John Deere R4038 Sprayer Service Manual TM115919 - PDF DOWNLOAD

R4030 and R4038 SelfPropelled Sprayer Repair

REPAIR TECHNICAL MANUAL Self-Propelled Sprayers models R4038, R4030 TM115919 06 FEB 15 (ENGLISH)

John Deere Agriculture Pinted by Belgreen

TM115919-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD Section 10 - GENERAL INFORMATION Group 05 - Safety Group 10 - General Information Group 15 - Tune-Up and Adjustment Group 20 - Fuel and Lubricants Section 20 - ENGINE Group 00 - Component Removal and Installation Section 30 - FUEL, AIR INTAKE, AND COOLING SYSTEMS Group 00 - Component Removal and Installation Group 05 - Diesel Fuel System Group 10 - Engine Cooling 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 10 - Planetary Hub Repair Section 60 - STEERING AND BRAKES Group 00 - Component Removal and Installation Group 05 - Steering Group 10 - Brakes Section 61 - SUSPENSION AND TREAD ADJUST REPAIR Group 00 - Component Removal and Installation Group 05 - Tread Adjust Cylinders Group 10 - Suspension Section 70 - HYDRAULIC SYSTEM Group 00 - Component Removal and Installation Group 05 - Hydraulic Pump Group 10 - Hydraulic Valves Group 15 - Hydraulic Cylinders Group 20 - Hydraulic Reservoir Group 25 - Accumulator Section 80 - SOLUTION SPRAY SYSTEM Group 00 - Component Removal and Installation Group 05 - Nozzle Repair Group 10 - Solution Tank Group 15 - Solution Pump—Standard Group 16 - Solution Pump—High Flow Group 20 - Control Valves Group 25 - Rinse Tank <- Go to Global Table of contents

TM115919-REPAIR TECHNICAL MANUAL

TM115919-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Group 30 - Eductor Group 35 - Direct Injection Group 40 - Flow Meter Section 81 - FOAM MARKER AND ON BOARD AIR SYSTEM Group 00 - Component Removal and Installation Group 05 - Foam Marker System Repair Section 82 - DRY SPREADER AND SOLUTION SYSTEM CONVERSION Group 05 - Dry Spreader and Solution System Section 90 - OPERATOR STATION Group 00 - Component Removal and Installation Group 05 - Heating, Ventilating, and Air Conditioning (HVAC) Group 10 - Air Conditioning System Group 15 - Cab Door Section 100 - BOOM Group 00 - Component Removal and Installation Section 199 - DEALER FABRICATED TOOLS Group 05 - Dealer Fabricated Tools

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TM115919-REPAIR TECHNICAL MANUAL

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TM115919-REPAIR TECHNICAL 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 10 page 1

TM115919-REPAIR TECHNICAL MANUAL

TM115919-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 10 - GENERAL INFORMATION Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 1 Handle Fluids Safely—Avoid Fires ......................................................................................................... 2 Prevent Battery Explosions ................................................................................................................... 2 Prepare for Emergencies ...................................................................................................................... 3 Handling Batteries Safely ..................................................................................................................... 3 Handle Agricultural Chemicals Safely ................................................................................................... 5 Service and Operate Chemical Sprayers Safely .................................................................................... 5 Avoid Contact with Agricultural Chemicals ........................................................................................... 6 Clean Vehicle of Hazardous Pesticides ................................................................................................. 7 Park Machine Safely ............................................................................................................................. 8 Support Machine Properly .................................................................................................................... 8 Wear Protective Clothing ...................................................................................................................... 9 Work in Clean Area ............................................................................................................................... 9 Service Machines Safely ..................................................................................................................... 10 Work In Ventilated Area ...................................................................................................................... 10 Illuminate Work Area Safely ............................................................................................................... 10 Replace Safety Signs .......................................................................................................................... 11 Use Proper Lifting Equipment ............................................................................................................. 11 Avoid High-Pressure Fluids ................................................................................................................. 11 Wait Before Opening High-Pressure Fuel System ............................................................................... 12 Service Accumulator Systems Safely .................................................................................................. 12 Remove Paint Before Welding or Heating ........................................................................................... 13 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 14 Service Tires Safely ............................................................................................................................ 14 Avoid Harmful Asbestos Dust ............................................................................................................. 15 Practice Safe Maintenance ................................................................................................................. 16 Use Proper Tools ................................................................................................................................. 16 Construct Dealer-Made Tools Safely ................................................................................................... 17 Dispose of Waste Properly .................................................................................................................. 17 Servicing Electronic Control Units ....................................................................................................... 18 Welding Near Electronic Control Units ................................................................................................ 20 Keep Electronic Control Unit Connectors Clean .................................................................................. 20 Precautions for Welding ...................................................................................................................... 22 Clean Exhaust Filter Safely ................................................................................................................. 23 Protect Against High Pressure Spray .................................................................................................. 24 Live With Safety ................................................................................................................................. 25 Group 10 - General Information ........................................................................................................... 26 Machine Specification ......................................................................................................................... 26 Dimensions—All Machines .................................................................................................................. 32 Standard Machine Dimensions ........................................................................................................... 33 Serial Number Plate Locations ............................................................................................................ 33 Sealants and Adhesives Cross-Reference Chart ................................................................................. 34 Face Seal Fittings Assembly and Installation—All Pressure Applications ............................................ 34 Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures ............................. 36 Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications ................. 37 SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures ................................. 38 SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications ..................... 39 <- Go to Global Table of contents

TM115919-REPAIR TECHNICAL MANUAL

TM115919-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications ................................. 39 SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications ............................. 41 SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications .................................... 42 External Hexagon Port Plug Torque Chart .......................................................................................... 43 Metric Bolt and Screw Torque Values ................................................................................................. 44 Unified Inch Bolt and Screw Torque Values ........................................................................................ 45 Programming Control Units ................................................................................................................ 46 Servicing and Connecting Snap to Connect STC STC is a registered trademark of Aeroquip Corporation Fittings ........................................................................................................................................ 48 Group 15 - Tune-Up and Adjustment .................................................................................................. 50 Tune-Up and Adjustment .................................................................................................................... 50 Care and Maintenance of Belts ........................................................................................................... 51 Defective Belts ................................................................................................................................... 52 Group 20 - Fuel and Lubricants ........................................................................................................... 55 Diesel Fuel .......................................................................................................................................... 55 Lubricity of Diesel Fuel ....................................................................................................................... 55 Diesel Engine Coolant (engine with wet sleeve cylinder liners) .......................................................... 57 Operating in Warm Temperature Climates ......................................................................................... 58 John Deere COOL-GARD™ II Coolant Extender ................................................................................... 58 Water Quality for Mixing with Coolant Concentrate ............................................................................ 59 Testing Coolant Freeze Point .............................................................................................................. 59 Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines ............. 60 Storing Diesel Exhaust Fluid (DEF) ..................................................................................................... 61 Testing Diesel Exhaust Fluid (DEF) ..................................................................................................... 61 Disposal of Diesel Exhaust Fluid (DEF) ............................................................................................... 62 Grease ................................................................................................................................................ 63 Hydrostatic/Hydraulic Drive Oil .......................................................................................................... 64 Suspension and Steering Grease ........................................................................................................ 64 Planetary Hub Oil ................................................................................................................................ 65 Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III ............................................................................................................................ 66 John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV ........... 66 Diesel Engine Oil — Tier 2 and Stage II .............................................................................................. 68 Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV ........................................... 69

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TM115919-REPAIR TECHNICAL MANUAL

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.

Follow Safety Instructions

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Section 10 page 1

TM115919-REPAIR TECHNICAL MANUAL

Section 10 - 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.

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 10 page 2

TM115919-REPAIR TECHNICAL MANUAL

Section 10 - 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.

Handling Batteries Safely

Caution <- Go to Section TOC

Section 10 page 3

TM115919-REPAIR TECHNICAL MANUAL