Miller Nitro Sprayer 4000-Series Models Maintenance & Repair Manual (21-47116)

Complete service repair manual with Electrical Wiring Diagrams for Miller Nitro Sprayer 4000-Series Models, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Miller Nitro Sprayer 4000-Series Models workshop service 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.
* 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.

21.47116 - Miller Nitro Sprayer 4000-Series Models Maintenance & Repair Manual.pdf

PRODUCT DETAILS:
Total Pages: 617 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
CHAPTER 1 - GENERAL AND SAFETY INFORMATION
Safety Precautions.. . . . 1-3
Notes, Notices, Cautions, Warnings, and Dangers Definitions. . . . 1-3
General Safety Precautions. . . 1-4
Sprayer Safety Precautions. . . 1-5
SPRAYER OPERATIONS. . . . 1-5
SPRAYER SERVICE AND MAINTENANCE. . . . . 1-5
Chemicals and Hazardous Substances Safety Precautions. . . . . 1-5
HAZARDOUS SUBSTANCE ALERT. . . . . 1-5
Engine Safety Precautions. . . . 1-6
ENGINE OPERATION. . . . 1-6
Wheels and Tires Safety Precautions. . . . 1-7
Electrical Safety Precautions. . . . . 1-7
OPERATION OF ELECTRICAL COMPONENTS. . . . 1-7
Towing Safety Precautions. . . . 1-8
Moving a Downed Vehicle. . . . 1-8
Safety Sign and Decal Locations. . . . 1-11
SAFETY SIGNS. . . . . 1-11
Major Components Locations. . . . 1-15
Hoses/Fittings - General. . . . . 1-16
Application Basics. . . . 1-16
Bending, Motion, Routing. . . . 1-16
Hose and Fitting Care. . . . 1-16
Fittings Specifications. . . . 1-18
TIGHTENING HYDRAULIC FITTINGS. . . . . 1-18
TIGHTENING FLARE TYPE FITTINGS. . . . . 1-19
Hardware Torque Specifications. . . . 1-20
4000 Series Nitro Sprayer Models Pressure Settings. . . 1-27
Location of Electrical Relays, Breakers, and Fuses. . . . . 1-32
Miller Nitro Sprayer Hydraulic Oil Recommendation. . . . 1-34
Blaster Extended Antifreeze/Coolant. . . . 1-37
Nitro Sprayer Model Specifications. . . . . 1-38
Model 4215 / 4215HT. . . . 1-38
Model 4240HT. . . . 1-39
Model 4275.. . . 1-40
Page Number
Model 4315.. . . 1-41
Model 4365.. . . 1-42
CHAPTER 2 - CAB
General Notices, Cautions, Warnings, and Dangers For Cab Procedures. . . 2-3
Cab Air Bags. . . . . 2-4
REMOVAL.. . . . 2-4
INSTALLATION.. . . 2-4
Cab Filters.. . . . 2-4
CLEAN/CHANGE. . . . 2-4
Recirculation Air Filter. . . . . 2-4
Cab Air (Charcoal) Filter. . . 2-5
AC Recirculation Blower Motor. . . 2-5
REMOVAL.. . . . 2-5
INSTALLATION.. . . 2-6
AC Blower Motor. . . . . 2-6
REMOVAL.. . . . 2-6
INSTALLATION.. . . 2-6
AC Evaporator Heater. . . . 2-7
REMOVAL.. . . . 2-7
INSTALLATION.. . . 2-8
AC Actuator Water Valve. . . . 2-9
REMOVAL.. . . . 2-9
INSTALLATION. . . . . 2-10
AC Duct Work.. . . 2-11
REMOVAL.. . . 2-11
RH AC Vent. . . . . 2-11
LH AC Vent.. . . 2-11
INSTALLATION. . . . . 2-12
LH AC Vent.. . . 2-12
RH AC Vent. . . . . 2-12
Cab Interior Convenience Electrical Outlets Power Strip. . . 2-13
GENERAL INFORMATION. . . . . 2-13
Cab Interior Panels and Floor Mat. . . 2-14
REMOVAL.. . . 2-14
Floor Mat. . . . . 2-14
Front Interior Panel. . . 2-14
Overhead Console Panel. . . . . 2-14
Overhead Interior Light. . . 2-16
Headliner. . . . . 2-17
INSTALLATION. . . . . 2-18
Headliner. . . . . 2-18
Overhead Interior Light. . . 2-20
Overhead Console Panel. . . . . 2-21
Front Interior Panel. . . 2-22
Floor Mat. . . . . 2-22
Cab Roof.. . . . 2-23
REMOVAL.. . . 2-23
INSTALLATION. . . . . 2-23
Cab Steering Column Covers. . . . 2-24
REMOVAL.. . . 2-24
INSTALLATION. . . . . 2-24
Cab Windshield. . . . . 2-25
REPLACEMENT. . . . . 2-25
Cab Windshield Wiper Motor. . . . 2-25
REMOVAL.. . . 2-25
INSTALLATION. . . . . 2-25
Operator Control Console. . . 2-25
REMOVAL.. . . 2-25
INSTALLATION. . . . . 2-26
Operator Seat.. . . . 2-27
REMOVAL.. . . 2-27
INSTALLATION. . . . . 2-27
Operator Seat Suspension. . . 2-27
REMOVAL.. . . 2-27
INSTALLATION. . . . . 2-27
Training Seat.. . . .
REMOVAL.. . .
INSTALLATION. . . . .
AC/Heater Housing Cover. . .
REMOVAL.. . .
INSTALLATION. . . . .
AC Hoses.. . .
REMOVAL.. . .
INSTALLATION. . . . .
CHAPTER 3 - FRAME AND SUSPENSION
General Notices, Cautions, Warnings, and Dangers For Frame and Suspension Procedures. . . 3-3
Rear Deck and Platforms. . . . 3-4
REAR DECK. . . . . 3-4
Removal.. . . 3-4
Installation. . . . . 3-4
MID-PLATFORM. . . . . 3-5
Removal.. . . 3-5
Installation. . . . . 3-5
FRONT PLATFORM. . . . . 3-6
Removal.. . . 3-6
Installation. . . . . 3-6
Suspension Cylinders. . . . 3-7
SUSPENSION SYSTEM - GENERAL. . . . 3-7
SUSPENSION SYSTEM CHECK. . . . 3-9
Suspension System Leak Down Check. . . 3-9
SUSPENSION CYLINDERS ADJUSTMENT. . . . 3-9
BLEED AIR FROM SUSPENSION SYSTEM. . . 3-10
SUSPENSION CYLINDER 21.40741 REBUILD. . . . 3-11
Repair Parts Available. . . 3-13
A-Frame.. . . . 3-15
REMOVAL.. . . 3-15
INSTALLATION. . . . . 3-35
Ladder Assembly.. . . . 3-50
REMOVAL.. . . 3-50
INSTALLATION. . . . . 3-51
Hydraulic Ladder Lift Cylinder. . . 3-52
REMOVAL.. . . 3-52
INSTALLATION. . . . . 3-52
Air Tank. . . . . 3-53
REMOVAL.. . . 3-53
INSTALLATION. . . . . 3-53
Fuel Tank.. . . . 3-54
REMOVAL.. . . 3-54
INSTALLATION. . . . . 3-54
Hand Rinse Tank.. . . . 3-55
REMOVAL.. . . 3-55
DISASSEMBLY. . . . . 3-55
ASSEMBLY. . . . . 3-56
INSTALLATION. . . . . 3-56
CHAPTER 4 - ENGINE
General Notices, Cautions, Warnings, and Dangers For Engine Procedures. . . . 4-5
ENGINE TROUBLESHOOTING. . . 4-7
Engine Fault Codes - General. . . . . 4-8
Engine Fault Codes - QSB and QSL Engines. . . . . 4-9
Upper Fan Screen.. . . 4-23
REMOVAL.. . . 4-23
INSTALLATION. . . . . 4-23
Lower Fan Screen.. . . 4-24
REMOVAL.. . . 4-24
INSTALLATION. . . . . 4-24
Fan.. . . 4-25
REMOVAL.. . . 4-25
INSTALLATION. . . . . 4-25
Fan Motor.. . . . 4-26
REMOVAL.. . . 4-26
INSTALLATION. . . . . 4-26
Fan Shroud Assembly.. . . 4-27
REMOVAL.. . . 4-27
DISASSEMBLY. . . . . 4-28
ASSEMBLY. . . . . 4-28
INSTALLATION. . . . .
Cooling Package.. . . .
REMOVAL.. . .
INSTALLATION. . . . .
Individual Component of Cooling Package. . . . .
REMOVAL.. . .
INSTALLATION. . . . .
Engine Enclosure and Doors. . . .
REMOVAL.. . .
Engine Enclosure Doors. . . . .
Engine Top Covers. . .
Rear Engine Bay Panel. . . . .
Left Engine Bay Panel. . .
Right-hand Bottom and Top Engine Enclosure Covers. . . . .
Exhaust Shield.. . .
Right Engine Bay Panel. . . . .
INSTALLATION. . . . .
Right Engine Bay Panel. . . . .
Exhaust Shield.. . .
Right-hand Bottom and Top Engine Enclosure Covers. . . . .
Left Engine Bay Panel. . .
Rear Engine Bay Panel. . . . .
Engine Top Covers. . .
Engine Enclosure Doors. . . . .
Fuel Pump.. . .
REMOVAL.. . .
INSTALLATION. . . . .
Engine Mounts. . . . .
REMOVAL.. . .
Front Engine Mount. . . . .
Rear Engine Mount. . .
INSTALLATION. . . . .
Rear Engine Mount. . .
Front Engine Mount. . . . .
Air Conditioner Compressor Belt. . . . 4-50
REMOVAL.. . . 4-50
INSTALLATION. . . . . 4-50
Serpentine Belt.. . . 4-50
REMOVAL.. . . 4-50
INSTALLATION. . . . . 4-51
Engine Belly Door.. . . . 4-52
REMOVAL.. . . 4-52
INSTALLATION. . . . . 4-54
Air Conditioning Compressor. . . . 4-55
REMOVAL.. . . 4-55
INSTALLATION. . . . . 4-55
AC Receiver Dryer.. . . 4-56
REMOVAL.. . . 4-56
INSTALLATION. . . . . 4-56
Alternator.. . . . 4-57
REMOVAL.. . . 4-57
INSTALLATION. . . . . 4-57
Starter Motor.. . . . 4-58
REMOVAL.. . . 4-58
INSTALLATION. . . . . 4-59
Air Cleaner Filter Element. . . 4-60
REMOVAL.. . . 4-60
INSTALLATION. . . . . 4-61
Air Cleaner Assembly. . . . 4-62
REMOVAL.. . . 4-62
INSTALLATION. . . . . 4-62
Exhaust Assembly.. . . 4-63
REMOVAL.. . . 4-63
INSTALLATION. . . . . 4-64
Fan Hydraulic Pump. . . . . 4-65
REMOVAL.. . . 4-65
INSTALLATION. . . . . 4-65
Air Compressor. . . . . 4-66
REMOVAL.. . . 4-66
INSTALLATION. . . . . 4-67
Air Governor.. . . .
REMOVAL.. . .
INSTALLATION. . . . .
ADJUSTMENT. . . . .
Fuel-Water Separator.. . .
DRAIN.. . .
Fuel-Water Separator Hand Priming Pump. . . . .
REMOVAL.. . .
INSTALLATION. . . . .
AC Charging.. . . .
FIELD CHARGING. . . . .
ALTERNATE CHARGING TECHNIQUE. . . .
PRESSURE TEMPERATURE CHART. . . . .
CHAPTER 5 - DRIVE AND HYDRAULICS
General Notices, Cautions, Warnings, and Dangers For Drive and Hydraulics Procedures. . . . . 5-3
Troubleshooting.. . . 5-4
HYDRAULIC SYSTEM CLEANLINESS. . . . . 5-4
HYDRAULIC SYSTEM PRESSURE. . . . . 5-4
Front Steering Cover. . . . . 5-4
REMOVAL.. . . . 5-4
INSTALLATION.. . . 5-5
Tire.. . . 5-6
NITRO 4000 SERIES MAIN LIFT JACK P/N 21.43250. . . . . 5-6
TIRE REMOVAL. . . . . 5-7
TIRE INSTALLATION. . . . 5-8
Wheel Drive Motor Assembly. . . 5-10
REMOVAL.. . . 5-10
INSTALLATION. . . . . 5-11
Wheel Drive Motor Start Up/Air Bleed and Auxiliary Brake. . . . . 5-12
AIR BLEED. . . . . 5-12
Wheel Drive Motor Start Up/Air Bleed. . . 5-12
Auxiliary Foot Brake Air Bleed. . . 5-12
Hydrostatic Pump Adjustment. . . 5-13
Specifications By Model. . . . . 5-13
Auxiliary Hydraulic Pump. . . 5-20
REMOVAL.. . . 5-20
INSTALLATION. . . . . 5-20
Brake/Shifting Valve. . . . . 5-21
REMOVAL.. . . 5-21
INSTALLATION. . . . . 5-21
Hydraulic Oil Tank.. . . 5-22
REMOVAL.. . . 5-22
INSTALLATION. . . . . 5-23
Cooler Bypass Valve. . . . 5-24
REMOVAL.. . . 5-24
INSTALLATION. . . . . 5-24
HYDRAULIC TANK VACUUM PROCEDURE. . . 5-25
Shop Vac or Vacuum Device Method. . . . 5-25
Brake Pedal/Valve.. . . 5-26
REMOVAL.. . . 5-26
Underneath Cab. . . . . 5-26
Inside Cab.. . . . 5-27
INSTALLATION. . . . . 5-27
Inside Cab.. . . . 5-27
Underneath Cab. . . . . 5-27
Hydrostatic Tandem Pump Set Coupler. . . . . 5-28
REMOVAL.. . . 5-28
INSTALLATION. . . . . 5-31
Wheel Drive Brake.. . . 5-33
REMOVAL.. . . 5-33
INSTALLATION. . . . . 5-33
Wheel Drive Brake Repair. . . 5-33
Accumulator Charging.. . . 5-34
BOOM LIFT ACCUMULATOR. . . 5-34
Charge.. . . . 5-34
BOOM TILT ACCUMULATORS. . . . . 5-38
Charge.. . . . 5-38
BRAKE ACCUMULATOR. . . . 5-42
Charge.. . . . 5-42
SUSPENSION ACCUMULATORS. . . . .
Charge.. . .
Steering Cylinder.. . . .
REMOVAL.. . .
INSTALLATION. . . . .
STEERING CYLINDER PHASING. . . . .
PRELIMINARY TASKS PRIOR TO STEERING CYLINDER TOE IN ADJUSTMENT. . . . .
SETTING STEERING CYLINDER TOE IN. . . . .
Hydrostatic Tandem Pump Assembly. . .
REMOVAL.. . .
INSTALLATION. . . . .
Electrical Hydraulic Shifting System Schematics. . .
CHAPTER 6 - SPRAYER
General Notices, Cautions, Warnings, and Dangers For Sprayer Procedures. . . 6-3
Spray Monitor.. . . . 6-4
Rinse Tank.. . . 6-6
REMOVAL.. . . . 6-6
INSTALLATION.. . . 6-6
Product Tank. . . . . 6-7
REMOVAL.. . . . 6-7
INSTALLATION.. . . 6-9
Product Pump.. . . 6-11
PRODUCT PUMP MAINTENANCE. . . . 6-12
Flush. . . . . 6-12
Corrosion Prevention. . . . 6-12
REMOVAL.. . . 6-12
DISASSEMBLY. . . . . 6-13
ASSEMBLY. . . . . 6-13
Pump Seal Replacement. . . . 6-13
Hydraulic Motor Disassembly. . . . 6-14
Motor Shaft Removal. . . . 6-15
Motor Shaft Disassembly. . . . 6-15
Motor Shaft Assembly. . . . 6-16
Motor Shaft Assembly Installation. . . 6-16
Hydraulic Motor Parts Assembly. . . . . 6-16
SPRAYER TROUBLESHOOTING. . . 6-18
Flow Meter Maintenance and Adjustment. . . 6-21
Flow Meter Recalibration. . . . 6-22
Foamer System. . . . . 6-23
FOAMER SYSTEM TROUBLESHOOTING. . . . . 6-23
FOAMER SYSTEM MAINTENANCE. . . . 6-24
FOAM MARKER CONTROL BOX TEST PROCEDURE. . . . 6-25
CHAPTER 7 - OPTIONS
Fender.. . . . 7-3
REMOVAL.. . . . 7-3
Front Fender.. . . 7-3
Rear Fender.. . . . 7-4
INSTALLATION.. . . 7-4
Front Fender.. . . 7-4
Rear Fender.. . . . 7-5
HYDRAULIC HOSE ROUTING CHARTS
Brake Valve/Hydraulic Hose Routing . Hyd Hose Routing - 3
Flow Control Valve/Hydraulic Hose Routing . Hyd Hose Routing - 4
Product Pump Motor/Hydraulic Hose Routing . Hyd Hose Routing - 5
Steering Valve/Hydraulic Hose Routing . Hyd Hose Routing - 6
Hydraulic Fan Motor/Hydraulic Hose Routing . Hyd Hose Routing - 7
Fan Pump/Hydraulic Hose Routing. Hyd Hose Routing - 8
Leg Widening Valves/Hydraulic Hose Routing . Hyd Hose Routing - 9
Shuttle Valve/Hydraulic Hose Routing . Hyd Hose Routing - 10
Reversing Valve/Hydraulic Hose Routing . Hyd Hose Routing - 11
Fan Relief Valve /Hydraulic Hose Routing . Hyd Hose Routing - 12
Hydrostatic Tandem Pump Set/Hydraulic Hose Routing . Hyd Hose Routing - 13
Hydraulic Oil Tank/Hydraulic Hose Routing . Hyd Hose Routing - 14
Suspension Cylinders and Accumulators/Hydraulic Hose Routing . Hyd Hose Routing - 15
Integrated Manifold Valve . Hyd Hose Routing - 16
APPENDIX
Appendix - General Information. . . . Appendix - 1
Poclain® MS02-MS18 Wheel Drive Motor
Troubleshooting, Repair, and Maintenance Manual. . . . Appendix - 3
Poclain® MW14 Wheel Drive Motor
Troubleshooting, Repair, and Maintenance Manual. . . . Appendix - 5
Poclain® MW24 Wheel Drive Motor
Troubleshooting, Repair, and Maintenance Manual. . . . Appendix - 7
Sauer Danfoss Series 90 Hydraulic Pumps
Troubleshooting, Repair, and Maintenance Manual. . . . Appendix - 9

Miller Nitro Sprayer 4000-Series Models Maintenance & Repair Manual (21-47116)