cab: into a treated area to work with contaminated application equipment such as nozzles which must be cleaned, changed or redirected to become involved with mixing and loading activities [4] - Before re-entering the cab, remove protective equipment and store either outside the cab in a closed box or some other type of sealable container or inside the cab in a pesticide resistant container, such as a plastic bag.

[5] - Clean your shoes or boots to remove soil or other contaminated particles prior to entering the cab.

Clean Vehicle of Hazardous Pesticides CAUTION: During application of hazardous pesticides, pesticide residue can build up on the inside or outside of the vehicle. Clean vehicle according to use instructions of hazardous pesticides.

When exposed to hazardous pesticides, 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.

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

Decontaminate Spray Equipment

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Section 10 page 11

4730 Self-Propelled Sprayer Repair

Section 10 - GENERAL INFORMATION

Group 05: Safety

CAUTION: Decontaminate all spraying equipment before servicing. Decontamination should be done in a safe area by washing with water, neutralization, or by means recommended by the manufacturer of the chemical last used.

Spray solutions or vapors may be extremely dangerous. Treat all spray chemicals, solutions, or solution residues with great caution. Don′t take chances. When in doubt, proceed as though contamination is present.

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

Support Machine Properly

Support Properly Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator′s manual.

Service Machines Safely

Moving Parts Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. <- Go to Section TOC

Section 10 page 12

4730 Self-Propelled Sprayer Repair

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