Complete service repair manual for John Deere 4940 Self-Propelled Sprayers (PIN Prefix N0 or 1N0), with all the shop information to maintain, repair, and service like professional mechanics.

John Deere 4940 Self-Propelled Sprayers workshop repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TM113619 - John Deere 4940 Self-Propelled Sprayers Technical Manual (Repair).PDF
TM113619 - John Deere 4940 Self-Propelled Sprayers Technical Manual (Repair).epub

Total Pages: 1,312 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
 Foreword
   General Information
      Safety
      General Information
      Fuel and Lubricants
   Engine
      Component Removal and Installation
   Fuel, Air Intake, and Cooling Systems
      Component Removal and Installation
      Diesel Fuel System
      Engine Cooling System
   Electrical
      Batteries
      Connector Repair
      Charging Circuit
      Starting Circuit
      Fuses and Relays
      Lighting
      Chassis Control System
      Engine Control System
      Spray Rate Control System
      Boom Control System
      Load Command™ Control System
      Cab Components
      Wiring Harness Routing
   Power Train Repair
      Remove and Install Hydrostatic Components
      Hydrostatic Drive Repair
      Planetary Hub Repair
   Steering and Brakes
      Component Removal and Installation
      Steering
      Brakes
   Suspension and Tread Adjust Repair
      Component Removal and Installation
      Tread Adjust Valves
      Tread Adjust Cylinders
      Suspension
   Hydraulic System
      Component Removal and Installation
      Hydraulic Pump
      Hydraulic Valves
      Boom Hydraulic Cylinders
      Hydraulic Reservoir
      Accumulator
   Solution Spray System
      Component Removal and Installation
      Nozzle Repair
      Solution Tank
      Solution Pump-Standard
      Solution Pump-High Flow
      Solution Control Valves
      Rinse Tank
      Eductor
      Load Command™ System
      Flow Meter
   Foam Marker System
      Component Removal and Installation
      Foam Marker System Repair
      On Board Air System
   Dry Box Conversion
      Dry System
      Liquid System
   Operator Station
      Component Removal and Installation
      Air Conditioning System
      Heating System
      Air Suspension Seat
      Cab Door
   Boom
      Component Removal and Installation
      Boom Repair
   Dealer Fabricated Tools
 

tm113619 - 4940 Self-Propelled Sprayer Repair

Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Perform Service Safely

Avoid High-Pressure Fluids

Park Machine Safely

Wait Before Opening High-Pressure Fuel System

Service Accumulator Systems Safely

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Protect Against High Pressure Spray

Prevent Acid Burns

Wear Protective Clothing

Clean Exhaust Filter Safely

Handle Agricultural Chemicals Safely

Service and Operate Chemical Sprayers Safely

Avoid Contact with Agricultural Chemicals

Clean Vehicle of Hazardous Pesticides

Decontaminate Spray Equipment

Support Machine Properly

Service Machines Safely

Practice Safe Maintenance

Avoid Harmful Asbestos Dust

Work In Ventilated Area

Work in Clean Area

Servicing Electronic Control Units

Welding Near Electronic Control Units

Precautions for Welding

Keep Electronic Control Unit Connectors Clean

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Service Tires Safely

Service Cooling System Safely

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Use Proper Tools

Construct Dealer-Made Tools Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Live With Safety

Group 10: General Information

Specifications

Dimensions

Identification Numbers

Sealants and Adhesives Cross-Reference Chart

Face Seal Fittings Assembly and Installation—All Pressure Applications

Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures

Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications

SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures

SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications

Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications

SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications

SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications

External Hexagon Port Plug Torque Chart

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Programming Control Units

Servicing and Connecting Snap to Connect STC™ Fittings

Group 15: Fuel and Lubricants

Diesel Fuel

Lubricity of Diesel Fuel

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

John Deere COOL-GARD™ II Coolant Extender

Water Quality for Mixing with Coolant Concentrate

Testing Coolant Freeze Point

Required Emission-Related Information

Hydrostatic/Hydraulic Drive Oil

Grease

Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III

John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV

Diesel Engine Oil — Tier 2 and Stage II

Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV

Suspension and Steering Grease

Planetary Hub Oil

Section 20: Engine

Group 00: Component Removal and Installation

Essential or Recommended Tools

Other Material

Specifications

John Deere Engine Repair—Use CTM

Remove and Install Engine—Interim Tier 4/Stage III B

Remove and Install Engine—Tier 2/Stage II

Hood Position for Operating Engine

Position Hood Forward

Remove and Install Hood

Remove and Install Exhaust Pipes and Filter—Interim Tier 4/Stage III B

Remove and Install Exhaust Pipes and Muffler—Tier 2/Stage II Engine

Remove and Install Auxiliary Drive Belt

Inspect Belt Tensioner

Auxiliary Drive Belt Routing

Remove and Install Drive Shaft

Inspect Drive Shaft

Section 30: Fuel, Air Intake, and Cooling Systems

Group 00: Component Removal and Installation

Other Material

Specifications

Remove and Install Fuel Tank

Remove and Install Fuel Level Sensor

Remove and Install Radiator/Charge Air Cooler

Remove and Install Fan Belt

Remove and Install Variable Speed Fan Drive Assembly

Remove and Install Variable Speed Fan Driven Assembly

Remove and Install Hydraulic Oil/Fuel Cooler

Remove and Install Air Conditioning Condenser

Group 05: Diesel Fuel System

Specifications

Clean and Inspect Fuel Tank

Replace Fuel Filter, Electric Fuel Pump, and Bleed Fuel System

Turbocharger Repair

Group 10: Engine Cooling System

Essential or Recommended Tools

Other Material

Specifications

Drain, Flush, and Refill Cooling System

Test Radiator and Deaeration Tank

Test Radiator Cap

Disassemble and Assemble Variable Speed Fan Drive Assembly

Disassemble and Assemble Variable Speed Fan Driven Assembly

Section 40: Electrical

Group 05: Batteries

Battery Safety

Prevent Damage to Electrical Systems

Checking Electrolyte Specific Gravity

Battery Replacement

Charging Batteries

Connecting Battery Cables

Group 10: Connector Repair

Essential or Recommended Tools

Using High-Pressure Washers

Connector Information

Installation of Repair Wire Assembly (RWA)

Repair Procedure R-A

Repair Procedure R-B

Repair Procedure R-C

Repair Procedure R-D

Repair Procedure R-E

Repair Procedure R-F

Repair Procedure R-G

Repair Procedure R-I

Repair Procedure R-J

Repair Procedure R-K

Repair Procedure R-M

Repair Procedure R-N

Repair Procedure R-AE

Repair Procedure R-AF

Repair Procedure R-AG

Repair Procedure R-AH

Repair Procedure R-AI

Repair Procedure R-AJ

Repair Procedure R-AK

Group 15: Charging Circuit

Specifications

Remove and Install Alternator

Group 20: Starting Circuit

Essential or Recommended Tools

Specifications

Remove and Install Starter Motor

Replace Starter Circuit Relay

Group 25: Fuses and Relays

Cab Load Center Fuses

Cab Load Center Relays and Diodes

Front Chassis Load Center

Rear Chassis Load Center

Battery Box Fuses and Relay

Group 30: Lighting

Safety Rules When Replacing Halogen Bulbs

Replace and Adjust Field Lights

Hood Head Light Bulb Replacement and Adjustment

Group 35: Chassis Control System

Specifications

Replace Hydraulic Oil Temperature Sensor and Level Switch

Remove and Install AutoTrac Control Unit

Replace Chassis Control Unit (CCU)

Replace Wheel Speed Sensor

Calibrate Wheel Speed Sensor

Replace Wheel Angle Sensor

Replace Tread Adjust Sensor

Adjust Tread Adjust Sensor

Group 40: Engine Control System

Specifications

Engine Sensor and Switches

Remove and Install Fan Speed Sensor

Group 45: Spray Rate Control System

Other Material

Replace Spray Rate Control Unit (SRC)

Replace Solution Pressure Sensor

Replace Boom Outer Wing Position Sensor

Replace Boom Inner Wing Position Sensor

Replace Boom Height Sensor

Remove and Install Flowmeter Sensor

Group 50: Boom Control System

Replace Boom Height Control Unit (BHC)

Remove and Install BoomTrac ProTM Breakaway Sensor

Remove and Install BoomTrac ProTM Inner Boom Sensor

Remove and Install BoomTrac ProTM Center Section Sensor

Remove and Install BoomTrac ProTM Roll Sensor

Group 55: Load Command™ Control System

Other Material

Specifications

Replace Load Command™ Controller

Replace Stop-Enable Switch

Replace Pump Speed Sensor

Replace Proximity Sensor

Replace Knock Sensor

Replace Knock Module

Replace Tank Level Sensor

Group 60: Cab Components

Other Material

Specifications

Side Console Switches

Remove and Install Dome Light Switch

Remove and Install Cab Door Light Switch

Remove and Install Starting Aid Switch

Remove and Install Ignition Switch

Remove and Install Air Conditioner Deicing Switch and Blower Motor Resistor

Remove and Install Boom Fold/Level Switch

Remove and Install Turn Signal Indicator Bulbs

Remove and Install Steering Column Mini-Pod

Remove and Install Steering Input Device Sensor

Remove and Install Three-Pin Accessory Outlets

Remove and Install Circulation Blower Motor

Remove and Install Air Quality (AQS) Pressurizer Blower Motor

Replace Wiper Motor

Remove and Install Radio and Speakers

Remove and Install Multi-function Lever Position Sensor

Remove and Install Multi-function Lever Position Harness

Remove and Install Throttle Control

Remove and Install Throttle Sensor

Remove and Install Armrest Rocker Switches

Remove and Install Secondary Brake Switch

Remove and Install Load Command Switch—Cab

Group 65: Wiring Harness Routing

Engine Harness Routing

Solution System Harness Routing

Chassis Harness Routing

CAN Terminator Locations

Guidance Harness Routing

Section 50: Power Train Repair

Group 00: Remove and Install Hydrostatic Components

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Emergency Tow Procedure (Serial No. —27999)

Emergency Tow Procedure (Serial No. 28000—)

Start-Up Procedure After Hydrostatic Repair

Flushing Hydrostatic Drive System

Replacing Wheel Hardware

Tightening Wheel Hardware

Remove and Install Drive Tire

Remove and Install Fender

Remove and Install Hydrostatic Drive Pumps

Remove and Install Hydrostatic Drive Motor

Remove and Install Planetary Hub

Remove, Install, and Adjust Hydrostatic Control Cable

Remove, Install, and Adjust Hydrostatic Control Linkage

Drain and Fill Planetary Hub (Serial No. —27999)

Drain and Fill Planetary Hub (Serial No. 28000—)

Group 05: Hydrostatic Drive Repair

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Replace Hydrostatic Drive Motor Shaft Seal

Repair Hydrostatic Drive Motor

Remove and Install Hydrostatic Pump Shaft Seal

Replace Broken Input Shaft on Hydrostatic Drive Pump

Remove and Install Hydrostatic Drive Pump Valve Plate

Replace Hydrostatic Pump Cartridge Valves

Replace Hydrostatic Pump Charge Pressure Relief Valve

Repair Charge Pump

Remove and Install Hydrostatic Pump Control Valve

Remove and Install Control Valve Neutral Start Switch

Adjust Neutral Start Switch

Adjust Control Valve Eccentric Plug

Disassemble Hydrostatic Drive Pump

Inspect and Repair Hydrostatic Drive Pump

Assemble Hydrostatic Drive Pump

Flush Procedure for Failed Wheel Motor

Group 10: Planetary Hub Repair

Essential or Recommended Tools

Service Equipment and Tools

Specifications

Planetary Hub—Exploded View (Serial No. —27999)

Planetary Hub—Exploded View (Serial No. 28000—)

Disassemble Planetary Hub (Serial No. —27999)

Disassemble Planetary Hub (Serial No. 28000—)

Assemble Planetary Hub (Serial No. —27999)

Assemble Planetary Hub (Serial No. 28000—)

Section 60: Steering and Brakes

Group 00: Component Removal and Installation

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Steering Valve

Remove and Install Steering Cylinder

Remove and Install Steering Arm

Remove and Install Toe Control Valve

Remove and Install Service Brake Valve

Remove and Install Brake Rotor

Remove and Install Service Brake Caliper

Remove and Install AutoTrac™ Valve

Group 05: Steering

Specifications

Repair Steering Column

Bleed Steering System

Repair Steering Valve

Check Front Axle Toe-In

Adjust Front Axle Toe-In

Repair AutoTrac™ Valve

Group 10: Brakes

Specifications

Inspect Service Brake System Components

Disassemble, Inspect, and Assemble Service Brake Linkage

Brake Valve Fittings Adjustment

Disassemble and Assemble Service Brake Caliper

Start-Up Procedure After Brake System Repair

Repair Park Brake (Serial No. —27999)

Repair Park Brake (Serial No. 28000—)

Section 61: Suspension and Tread Adjust Repair

Group 00: Component Removal and Installation

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Air Spring Assembly

Remove and Install Suspension/Drive Mount Housing

Remove and Install Air Spring Leveling System Control Valve

Remove and Install Tread Adjust Valve

Remove and Install Tread Adjust Cylinders

Replace Tread Adjust Shim Pads

Group 05: Tread Adjust Valves

Essential or Recommended Tools

Specifications

Tread Adjust Valve Block

Replace Control Valve Coil(s)

Replace Tread Adjust Valve

Remove, Inspect, and Install Manifold Check Valve and Pilot Piston

Group 10: Tread Adjust Cylinders

Specifications

Disassemble and Assemble Tread Adjust Cylinders

Group 15: Suspension

Essential or Recommended Tools

Other Material

Specifications

Front Suspension—Exploded View

Rear Suspension—Exploded View

Replace Air Spring Assembly Valve

Replace Suspension/Drive Mount Housing Seals and Bushings

Replace Front Axle Knee Bushings

Adjust Front and Rear Air Spring Assemblies

Section 70: Hydraulic System

Group 00: Component Removal and Installation

Essential or Recommended Tools

Specifications

Remove and Install Hydraulic Pump Compensator

Remove and Install Hydraulic Pump

Remove and Install Boom Control Valve

Remove and Install Priority Valve

Remove and Install Full Boom Breakaway Valve

Remove and Install Combination Valve

Remove and Install Load Command Combination Valve

Remove and Install Ladder Valve

Remove and Install Park Brake Valve

Remove and Install Boom Lift Cylinders

Remove and Install Boom Leveling Cylinders

Remove and Install Boom Inner Fold Cylinders

Remove and Install Boom Outer Fold Cylinders

Remove and Install Boom Breakaway Fold Cylinders

Remove and Install Full Boom Breakaway Cylinder

Remove and Install Boom Roll Lock Cylinder

Remove and Install Hydraulic Reservoir

Remove and Install Boom Lift Accumulator

Remove and Install Full Boom Breakaway Accumulator

Group 05: Hydraulic Pump

Other Material

Specifications

Relieve Hydraulic System Pressure

Disassemble and Assemble Hydraulic Pump Compensator

Disassemble and Assemble Hydraulic Pump

Group 10: Hydraulic Valves

Essential or Recommended Tools

Specifications

Boom Control Valve General Information

Boom Control Valve Solenoid Identification

Disassemble, Inspect, and Assemble Boom Control Valve

Disassemble and Assemble Combination Valve

Repair Load Command Combination Valve

Repair Full Boom Breakaway Valve

Group 15: Boom Hydraulic Cylinders

Specifications

Boom Cylinder Orifice Locations

Disassemble and Assemble Boom Lift Cylinders

Disassemble and Assemble Boom Leveling Cylinders

Disassemble and Assemble Boom Inner Fold Cylinders

Adjust Boom Inner Fold Cylinder

Disassemble and Assemble Boom Outer Fold Cylinders

Disassemble and Assemble Boom Breakaway Fold Cylinders

Disassemble and Assemble Roll Lock Cylinder

Group 20: Hydraulic Reservoir

Clean Hydraulic Reservoir Strainers

Group 25: Accumulator

Essential or Recommended Tools

Service Equipment and Tools

Specifications

Service Accumulator Systems Safely

Relieve Full Boom Breakaway System Pressure

Charge Accumulator

Section 80: Solution Spray System

Group 00: Component Removal and Installation

Service Equipment and Tools

Other Material

Specifications

Remove and Install Solution Tank

Remove and Install Agitation Nozzles

Remove and Install Standard Solution Pump and Motor

Remove and Install High Flow Solution Pump and Motor

Remove and Install Load Command Pump

Remove and Install Flowmeter Assembly

Remove and Install Boom Section Shut-Off Valves

Remove and Install Rinse Water Control Valve Assembly

Remove and Install Solution Control Valves

Remove and Install Rinse Tank Assembly

Remove and Install AutoTrac™ Vision Sensor

Remove and Install AutoTrac™ RowSense™ Sensor

Group 05: Nozzle Repair

Cleaning SprayMater™ 5-Position Nozzle Bodies—High Flow

Group 10: Solution Tank

Flush Solution Tank and Spray System

Positioning Agitation Nozzles

Group 15: Solution Pump—Standard

Service Equipment and Tools

Other Material

Specifications

Standard Solution Pump Exploded View

Disassemble and Assemble Standard Solution Pump

Disassemble and Assemble Standard Solution Pump Motor

Group 16: Solution Pump—High Flow

Other Material

Specifications

Disassemble and Assemble High Flow Solution Pump

Disassemble and Assemble High Flow Solution Pump Motor

Group 20: Solution Control Valves

Essential or Recommended Tools

Other Material

Specifications

Disassemble and Assemble Fittings

Repair Check Valves and Strainers

Diagnose and Repair Boom Shut-Off Valves

Repair Solution Control Valves

Group 25: Rinse Tank

Essential or Recommended Tools

Repair Polyethylene Plastic

Group 30: Eductor

Eductor Assembly

Remove and Install Eductor System Venturi

Group 35: Load Command™ System

Essential or Recommended Tools

Service Equipment and Tools

Specifications

Load Command Pump Disassemble and Assemble

Sprayer Coupler Disassemble and Assemble

Nurse Arm Disassemble and Assemble

Poppet Cylinder Disassemble and Assemble

Group 40: Flow Meter

Replace Flowmeter Insert

Recondition Flowmeter

Calibrate Flowmeter

Section 81: Foam Marker System

Group 00: Component Removal and Installation

Other Material

Specifications

Remove and Install Foam Marker Concentrate Tank

Remove and Install Control Box (Single Drop)

Remove and Install On Board Air Compressor

Remove and Install On Board Air Dryer

Replace Foam Mixing Chamber

Group 05: Foam Marker System Repair

Other Material

On Board Air (OBA) Foam Marker Schematic

Repair Control Box (Single Drop)

Repair Control Box Solenoid

Repair Foam Marker Tubes

Tube Fittings

Group 10: On Board Air System

Specifications

Service Parts Kit

Repair On Board Air Dryer

Section 82: Dry Box Conversion

Group 05: Dry System

Specifications

Remove Dry Spreader

Install Dry Spreader

Group 10: Liquid System

Specifications

Empty Tank and Boom Plumbing—Decontaminate Spray Equipment

Service Spray Equipment Safely

Remove Liquid System

Install Liquid System

Section 90: Operator Station

Group 00: Component Removal and Installation

Specifications

Remove and Install Cab

Remove and Install Armrest

Remove and Install Armrest Control Cover

Remove and Install Multi-Function Lever

Remove and Install Seat from Suspension

Remove and Install Air Seat Suspension System

Remove and Install Windshield Glass or Seal

Remove and Install Door Cylinder

Remove and install Cab Door Latch Assembly

Remove and Install Air Conditioning Compressor

Remove and Install Compressor Relief Valve

Remove and Install Receiver-Dryer

Remove Heater Control Valve

Remove, Install, and Adjust Temperature Control Cable

Remove and Install Heater Control Valve—ClimaTrak™

Remove and Install Expansion Valve

Remove and Install Air Quality System Module

Remove and Install Heater Core or Evaporator

Group 05: Air Conditioning System

System Information

Compressor Oil Information

Charge Air Conditioning System

Check Refrigerant Oil Charge

Determine Correct Refrigerant Oil Charge

Discharge Air Conditioning System

Evacuate Air Conditioning System

Flush Air Conditioning System

Leak Testing Air Conditioning System With Dye

Purge Air Conditioning System

Test Shaft Seal Leakage

Test Volumetric Efficiency

Check Clutch Hub Clearance

Inspect Compressor Manifold

Disassemble and Assemble Compressor Clutch

Disassemble, Inspect, and Assemble Compressor

Leak Test Air Quality System Module

Group 10: Heating System

Leak Test Heater Control Valve

Group 15: Air Suspension Seat

Operator Seat—Exploded View

Operator Seat Air Suspension Assembly—Exploded View

Disassemble and Assemble Operator's Seat Air Suspension Assembly

Group 20: Cab Door

Specifications

Cab Door Adjustment—Step 1

Cab Door Adjustment—Step 2

Cab Door Adjustment—Step 3

Cab Door Adjustment—Step 4

Section 100: Boom

Group 00: Component Removal and Installation

Specifications

Remove and Install Boom Shock Absorbers and Rubber Stops

Remove and Install Boom Roll Springs

Remove Boom Rear Support Bar

Remove and Install Boom Center Roll Bearing

Group 05: Boom Repair

Specifications

Inner Wing

Section 199: Dealer Fabricated Tools

Group 05: Dealer Fabricated Tools

DFNXT7—Agitation Nozzle Tool

DFNX65-A1 Eccentric Plug Adjustment Tool

DFNX65-A2 Sizing Arbor

DFN20 Solution Pump Seal Driver—Standard Solution Pump

DFN21 Pump Support Fixture—Standard Solution Pump

DFN22 Bearing Seat Driver

DFNXT9—Load Command Pump Holding Fixture

DFNXT10—Hydraulic Cylinder Spring Compressor

John Deere 4940 Self-Propelled Sprayers Repair Service Manual (TM113619)