John Deere 4630 Sprayers Technical Repair Manual TM106119 - PDF DOWNLOAD

4630 Self-Propelled Sprayer Repair

REPAIR TECHNICAL MANUAL Self-Propelled Sprayers models 4630 TM106119 18 AUG 15 (ENGLISH)

For complete service information also see: GreenStar 3 2630 Display Technical Solutions Manual

TM112219

JDPS Master Tool Manual

TM111119

4630 Self-Propelled Sprayer Diagnostic

TM106219

GreenStar 2 Diagnosis and Tests Manual

TM1061

Alternators and Starting Motors

CTM77

PowerTech E 4.5 and 6.8L Diesel Engines Level 16 Electronic Fuel System With Denso HPCR

CTM502

CTM441 - Machine Connection Information

CTM441

120 Series Hydraulic Cylinders

CTM120519

PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage CTM104 IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine) 100 Series Hydraulic Cylinders

CTM103519

John Deere Agriculture Pinted by Belgreen

4630 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 - Remove and Install Components Group 05 - Engine Cooling System Section 30 - FUEL AND AIR Group 00 - Remove and Install Components Group 05 - Diesel Fuel System Section 40 - ELECTRICAL Group 05 - Batteries Group 10 - Connector Repair Group 15 - Charging Circuit Group 20 - Starting Circuit Group 25 - Fuses and Relays Group 30 - Lighting Group 35 - Chassis Control System Group 40 - Engine Control System Group 45 - Spray Rate Control System Group 50 - Boom Control System Group 55 - Cab Components Group 60 - Wiring Harness Routing Section 50 - POWER TRAIN REPAIR Group 00 - Remove and Install Hydrostatic Components Group 05 - Hydrostatic Drive Repair Group 15 - Planetary Hub Repair Section 60 - STEERING AND BRAKES Group 00 - Component Removal and Installation Group 05 - Steering Column Group 10 - Steering Valve Group 15 - Steering Cylinder Group 20 - Service Brakes Section 61 - SUSPENSION AND TREAD ADJUST Group 00 - Component Removal and Installation Group 05 - Tread Adjust Valves Group 10 - Tread Adjust Cylinders Section 70 - HYDRAULIC SYSTEM Group 00 - Component Removal and Installation 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 00 - Component Removal and Installation Group 05 - Nozzle Repair Group 10 - Solution Tank Group 15 - Solution Pump <- Go to Global Table of contents

4630 Self-Propelled Sprayer Repair

4630 Self-Propelled Sprayer Repair

(g) by Belgreen v2.5

Group 20 - Solution Control Valves Group 25 - Rinse Tank Group 30 - Eductor Group 35 - Flow Meter Section 81 - FOAM MARKER SYSTEM Group 00 - Component Removal and Installation Group 05 - Foam Marker System Repair Group 10 - On Board Air System Section 90 - OPERATOR STATION Group 05 - Cab Component Removal and Installation Group 10 - Armrest 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 00 - Component Removal and Installation Section 199 - SPECIAL TOOLS Group 05 - Dealer-Fabricated Tools

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4630 Self-Propelled Sprayer Repair

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4630 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

4630 Self-Propelled Sprayer Repair

4630 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 Handle Fluids Safely—Avoid Fires ......................................................................................................... 3 Prevent Battery Explosions ................................................................................................................... 4 Prepare for Emergencies ...................................................................................................................... 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 Decontaminate Spray Equipment ....................................................................................................... 10 Support Machine Properly .................................................................................................................. 11 Service Machines Safely ..................................................................................................................... 11 Practice Safe Maintenance ................................................................................................................. 13 Avoid Harmful Asbestos Dust ............................................................................................................. 13 Work In Ventilated Area ...................................................................................................................... 14 Work in Clean Area ............................................................................................................................. 14 Remove Paint Before Welding or Heating ........................................................................................... 15 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 16 Avoid High-Pressure Fluids ................................................................................................................. 16 Service Tires Safely ............................................................................................................................ 18 Service Cooling System Safely ........................................................................................................... 18 Illuminate Work Area Safely ............................................................................................................... 19 Replace Safety Signs .......................................................................................................................... 19 Use Proper Lifting Equipment ............................................................................................................. 20 Use Proper Tools ................................................................................................................................. 20 Construct Dealer-Made Tools Safely ................................................................................................... 20 Dispose of Waste Properly .................................................................................................................. 21 Servicing Electronic Control Units ....................................................................................................... 21 Welding Near Electronic Control Units ................................................................................................ 23 Keep Electronic Control Unit Connectors Clean .................................................................................. 23 Handle Electronic Components and Brackets Safely .......................................................................... 24 Live With Safety ................................................................................................................................. 24 Group 10 - General Information ........................................................................................................... 26 Machine Specification ......................................................................................................................... 26 Dimensions ......................................................................................................................................... 30 Dimensions—All Machines .................................................................................................................. 31 Identification Numbers ....................................................................................................................... 33 Sealants and Adhesives Cross-Reference Chart ................................................................................. 36 Face Seal Fittings Assembly and Installation—All Pressure Applications ............................................ 37 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 SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications ..................... 41 <- Go to Global Table of contents

4630 Self-Propelled Sprayer Repair

4630 Self-Propelled Sprayer Repair

(g) by Belgreen v2.5

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 Programming Control Units ................................................................................................................ 51 Preparing and Painting Sprayer Components ..................................................................................... 52 Group 15 - Fuels and Lubricants ......................................................................................................... 53 Diesel Fuel .......................................................................................................................................... 53 Lubricity of Diesel Fuel ....................................................................................................................... 53 Diesel Engine Coolant (engine with wet sleeve cylinder liners) .......................................................... 55 Operating in Warm Temperature Climates ......................................................................................... 56 John Deere COOL-GARD™ II Coolant Extender ................................................................................... 56 Water Quality for Mixing with Coolant Concentrate ............................................................................ 57 Testing Coolant Freeze Point .............................................................................................................. 57 Hydrostatic/Hydraulic Drive Oil .......................................................................................................... 59 Planetary Hub Oil ................................................................................................................................ 60 Grease ................................................................................................................................................ 61 Suspension and Steering Grease ........................................................................................................ 61 Lubricant Storage ............................................................................................................................... 61 Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III ............................................................................................................................ 62 Diesel Engine Oil — Tier 3 and Stage III ............................................................................................. 63

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4630 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

4630 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, confirm that the fuel pressure is relieved.

Service Accumulator Systems Safely

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Section 10 page 2

4630 Self-Propelled Sprayer Repair

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.

Handle Fluids Safely—Avoid Fires

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Section 10 page 3

4630 Self-Propelled Sprayer Repair