John Deere Trailed Crop Sprayers Models 824, 832, 840 Diagnosis & Tests Service Manual (TM4782)

TM4782 - John Deere Trailed Crop Sprayers Models 824, 832 and 840 with ELC-1/EHC-2/EL-4 Control Unit / with TwinFluid Spraying System Technical Service Manual (Diagnosis & Tests).PDF

Complete Diagnosis & Tests manual with Electrical Wiring Diagrams for John Deere Trailed Crop Sprayers Models 824, 832, 840, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere Trailed Crop Sprayers Models 824, 832, 840 workshop Operation & Test 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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.

Total Pages: 1,068 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
  Foreword
   Safety
      Safety Information
   General Information
      Description of the Machine
      Torques for Hardware
      Specifications
   Electrical System
      Connector Repair
      Electrical Control
      Troubleshooting (General)
      Troubleshooting – EL4 Control Unit
      Troubleshooting – ELC-1/EHC-2 Control Units
      GreenStar™ Programming and Info
      GreenStar™ Caution and Warning Statements
   Power Train
      Compressor
      Gearbox
   Brake System
      Hydraulic Brake System
      Pneumatic Brake System
   Hydraulic System
      Hydraulic Functions
      Hydraulic Cylinders
      Control Valves
      Accumulator
      Sensors
      Adjustments
      Hydraulic Diagrams
   Miscellaneous
      Welding and Repair
      Function Diagrams
      Sprayboom
      Sprayboom Adjustments
      Center Frame
      Track Width Adjustment
      Axle
      Drawbar Adjustments
      Drawbar
      Parallelogram
   Tank and Accessories
      Spraying Liquid Tank
      Rinse Tank
   Pump
      Pump
   Lines and Valves
      Sprayline
   Activation Systems
      Sensors
      Boom Tilt Cylinder
      Ball Valves
      Regulating Unit
      Air Pressure Regulating Unit
   Spray Nozzles
      Spray Nozzles
   VRS
      Distributor Tube

tm4782 - 824, 832 and 840 Trailed Crop Sprayers withELC-1/EHC-2 Control Unit/ with EL-4 Control Unit/ with TwinFluid- Spraying System

Table of Contents

Foreword

Section 05: Safety

Group 05: Safety Information

Admissible Use

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Keep Riders Off Machine

Prepare for Emergencies

Use of Safety Lighting and Provisions

Work in Clean Area

Chemical Safety

Danger Symbols

Mechanical Safety

Non-Permissible Use

Operators

Working Area

Means of Personal Protection

Illuminate Work Area Safely

Respiratory Protection

Skin Protection

Maintenance of Means of Personal Protection

Tractor Cab

Use Proper Lifting Equipment

Safety During Maintenance Work

Avoid High-Pressure Fluids

Avoid Heating Near Pressurized Fluid Lines

Use Proper Tools

Construct Dealer-Made Tools Safely

Live With Safety

Service Machines Safely

Remove Paint Before Welding or Heating

Section 10: General Information

Group 05: Description of the Machine

Identification Views

Machine Composition

Group 10: Torques for Hardware

Unified Inch Bolt and Cap Screw Torque Values

Metric Bolt and Cap Screw Torque Values

Group 15: Specifications

Capacities

Dimensions and Weights

Sound Level

Electrical Connection Requirements

Products to be Processed

Materials Applied

Physical Operating Conditions

Storing Lubricants

Use Genuine John Deere Parts

Section 40: Electrical System

Group 05: Connector Repair

Special Tools

Electrical Connector Handling

Disconnecting Electrical Circuit

Replacing Connectors

Insulated and Non-Insulated Connectors

Replacing DEUTSCHDEUTSCH is a trademark of Deutsch Co. Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact

Group 10: Electrical Control

Electrical Control - Diagram

Power Supply

Fitting Electrical Socket to Tractor

Group 15: Troubleshooting (General)

Replacing Fuses

Circuit Board Connectors

Connector Identification

Other Designations (Identification)

Troubleshooting

Blown Fuse

Colour Codes according to DIN 47100

Pressure Sensor

Air Pressure Sensor

Flow Sensor

Wheel Sensor

Sensors for Drawbar Steering

Hydraulic Valve Block

Locking System Pull Switch

Electrical Function Diagrams

Hydraulic Function Diagrams

Group 20: Troubleshooting – EL4 Control Unit

Legend for Electrical Diagrams

Section Survey

Circuit Board Survey

Wire Survey

EL-4 Control Unit with Hy-Select

EHS-1 Control Unit

EHB-2 Control Unit

Wire W1 - EL-4 Control Unit to Main Board

Connector Function, Wire W1

Wire W2 - Hy-Select Control Unit to Hy-Select Board

Wiring Diagram – Wire W2

Connector Function, Wire W2

Wire W3 - EHS-1 Control Unit

Wiring Diagram – Wire W3

Wire W4 - EHB-2 Control Unit

Wiring Diagram – Wire W4

Main Board A01 (Standard Version)

Main board A05 (Edge Nozzle Version)

Main board A06 (OC Nozzle Version)

Main Board LEDs

Board A02 (Control of Main Shut-Off Valve and VRS Valves)

Function Diagram, Board A02

Board A03 (Control of Hy-Select Valve Block)

LEDs and Fuses of Board A03 (Hy-Select)

Circuit State of Board A03 (Hy-Select)

Board A04 (Electrical Boom Tilt Correction via Rotary Switch)

Board A04 (Hydraulic Boom Tilt Correction via Rotary Switch)

Board A07 (Drawbar Steering)

LEDs and Fuses of Board A07 (Drawbar Steering)

Wiring Diagram, Main Power Supply

SE01 – Wiring Diagram, Sensors, Pressure Regulator up to SN 002478

SE02 – Wiring Diagram, Boom Section Valves

SE03 – Wiring Diagram, Main Shut-Off Valve/VRS Valves

SE04 – Wiring Diagram, Sensors for Drawbar Steering/Wire W2 (Hy-Select Control Unit to Board A03)

SE05 – Wiring Diagram, Hy-Select Solenoid Valves

SE06 – Wiring Diagram, Electrical Boom Tilt Correction via Rotary Switch

SE07 – Wiring Diagram, Electrical Boom Tilt Correction via Toggle Switch

SE08 – Wiring Diagram, Edge Nozzle Control

SE09 – Wiring Diagram, OC Nozzle Control

SE10 – Wiring Diagram, Wire W1

SE11 – Wiring Diagram, Sensors for Drawbar Steering/Wire W4 (EHB-2 Control Unit to Board A07)

SE12 – Wiring Diagram, Hydraulic Boom Tilt Correction via Rotary Switch

SE13 – Wiring Diagram, Sensors, Pressure Regulator from SN 002478

Edge Nozzle Control

OC Nozzle Control

Test Sequence

Electrical System Troubleshooting

Application Rate Too High/Too Low

Main shut-off valve M/VRS valves do not operate. Relays K6, K7 do not operate

Main shut-off valve M/VRS valves do not operate. Relays K6, K7 are OK

Main shut-off valve/VRS valves do not operate. Fuse F7 blown.

Edge nozzle and/or last nozzle do not operate (main board A05)

OC nozzle does not operate (main board A06)

Drawbar steering not correct

Boom section valves do not operate. Fuse F8 OK

Boom section valve does not operate. Fuse F8/2A blown.

Boom folding/unfolding does not operate

Spraying pressure cannot be adjusted at the pressure regulator

Boom tilt correction via toggle switch does not operate

Boom tilt correction via rotary switch does not operate

Boom tilt system moves boom to left-hand or right-hand end position, regardless of rotary switch (potentiometer) position.

Control unit without operating voltage. Operating voltage present at main board/X101.

Spraying computer on control unit without operating voltage

Group 25: Troubleshooting – ELC-1/EHC-2 Control Units

Legend for Electrical Diagrams

Section Survey

Circuit Board Survey

Wire Survey

EHC-2 Control Box

Wire W1 – Main Power Supply

Functional Schematic – Main Power Supply

Connection Identification – Main Connector X1

Wire W2 – T-Splitter

Wire W4 – Main Connection of Main Board A03

Wire W5 – Board Main Power Supply

Wires W6, W7, W8 - Powerlink Extension

Board A01 - CAN-BUS

Board A02 - Powerlink Extension

Board A03 – Main Functions

Board A04 – Electrical Options (Standard Version)

Board A05 - Control of Main Shut-Off Valve / VRS Valves

Function Diagram of Board A05 - Control of Main Shut-Off Valve / VRS Valves

Connectors of board A05

Board A06 – Hydraulic Functions

Board A07 - TF Sections

SE01 - Wiring Diagram - Sensors, Pressure Regulator

SE02 - Wiring Diagram - Boom Section Valves (Spraying Liquid)

SE03 - Wiring Diagram - Main Shut-Off Valve/VRS Valves

SE04 - Wiring Diagram – Sensors, Electrical Boom Tilt Correction

SE05 - Wiring diagram – Sensors, Hydraulic Boom Tilt Correction

SE06 - Wiring Diagram – Electrical Options (Hydraulic Boom Tilt Correction)

SE07 - Wiring Diagram – Electrical Options (Electrical Boom Tilt Correction)

SE08 - Wiring Diagram – Hydraulic Functions

SE09 - Wiring diagram - TF Sections

SE10 - Wiring Diagram - Edge Nozzle

SE11 - Wiring Diagram - OC Nozzle

SE12 – Wiring Diagram – Electrical Boom Tilt Correction

SE13 - Wiring Diagram – Hydraulic Boom Tilt Correction

SE14 - Wiring Diagram – Automatic Filling

SE15 - Wiring Diagram - Semi-Automatic Filling

Test Sequence

Electrical System Troubleshooting

Control unit not operating

Control switch on control unit not operating

Application rate too high/too low

Main shut-off valve M/VRS valves do not operate. Relays K501, K502 do not operate.

Edge nozzle and/or last nozzle do not operate

OC nozzle does not operate

Drawbar steering does not operate correctly

Boom section valves do not operate.

Spraying pressure cannot be adjusted at the pressure regulator

Check Powerlink Boards for Proper Operation

Group 30: GreenStar™ Programming and Info

GREENSTARGREENSTAR is a trademark of Deere & Company Display and Keypad

Display and Keypad Function Identification

General Information

Quick Reference Chart RUN Page

RUN

Quick Reference Chart SETUP Page

SETUP

SETUP JD Sprayer

SETUP Job Settings

SETUP Tank Filling

SETUP Machine Settings

SETUP Sensor Calibration

SETUP Flow Sensor

SETUP Liquid Pressure Sensor

SETUP Wheel Sensor

SETUP Tank Sensor

SETUP Air Pressure Sensor

SETUP Spray Boom Settings

SETUP Nozzle Presets

SETUP Tank Settings

SETUP Regulation Settings

SETUP OEM Settings

SETUP Sensor Configuration

SETUP Spray Boom Configuration

SETUP Boom Balance PAGE 1

SETUP Boom Balance PAGE 2

SETUP Tank Configuration

SETUP Tank Shape

SETUP Regulation Details

SETUP Alarm Configuration

SETUP Language

SETUP GreenStar Display

SETUP Display Address

SETUP CAN Physical Layer

SETUP Run Page Layout

SETUP Tracking

Quick Reference Chart INFO Page

INFO

INFO JD Sprayer

INFO Wind Speed

INFO Field Data

INFO Total Data

INFO Diagnostics

INFO Sensor Status

INFO Switchbox Status

INFO Recent Problems JD Sprayer

INFO GreenStar Display

INFO Recent Problems GreenStar Display

INFO Display Diagnostics

INFO Watchdog Trace

INFO Can Bus Analyzer

INFO Tracking

Simulated Speed

GreenStar Caution and Warning Statements

Group 35: GreenStar™ Caution and Warning Statements

C001 –– Minimum Regulation Pressure

C002 –– Maximum Regulation Pressure

C003 –– Target Rate Impossible, Actual Rate Too High

C004 –– Target Rate Impossible, Actual Rate Too Low

C005 –– No Wheel Sensor Pulses

C006 –– Flow / Pressure Cross Check Alarm

C007 –– Tank Almost Empty

C008 –– Stop Tank Agitation

C009 –– Tank Agitation Stopped

C010 –– No flow sensor pulses

C011 –– Below Minimum Speed

C012 –– Working Pressure Based (Low Flow)

C013 –– Low Flow Alarm

C014 –– Pressure Too Low

C015 –– Pressure Too High

C016 –– Density not 1.00 Kg/L

C017 –– Air Pressure Too Low, Increase Speed

C018 –– Air Pressure Too High, Reduce Speed

C019 –– Liquid Pressure Too Low; Increase Travel Speed

C020 –– Liquid Pressure Too High; Decrease Travel Speed

W001 –– 12 V POWER

W003 –– BOOM SECTION OUTPUT

W004 –– FLOW SENSOR

W005 –– LIQUID PRESSURE SENSOR

W006 –– PUMP OIL LEVEL

W007 –– AIR PRESSURE SENSOR

Section 50: Power Train

Group 05: Compressor

Specifications

Remove and Install Flex Coupler

Remove and Install Compressor

Repair Compressor

Troubleshooting

Remove and Install Pressure Relief Valve

Disassemble and Assemble Pressure Relief Valve

Group 10: Gearbox

Other Material

Remove and Install Gearbox

Sealing the Gearbox

Repair Gearbox

Section 60: Brake System

Group 05: Hydraulic Brake System

Hydraulic Brake System (Not for Germany)

Remove and Install Hydraulic Brake Cylinder (Adjustable Axle)

Remove and Install Hydraulic Brake Cylinder (Fixed Axle)

Repair Hydraulic Brake Cylinder

Adjust Parking Brake

Remove and Install Parking Brake Operating Assembly

Replace Cable Disk

Replace Tension Cable (Parking Brake of Adjustable Axle)

Replace Tension Cable (Parking Brake of Fixed Axle)

Group 10: Pneumatic Brake System

Pneumatic Brake System

Public Roads

Replace Coupling

Clean/Replace Line Filter Strainer

Replace Release Valve

Replace Brake Power Regulator

Replace Brake Valve

Replace Quick Release Valve or Switch Valve

Replace Shut-Off Valve

Replace Compressed Air Storage Tank

Replace Brake Cylinder

Section 70: Hydraulic System

Group 05: Hydraulic Functions

General Information

Operation of Hydraulic Functions

Group 10: Hydraulic Cylinders

Other Material

Replace Restrictor of Drawbar Steering Cylinder

Remove and Install Drawbar Steering Cylinder

Repair Drawbar Steering Cylinder

Remove and Install Height Adjustment Cylinder

Repair Height Adjustment Cylinder

Remove and Install Sprayboom Lift Cylinder (If Equipped)

Repair Sprayboom Lift Cylinder

Group 15: Control Valves

Avoid High Pressure Fluids

General Repair Information

Remove and Install Distributor Block with Sequence Valve (Machines with Hy-Select)

Replace Solenoid Valve/Non Return Valve

Group 20: Accumulator

Remove and Install Distributor with Accumulator

Replace Accumulator

Group 25: Sensors

Replace Sensors (Drawbar Steering)

Group 30: Adjustments

Adjust the Sequence Valves

Folding and Unfolding

Group 35: Hydraulic Diagrams

Hydraulic Diagrams, Standard or Hy-Select

Hydraulic Diagram for Sprayers with Double Folding Boom

Hydraulic Diagram for Sprayers with Triple Folding Boom

Section 80: Miscellaneous

Group 05: Welding and Repair

Unauthorized Modifications

Frame Repair

Welding

Emergency Crack Repair

Emergency “T” Joint Repair

Skip Welding

Stress Relief (Normalizing)

Group 10: Function Diagrams

Function Diagram Sprayer with Single Pump

Function Diagram Sprayer with Single Pump and VRS

Function Diagram Sprayer with Single Pump and Automatic Tank Filling

Function Diagram Sprayer with Single Pump, VRS and Automatic Tank Filling

Function Diagram Sprayer with Double Pump

Function Diagram Sprayer with Double Pump and VRS

Function Diagram Sprayer with Double Pump and Automatic Tank Filling

Function Diagram Sprayer with Double Pump, VRS and Automatic Tank Filling

Group 15: Sprayboom

Remove and Install Complete Sprayboom (On One Side)

Remove and Install End Section

Remove and Install Center Section

Remove and Install, Replace Starting Section

Replace Hinge Arm

Replace Spindle

Replace Tension Spring (On End Section)

Remove and Install Folding/Unfolding Cylinder

Repair Folding/Unfolding Cylinder

Remove and Install Transport Support/Roll (Center Section)

Remove and Install Transport Support (Starting Section)

Remove and Install Locking Stay (20/15 und 21/15m)

Remove and Install Locking Stay (All Versions Except 20/15 und 21/15m)

Replace Pressure Roll for End Section (24/12; 28/14 and 30/15 m Versions Only)

Group 20: Sprayboom Adjustments

Specifications

Adjusting The Sprayboom Transport Position

Adjusting and Aligning the Sprayboom

Balancing Sprayboom

Group 25: Center Frame

Special Tools

Specifications

Other Material

Remove and Install Complete Attaching Frame

Replace Attaching Frame

Replace Gas Pressure Shock Absorber

Replace Bearing of Anti-Yaw Device

Replace Intermediate Bar

Replace Damper/Stop Wedge

Remove and Install Folding/Unfolding Cylinder

Repair Folding/Unfolding Cylinder

Remove and Install Locking Cylinder

Repair Locking Cylinder

Remove and Install Connecting Rod

Replace Deflector Roll of Hook Tension Cable

Replace Hook Tension Cable

Adjust Hook Tension Cable

Replace Transport Roll/Wear Plates

Replace Hook

Remove and Install Balancing Springs

Replace Guide Strips (on Attaching Frame)

Adjusting The Center Frame

Replace Guide Strips (on Guide Tube)

Group 30: Track Width Adjustment

Track Width Adjustment With Sliding Axle

Group 35: Axle

Special Tools

Specifications

Other Material

Remove and Install Axle

Remove and Install Spring Element or Support

Replace Speed Sensor

Replace Taper Roller Bearings (Wheel Hub)

Amount of Grease For Each Wheel Hub

Check Brake Drum

Replace Brake Drum or Magnet Wheel

Check Brake Linings, Replace Brakes Shoes

Brake Adjustment

Remove and Install Linkage Adjuster

Remove and Install Brake Camshaft (Adjustable Axle)

Remove and Install Brake Camshaft (Fixed Axle)

Group 40: Drawbar Adjustments

Installing the Lower Linkage Drawbar (Automatic Tracking System)

Universal Drawbar Pivot

Installing the Universal Drawbar (Automatic Tracking System)

Adjusting the Automatic Tracking System With Lower Linkage Drawbar

Adjusting The Automatic Tracking System With Universal Drawbar

Steering Cylinder Speed Adjustment

Group 45: Drawbar

Specifications

Other Material

Remove and Install Tow Eye or Connecting Frame

Remove and Install Drawbar

Group 50: Parallelogram

Remove and Install Parallelogram Arm (Top)

Remove and Install Parallelogram Arm (Bottom)

Section 100: Tank and Accessories

Group 05: Spraying Liquid Tank

Other Material

Replace Breather Valve/Tank Lid/Hinge Arm/Edge Cover

Replace Breather Valve

Replace Tank Lid Adapter

Replace Tank Level Indicator

Replace Float Cable/Float Guide/Float

Replace Injectors for Agitation

Remove and Install Tank

Group 10: Rinse Tank

Replace Breather Valve

Remove and Install Rinse Tank

Section 110: Pump

Group 05: Pump

Other Material

Remove and Install Pump

Disassemble and Assemble Pump

Seal Pump

Replace Accumulator Diaphragm

Section 120: Lines and Valves

Group 05: Sprayline

Remove and Install Line Filter

Replace Two-Way Ball Valve

Repair Two-Way Ball Valve

Replace Air Distributor Section

Replace 3/4” Solenoid Valve

Section 130: Activation Systems

Group 05: Sensors

Replace Flow Sensor (If Equipped)

Replace Liquid Pressure Sensor (If Equipped)

Replace Air Pressure Sensor

Group 10: Boom Tilt Cylinder

Specifications

Other Material

Remove and Install Boom Tilt Cylinder

Adjust Electrical Boom Tilt Cylinder with EL-4 Control

Adjust Boom Tilt Cylinder (ELC-1 and EHC-2 Control Unit)

Group 15: Ball Valves

Remove and Install Protective Cap on L.H. Side

Repair and Seal Four-Way Ball Valve (Pressure Selection Valve)

Replace Injector Shut-Off Valve

Repair and Seal Injector Shut-Off Valve

Replace Agitation Shut-Off Valve

Remove and Install Four-Way Ball Valve (Spraying Pump Suction Unit)

Remove and Install Four-Way Ball Valve (Agitation Pump Suction Unit)

Repair and Seal Four-Way Ball Valve (Suction Valve)

Remove and Install Three-Way VRS Suction Valve (If Equipped)

Remove and Install Drain Valve

Repair and Seal Drain Valve

Remove and Install Three-Way Electrical Ball Valve

Repair and Seal Three-Way Electrical Ball Valve

Group 20: Regulating Unit

Remove and Install Complete Regulating Unit

Disassemble and Assemble Regulating Unit

Remove and Install Primary Pressure Regulator

Repair Primary Pressure Regulator

Replace Diaphragm of Electrical Pressure Regulator

Replace Motor of Electrical Pressure Regulator

Replace Upper Microswitch of Electrical Pressure Regulator

Replace Lower Microswitch of Electrical Pressure Regulator

Replace Socket in Electrical Pressure Regulator

Remove and Install Pressure Filter

Remove and Install Suction Filter(s)

Remove and Install Three-Way Diverter Valve

Repair Three-Way Diverter Valve

Group 25: Air Pressure Regulating Unit

Replace Air Filter Restriction Indicator

Remove and Install Air Filter for Compressor

Remove and Install Sound Absorber

Remove and Install Complete Air Pressure Regulating Unit

Disassemble and Assemble Air Pressure Regulating Unit

Section 140: Spray Nozzles

Group 05: Spray Nozzles

Remove and Install Nozzle Holder with Nozzle

Replace Diaphragm

Seal Carrousel

Section 160: VRS

Group 05: Distributor Tube

Remove and Install VRS Filter

Remove and Install Non Return Valve

Replace Distributor Tube