Complete service repair manual for John Deere R4030, R4038 Self-Propelled Sprayers, with all the workshop information to maintain, repair, and service like professional mechanics.

John Deere R4030, R4038 Self-Propelled Sprayers workshop technical 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.

TM115919 - John Deere R4030, R4038 Self-Propelled Sprayers Technical Manual (Repair).PDF
TM115919 - John Deere R4030, R4038 Self-Propelled Sprayers Technical Manual (Repair).EPUB

Total Pages: 1,310 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
      Tune-Up and Adjustment
      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
      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 Cylinders
      Suspension
   Hydraulic System
      Component Removal and Installation
      Hydraulic Pump
      Hydraulic Valves
      Hydraulic Cylinders
      Hydraulic Reservoir
      Accumulator
   Solution Spray System
      Component Removal and Installation
      Nozzle Repair
      Solution Tank
      Solution Pump-Standard
      Solution Pump-High Flow
      Control Valves
      Rinse Tank
      Eductor
      Direct Injection
      Flow Meter
   Foam Marker and On Board Air System
      Component Removal and Installation
      Foam Marker System Repair
   Dry Spreader and Solution System Conversion
      Dry Spreader and Solution System
   Operator Station
      Component Removal and Installation
      Heating, Ventilating, and Air Conditioning (HVAC)
      Air Conditioning System
      Cab Door
   Boom
      Component Removal and Installation
   Dealer Fabricated Tools
      Dealer Fabricated Tools

tm115919 - R4030 and R4038 Self-Propelled Sprayer Repair

Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Handling Batteries Safely

Handle Agricultural Chemicals Safely

Service and Operate Chemical Sprayers Safely

Avoid Contact with Agricultural Chemicals

Clean Vehicle of Hazardous Pesticides

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Avoid High-Pressure Fluids

Wait Before Opening High-Pressure Fuel System

Service Accumulator Systems Safely

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Construct Dealer-Made Tools Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Servicing Electronic Control Units

Welding Near Electronic Control Units

Keep Electronic Control Unit Connectors Clean

Precautions for Welding

Clean Exhaust Filter Safely

Protect Against High Pressure Spray

Live With Safety

Group 10: General Information

Machine Specification

Dimensions—All Machines

Standard Machine Dimensions

Serial Number Plate Locations

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: Tune-Up and Adjustment

Tune-Up and Adjustment

Care and Maintenance of Belts

Defective Belts

Group 20: Fuel and Lubricants

Essential or Recommended Tools

Diesel Fuel

Lubricity of Diesel Fuel

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Operating in Warm Temperature Climates

John Deere COOL-GARD™ II Coolant Extender

Water Quality for Mixing with Coolant Concentrate

Testing Coolant Freeze Point

Required Emission-Related Information

Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines

Storing Diesel Exhaust Fluid (DEF)

Testing Diesel Exhaust Fluid (DEF)

Disposal of Diesel Exhaust Fluid (DEF)

Grease

Hydrostatic/Hydraulic Drive Oil

Suspension and Steering Grease

Planetary Hub Oil

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

Section 20: Engine

Group 00: Component Removal and Installation

Essential or Recommended Tools

Specifications

Other Material

John Deere Engine Repair—Use CTM

Remove and Install Engine without Oil Pan (R4038)

Remove and Install Engine with Oil Pan (R4038)

Remove and Install Engine without Oil Pan (R4030)

Remove and Install Engine with Oil Pan (R4030)

Install Timing Gear Cover

Position Hood Forward

Remove and Install Hood

Remove and Install Selective Catalytic Reduction (SCR)

Remove and Install Exhaust Pipes and Filter—Tier 4/Stage IV

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

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

Specifications

Remove and Install Fuel Tank

Remove and Install Fuel Level Sensor

Remove and Install Diesel Exhaust Fluid (DEF) Tank—Style A

Remove and Install Diesel Exhaust Fluid (DEF) Tank—Style B

Remove and Install Diesel Exhaust Fluid (DEF) Tank Header—Style A

Remove and Install Diesel Exhaust Fluid (DEF) Tank Header—Style B

Remove and Install Diesel Exhaust Fluid (DEF) Injection Pump

Remove and Install Cooling Package

Remove and Install Radiator

Remove and Install Charge Air Cooler

Remove and Install Fan Belt

Remove and Install Hydraulic Oil Cooler

Remove and Install Fuel Cooler

Remove and Install Air Conditioning Condenser

Remove and Install Viscous Fan Drive

Group 05: Diesel Fuel System

Specifications

Clean and Inspect Fuel Tank

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

Turbocharger Repair—Use CTM

DEF Tank Exploded View—Style A

DEF Tank Exploded View—Style B

Group 10: Engine Cooling System

Essential or Recommended Tools

Specifications

Drain, Flush, and Fill Cooling System (R4030)

Drain, Flush, and Fill Cooling System (R4038)

Test Radiator, Deaeration Tank, and Overflow Tank

Test Deaeration Tank Cap and Overflow Tank Cap

Section 40: Electrical

Group 05: Batteries

Essential or Recommended Tools

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

Repair Procedure R-AV

Group 15: Charging Circuit

Specifications

Remove and Install Alternator

Group 20: Starting Circuit

Specifications

Remove and Install Starter Motor

Remove and Install Starter Circuit Relay

Group 25: Fuses and Relays

Cab Load Center Fuses and Relays

Front Chassis Load Center

Rear Chassis Load Center

Vehicle Electrification Center (VEC)

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

Remove and Install Hydraulic Oil Temperature Sensor and Oil Level Sensor

Remove and Install AutoTrac Control Unit

Remove and Install Chassis Control Unit (CCU)

Remove and Install Wheel Speed Sensor

Remove and Install Wheel Angle Sensor

Remove and Install Tread Adjust Sensor

Group 40: Engine Control System

Engine Sensor and Switches

Group 45: Spray Rate Control System

Other Material

Specifications

Remove and Install Spray Rate Control Unit (SRC)

Remove and Install Spray Rate Control Unit (SRC) with ExactApply™

Remove and Install Master Nozzle Control Unit (MNC)

Remove and Install Key FOB Receiver

Remove and Install Solution Pressure Sensor

Remove and Install Flowmeter Sensor

Group 50: Boom Control System

Remove and Install Boom Height Control Unit (BHC)

Remove and Install Boom Height Control Unit (BHC) with ExactApply ™

Remove and Install BoomTrac Pro™ Sensor

Remove and Install BoomTrac Pro™ Roll Sensor

Remove and Install Boom Height Sensor

Remove and Install Boom Tilt Sensor

Remove and Install Boom Inner Fold Sensor—Steel Boom

Remove and Install Boom Outer Wing Position Sensor—Steel Boom

Remove and Install Boom Fold Sensors—Carbon Fiber Boom

Group 55: Cab Components

Other Material

Specifications

Remove and Install Dome Light Switch

Remove and Install Cab Door Light Switch

Remove and Install Ignition Switch (S.N. —6000)

Remove and Install Ignition Switch (S.N. 6001—)

Remove and Install Ether Aid Switch (S.N. —6000)

Remove and Install Ether Aid Switch (S.N. 6001—)

Remove and Install Air Conditioner Blower Motor Resistor

Remove and Install Air Conditioner Blower Motor Speed Control—(S.N. 180001—)

Remove and Install Air Conditioner Deicing Switch

Remove and Install Case/Duct Temperature Sensor—(S.N. 180001—)

Remove and Install Air Conditioner Dual Pressure Switch

Remove and Install Boom Fold/Level Switch

Remove and Install Turn Signal Indicator Lighting

Remove and Install Steering Column Mini-Pod (S.N. —6000)

Remove and Install Steering Column Mini-Pod (S.N. 6001—)

Remove and Install Rotary Light Switch

Remove and Install Rotary Wiper Switch

Remove and Install Mini-Pod Backlight

Remove and Install Turn Signal-Horn Switch

Remove and Install Steering Input Device Sensor (S.N —6000)

Remove and Install Steering Input Device Sensor (S.N. 6001—)

Remove and Install Accessory Outlets (S.N. —6000)

Remove and Install Accessory Outlets (S.N. 6001—)

Remove and Install Auxiliary Power Strip

Remove and Install Circulation Blower Motor

Remove and Install Air Quality (AQS) Pressurizer Blower Motor

Remove and Install Wiper Motor

Remove and Install Radio and Speakers

Remove and Install Corner Post Display Unit—(S.N.—18000)

Remove and Install Corner Post Display Unit—(S.N. 180001—)

Remove and Install Hands Free Microphone—(S.N. 180001—)

Remove and Install Armrest Console Switch Panel—(S.N.—180000)

Remove and Install Armrest Console—(S.N. 180001—)

Remove and Install Armrest Control Cover (S.N. —6000)

Remove and Install Armrest Control Cover—(S.N. 180001—)

Remove and Install Side Console

Remove and Install Armrest Display Unit (S.N. —6000)

Remove and Install Armrest Display Unit—(S.N. 180001—)

Remove and Install Navigation Bar Assembly—(S.N. 180001—)

Remove and Install Multi-Function Lever—(S.N. 180001—)

Remove and Install Multi-Function Lever—(S.N.—180000)

Remove and Install Multi-Function Lever Position Switches—(S.N.—180000)

Remove and Install Multi-Function Lever Position Sensor—(S.N.—180000)

Remove and Install Multi-Function Lever Position Assembly—(S.N. 180001—)

Remove and Install Armrest Console Control Module—(S.N. 180001—)

Remove and Install Armrest Console Auxiliary Power Outlet—(S.N. 180001—)

Remove an Install Armrest Console USB Ports—(S.N. 180001—)

Remove and Install Secondary Brake Switch—(S.N. 180001—)

Remove and Install SCM Module—(S.N. 180001—)

Remove and Install House Control Module—(S.N. 180001—)

Remove and Install DCM Module—(S.N. 180001—)

Remove and Install Spray Nozzle Encoders Module—(S.N. 180001—)

Remove and Install Spray Nozzle Encoders Backlight—(S.N. 180001—)

Remove and Install Engagement Switch Backlight—(S.N. 180001—)

Remove and Install Secondary Handbrake Switch—(S.N.—180000)

Remove and Install Rate Selector Potentiometer—(S.N.—180000)

Remove and Install Roof Control Unit

Remove and Install Modular Telematics Gateway (MTG) Control Unit (S.N. —6000)

Remove and Install Modular Telematics Gateway (MTG) Control Unit (S.N. 6001—)

Remove and Install Cab Control Unit

Remove and Install JDLink™ Antenna (S.N. —6000)

Remove and Install JDLink™ Antenna (S.N. 6001—)

Group 60: Wiring Harness Routing

Engine Harness Routing

Solution System Harness Routing

Solution Skid with ExactApply™ Harness Routing

Solution System with ExactApply™ Harness Routing

Chassis Harness Routing

Cab Harness Routing

Direct Injection Harness Routing

Boom Center Frame Harness Routing

Boom Center Frame with ExactApply™ Harness Routing

Boom Wiring Harness

Carbon Fiber Boom with ExactApply™ 36 M Wiring Harness

Guidance Harness Routing

Section 50: Power Train Repair

Group 00: Remove and Install Hydrostatic Components

Essential or Recommended Tools

Service Equipment and Tools

Specifications

Other Material

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

Group 05: Hydrostatic Drive Repair

Essential or Recommended Tools

Specifications

Other Material

Emergency Tow Procedure

Start-Up Procedure After Hydrostatic Repair

Flushing Hydrostatic Drive System

Replace Hydrostatic Drive Motor Shaft Seal

Remove and Install Hydrostatic Pump Side Cover Nuts

Repair Hydrostatic Drive Motor

Remove and Install Hydrostatic Pump Shaft Seal

Replace Broken Input Shaft on Hydrostatic Drive Pump

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

Specifications

Other Material

Disassemble Planetary Hub—R4030

Assemble Planetary Hub—R4030

Disassemble Planetary Hub—R4038

Assemble Planetary Hub—R4038

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

Remove and Install Secondary Steering Pump

Group 05: Steering

Specifications

Disassemble and Assemble Steering Column (S.N. —6000)

Disassemble and Assemble Steering Column (S.N. 6001—)

Bleed Steering System

Check Front Axle Toe-In

Adjust Front Axle Toe-In

Disassemble and Assemble AutoTrac™ Valve

Steering Valve Identification

Disassemble and Assemble Steering Valve

Disassemble and Assemble Secondary Steering Pump

Group 10: Brakes

Specifications

Inspect Service Brake System Components

Disassemble, Inspect, and Assemble Service Brake Linkage (S.N. —6000)

Disassemble, Inspect, and Assemble Service Brake Linkage (S.N. 6001—)

Disassemble and Assemble Service Brake Caliper

Start-Up Procedure After Brake System Repair

Repair Park Brake

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 Cylinders

Remove and Install Tread Adjust Shim Pads

Group 05: Tread Adjust Cylinders

Disassemble and Assemble Tread Adjust Cylinder

Group 10: Suspension

Essential or Recommended Tools

Other Material

Specifications

Front Suspension—Exploded View

Rear Suspension—Exploded View

Remove and Install Suspension/Drive Mount Housing Seals and Bushings

Remove and Install Front Axle Knee Bushings

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 Hydraulic Reservoir

Remove and Install Boom Control Valve

Remove and Install Full Boom Breakaway Valve

Remove and Install Combination Valve

Remove and Install Park Brake/Ladder Valve

Remove and Install Proportional Valve

Remove and Install Thermal Bypass Valve

Remove and Install Boom Lift Accumulator

Remove and Install Full Boom Breakaway Accumulator

Group 05: Hydraulic Pump

Specifications

Other Material

Relieve Hydraulic System Pressure

Disassemble and Assemble Hydraulic Pump Compensator

Disassemble and Assemble Hydraulic Pump

Group 10: Hydraulic Valves

Specifications

Boom Control Valve General Information

Boom Control Valve Solenoid Identification

Disassemble and Assemble Boom Control Valve

Disassemble and Assemble Park Brake/Ladder Valve

Disassemble and Assemble Combination Valve

Disassemble and Assemble Proportional Valve

Disassemble and Assemble Full Boom Breakaway Valve

Group 15: Hydraulic Cylinders

Specifications

Boom Cylinder Orifice Locations

Remove and Install Ladder Cylinder

Disassemble and Assemble Ladder Cylinder

Remove and Install Boom Lift Cylinders

Remove and Install Boom Inner Fold Cylinders

Remove and Install Full Boom Breakaway Cylinder

Remove and Install Boom Swing Cylinder

Remove and Install Boom Tilt Cylinders—Steel Boom

Remove and Install Boom Outer Fold Cylinders—Steel Boom

Remove and Install Tilt Cylinder—Carbon Fiber Boom

Remove and Install Boom Inner Fold Cylinder—Carbon Fiber Boom

Remove and Install Outer Boom Fold Cylinder—Carbon Fiber Boom

Remove and Install Breakaway Fold Cylinder—Carbon Fiber Boom

Group 20: Hydraulic Reservoir

Specifications

Clean Hydraulic Reservoir Strainers

Group 25: Accumulator

Essential or Recommended 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

Essential or Recommended Tools

Specifications

Other Material

Empty Tank and Boom Plumbing—Decontaminate Spray Equipment

Service Spray Equipment Safely

Remove and Install Solution Tank

Remove and Install Agitation Nozzles

Remove and Install Solution Pump and Motor

Remove and Install Boom Solution Control Valves

Remove and Install Rinse Water Control Valve

Remove and Install Solution Control Valves

Remove and Install Flowmeter Assembly

Remove and Install Rinse Tank Assembly

Remove and Install Tank Level Sensor

Remove and Install Target Fill Sensor

Remove and Install AutoTrac™ Vision Sensor

Remove and Install AutoTrac™ RowSense™ Sensor

Remove and Install ExactApply™ Nozzle Body

Group 05: Nozzle Repair

Essential or Recommended Tools

Other Material

Cleaning SPRAY MASTER 5-Position Nozzle Bodies

Disassemble and Assemble ExactApply™ Nozzle Body

Group 10: Solution Tank

Flush Solution Tank and Spray System

Positioning Agitation Nozzles

Group 15: Solution Pump—Standard

Other Material

Specifications

Solution Pump—Standard Exploded View

Disassemble and Assemble Standard Solution Pump

Group 16: Solution Pump—High Flow

Specifications

Other Material

Solution Pump—High Flow Exploded View

Disassemble and Assemble High Flow Solution Pump

Group 20: Control Valves

Specifications

Other Material

Disassemble and Assemble Fittings

Repair Check Valves and Strainers

Diagnose and Repair Boom Solution Control Valves

Diagnose and Repair Solution and Rinse Water Control Valves

Disassemble and Assemble Solution and Rinse Water Control Valves

Disassemble and Assemble Boom Solution Control Valves

Group 25: Rinse Tank

Repair Polyethylene Plastic

Group 30: Eductor

Eductor Assembly

Remove and Install Eductor System Venturi

Group 35: Direct Injection

Other Material

Remove and Install Tank Assembly

Remove and Install Mixer Assembly

Remove and Install High Volume Pump Assembly

Remove and Install Low Volume Pump Assembly—If Equipped

Remove and Install High Volume Rinse Valve

Remove and Install Low Volume Rinse Valve

Disassemble and Assemble Rinse Valve

Group 40: Flow Meter

Specifications

Replace Flowmeter Insert

Recondition Flowmeter

Calibrate Flowmeter (S.N. —180000)

Calibrate Flowmeter (S.N. 180001— )

Section 81: Foam Marker and On Board Air System

Group 00: Component Removal and Installation

Specifications

Other Material

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

Remove and Install 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

Section 82: Dry Spreader and Solution System Conversion

Group 05: Dry Spreader and Solution System

Remove and Install Dry Spreader and Solution System

Section 90: Operator Station

Group 00: Component Removal and Installation

Special Tools

Other Material

Specifications

Remove and Install Cab

Repair Cab

Remove and Install Cab Roof

Remove and Install Cab Headliner

Remove and Install Cab Inner Roof

Remove and Install Steering Wheel

Remove and Install Operator Seat—(S.N.—180000)

Remove and Install Operator Seat—(S.N. 180001—)

Remove and Install Operator Presence Switch

Remove and Install Seat Cushions

Remove and Install Seat Angle and Seat Depth Adjuster—(S.N. 180001—)

Remove and Install Lumbar Support Compressor—(S.N. 180001—)

Remove and Install Lumbar Support—(S.N. 180001—)

Remove and Install Lumbar Support Switch—(S.N. 180001—)

Remove and Install Climate Control Switch—(S.N. 180001—)

Remove and Install Back Seat Cushion Cooling Blower Unit—(S.N. 180001—)

Remove and Install Lap Belt

Remove and Install Left-Hand Armrest

Remove and Install Operator Seat Fore/Aft Rail Assembly—(S.N. 180001—)

Remove and Install Operator Seat Sideway Lock Assembly—(S.N. 180001—)

Remove and Install Operator Seat Sideway Damper Shocks—(S.N. 180001—)

Remove and Install Operator Air Seat Suspension

Remove and Install Operator Seat Swivel Locking Mechanism—(S.N. 180001—)

Remove and Install Seat Suspension Bellows

Remove and Install Vertical Shock Absorber Control Cable Handle

Remove and Install Vertical Shock Absorber Control Cable

Remove and Install Vertical Shock Absorber

Remove and Install Horizontal Shock Absorber

Remove and Install Fore/Aft Isolator Handle

Remove and Install Fore/Aft Isolator Locking Mechanism

Remove and Install Fore/Aft Isolator Assembly

Remove and Install Seat Suspension Compressor

Remove and Install Seat Level Indicator

Remove and Install Seat Suspension Air Spring

Remove and Install Seat Air Reservoir —(S.N.—180000)

Remove and Install Seat Height Control

Remove and Install Upper Seat Suspension Frame

Remove and Install Lower Seat Suspension Frame

Remove, Adjust, and Install Cab Door Latch

Remove and Install Windshield Glass or Side Window

Remove and Install Door Cylinder

Remove and Install Air Conditioning Compressor

Remove and Install Receiver-Dryer

Remove and Install Expansion Valve

Remove and Install HVAC Module

Remove and Install Heater Control Valve (Without ClimaTrak™)

Remove and Install Heater Control Valve (With ClimaTrak™)

Remove and Install Mode Control Cable

Remove and Install Ladder

Remove and Install Ladder Cylinder

Group 05: Heating, Ventilating, and Air Conditioning (HVAC)

Heater Line Routing

Leak Test Manual Heater Control Valve

Group 10: Air Conditioning System

Essential or Recommended Tools

Other Material

Specifications

Hose and Tubing O-Ring Connection Torques

Add Refrigerant Oil to System

Add Refrigerant Oil to Pressurized System

System Information

Refrigerant 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 Test with Dye

Purge Air Conditioning System

Test Volumetric Efficiency

Leak Test Air Quality System Module

Group 15: 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: Center Frame

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Boom Swing Shock Absorbers

Remove and Install Boom Swing Link

Remove and Install Center Frame Roll Bushings

Group 10: Steel Boom

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Boom Section

Remove and Install Boom Breakaway Spring

Remove and Install Outer Wing Hinge Bushings

Remove and Install Outer Wing Fold Linkage Bushings

Remove and Install Breakaway Spring Link Bushings

Remove and Install Breakaway Fold Linkage Bushings

Group 15: Carbon Fiber Boom

Other Material

Specifications

Carbon Fiber Boom Terminology

Remove and Install Inner Boom Section

Remove and Install Inner Boom Tilt and Strut Bushings

Remove and Install T6/T7 Rope

Remove and Install Retraction Lines

Remove and Install T1 Link, Compression Post, and T2 Link

Remove and Install Outer Boom Section

Remove and Install Outer Boom Fold and Fold Cylinder Bushings

Remove and Install Breakaway Fold Link Bushings—36 m (118 ft)

Remove and Install Breakaway Tension Chain—36 m (118 ft)

Boom Alignment Specification Overview

Adjust Outer Wing, T3 Link, and T6/T7 Rope

Adjust Breakaway Tension

Adjust Breakaway Tension Chain—36 m (118 ft)

Adjust Breakaway Alignment—36 m (118 ft)

Spray Boom Carbon Fiber Repair

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

DFNXT13—Rear Planetary Assembly Spacer

DFNXT18—Spindle Driver

DFNXT19—Hydrostatic Pump Removal Tool

John Deere R4030, R4038 Self-Propelled Sprayers Service Repair Service Manual (TM115919)