John Deere Demountable Self-Propelled Crop Sprayers 5430i Repair Service Manual (TM402219)
Complete service repair manual for John Deere Demountable Self-Propelled Crop Sprayers 5430i (PIN Prefix WZ & 1WZ), with all the shop information to maintain, repair, and rebuild like professional mechanics.
John Deere Demountable Self-Propelled Crop Sprayers 5430i 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.
* 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.
TM402219 - John Deere 5430i Demountable Self-Propelled Crop Sprayer Technical Manual (Repair).PDF
TM402219 - John Deere 5430i Demountable Self-Propelled Crop Sprayer Technical Manual (Repair).epub
Total Pages: 1,111 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
Foreword
General Information
Safety
General Information
Fuels and Lubricants
Engine
Remove and Install Components
Fuel, Air Intake, and Cooling Systems
Component Removal and Installation
Diesel Fuel System
Engine Cooling System
Electrical System
Battery
Harness and 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 Routings
Power Train
Component Removal and Installation
Hydrostatic Drive Repair
Planetary Hub Repair
Steering and Brakes
Component Removal and Installation
Steering
Service Brakes
Suspension and Tread Adjust
Component Removal and Installation
Tread Adjust Valves
Tread Adjust Cylinders
Hydraulic System
Component Removal and Installation
Hydraulic Pump
Hydraulic Valves
Hydraulic Reservoir
Solution Spray System
Component Removal and Installation
Solution Tank
Solution Pump
Spray Nozzles
Solution Control Valves
Eductor
Fast Fill Pump
Pneumatic System
Component Removal and Installation
Component Repair
Operator`s Station
Cab
Controls
Air Conditioning System
Heating System
Air Suspension Seat
Cab Door and Windshield
Boom Repair
Boom Repair
Dealer Fabricated Tools
TABLE OF CONTENTS....1
Section 10: General Information....18
Group 05: Safety....18
Recognize Safety Information....22
Understand Signal Words....23
Perform Service Safely....24
Wait Before Opening High-Pressure Fuel System....25
Service Accumulator Systems Safely....26
General Machine Operation Safety....27
Transport in the Field and on the Road....28
Park Machine Safely....30
Servicing Electronic Control Units....31
Welding Near Electronic Control Units....32
Keep Electronic Control Unit Connectors Clean....33
Handle Fluids Safely—Avoid Fires....34
Prevent Battery Explosions....195
Prepare for Emergencies....36
Protect Against High Pressure Spray....37
Prevent Acid Burns....38
Wear Protective Clothing....40
Handle Agricultural Chemicals Safely....41
Service and Operate Chemical Sprayers Safely....43
Avoid Contact with Agricultural Chemicals....45
Clean Vehicle of Hazardous Pesticides....484
Support Machine Properly....48
Service Machines Safely....49
Practice Safe Maintenance....50
Avoid Harmful Asbestos Dust....52
Work In Ventilated Area....53
Work in Clean Area....54
Remove Paint Before Welding or Heating....55
Avoid Heating Near Pressurized Fluid Lines....56
Avoid High-Pressure Fluids....57
Service Tires Safely....58
Service Cooling System Safely....59
Illuminate Work Area Safely....60
Replace Safety Signs....61
Use Proper Lifting Equipment....62
Use Proper Tools....63
Construct Dealer-Made Tools Safely....64
Decommissioning — Proper Recycling and Disposal of Fluids and Components....65
Handle Electronic Components and Brackets Safely....66
Live With Safety....67
Group 10: General Information....19
Machine Specification....72
Machine Dimensions....76
Face Seal Fittings Assembly and Installation—All Pressure Applications....79
Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures....80
Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications....82
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures....84
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications....86
Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications....88
SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications....89
SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications....90
External Hexagon Port Plug Torque Chart....91
Identifying Zinc-Flake Coated Fasteners....93
Metric Bolt and Screw Torque Values....94
Unified Inch Bolt and Screw Torque Values....96
Programming Control Units....98
Preparing and Painting Sprayer Components....101
Group 15: Fuels and Lubricants....19
Diesel Fuel....104
Handling and Storing Diesel Fuel....106
Lubricity of Diesel Fuel....107
Diesel Engine Coolant (engine with wet sleeve cylinder liners)....108
Testing Diesel Engine Coolant....110
Supplemental Coolant Additives....111
Operating in Warm Temperature Climates....112
Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER....113
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III....115
Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I....117
Extended Diesel Engine Oil Service Intervals — Non-Emissions Certified and Certified Tier 1 and Stage I....119
Hydrostatic/Hydraulic Drive Oil....120
Planetary Hub Oil....121
Grease....122
Suspension and Steering Grease....123
Alternative and Synthetic Lubricants....124
Lubricant Storage....125
Section 20: Engine....126
Group 00: Remove and Install Components....126
Essential or Recommended Tools....993
Specifications....1087
John Deere Engine Repair—Use CTM....371
Clean Vehicle of Hazardous Pesticides....484
Remove and Install Engine....132
Remove and Install Hood....141
Remove and Install Exhaust System....142
Section 30: Fuel, Air Intake, and Cooling Systems....144
Group 00: Component Removal and Installation....144
Specifications....1087
Remove and Install Air Cleaner Housing....147
Remove and Install Fan Drive and Shroud....148
Remove and Install Radiator....152
Remove and Install Aftercooler....166
Remove and Install Diesel Fuel Cooler....169
Remove and Install Expansion Tank....170
Remove and Install Fuel Tank....174
Group 05: Diesel Fuel System....144
Specifications....1087
Clean and Inspect Fuel Tank....179
Replace Fuel Filter, Fuel Pump, and Bleed Fuel System....180
Group 10: Engine Cooling System....144
Specifications....1087
Drain, Flush, and Fill Cooling System....183
Test Radiator and Coolant Tank Cap....186
Section 40: Electrical System....188
Group 05: Battery....188
Essential or Recommended Tools....993
Specifications....1087
Prevent Battery Explosions....195
Battery Safety....196
Prevent Damage to Electrical Systems....198
Check Electrolyte Specific Gravity....199
Charging Batteries....201
Connecting Battery Cables....203
Battery Replacement....204
Group 10: Harness and Connector Repair....188
Essential or Recommended Tools....993
Other Material....1022
Use Electrical Insulating Compound....216
Using High-Pressure Washers....217
Electrical System Visual Inspection....218
Basic Electrical Component Handling / Precautions for Vehicles Equipped with Computer Controlled Systems....219
Electrical Connector / Wiring Harness Handling and Repair....220
Installation of Repair Wire Assembly (RWA)....221
Repair Procedure R-A....230
Repair Procedure R-B....235
Repair Procedure R-C....239
Repair Procedure R-D....244
Repair Procedure R-E....247
Repair Procedure R-F....251
Repair Procedure R-G....255
Repair Procedure R-I....258
Repair Procedure R-J....261
Repair Procedure R-K....266
Repair Procedure R-M....269
Repair Procedure R-N....273
Repair Procedure R-AA....277
Repair Procedure R-AE....278
Repair Procedure R-AF....283
Repair Procedure R-AG....286
Repair Procedure R-AH....289
Repair Procedure R-AI....291
Repair Procedure R-AJ....294
Repair Procedure R-AK....299
Repair Procedure R-AL....302
Repair Procedure R-AM....306
Repair Procedure R-AN....309
Repair Procedure R-AO....312
Repair Procedure R-AP....315
Repair Procedure R-AQ....318
Group 15: Charging Circuit....189
Specifications....1087
Remove and Install Alternator....323
Group 20: Starting Circuit....189
Essential or Recommended Tools....993
Remove and Install Starter Motor....327
John Deere Starting Motor Repair—Use CTM....328
Group 25: Fuses and Relays....189
Replace Fuses and Relays....334
Group 30: Lighting....189
Safety Rules When Replacing Halogen Bulbs....340
Safety Instructions for Replacing a Halogen Bulb....341
Safety Instructions for Replacing Xenon (HID) Bulbs and Ballast Units....343
Hood Headlight Bulb Replacement and Adjustment....345
Remove and Install Headlight Assembly....349
Handling HID Light Bulbs Safely....350
Replacing Road Light Bulbs....351
Replace Roof Flood Light Halogen Bulb....354
Replace Rear Warning Light Bulbs....356
Replace Extremity Front Warning Light Bulb....357
Replacing Xenon (HID) Worklights and Ballast Units....359
Group 35: Chassis Control System....190
Specifications....1087
Replace Hydraulic Oil Temperature Sensor....363
Replace Wheel Speed Sensor....365
Replace Fuel Level Sender....366
Replace Chassis Control Unit (CCU) and Steering System Control Unit (SSU)....368
Group 40: Engine Control System....190
John Deere Engine Repair—Use CTM....371
Group 45: Spray Rate Control System....190
Specifications....1087
Remove and Install Auxiliary Fill Pressure Sensor....374
Remove and Install Solution Pressure Sensor....375
Remove and Install Spray Rate Control Unit....376
Remove and Install Solution Command System Electronic Power Module....378
Remove, Adjust, and Install Solution Pump Hydraulic Motor Speed Sensor....380
Group 50: Boom Control System....190
Remove and Install BoomTrac Sensor (If Equipped)....383
Replace Boom Hydraulic Control Unit (BHC)....384
Remove and Install Boom Inner Fold Position Sensor....385
Remove and Install Boom Outer Fold Position Switch....386
Remove and Install Pendulum Lock Position Sensor....387
Remove and Install Boom Tilt Sensor....388
Remove and Install Boom Height Sensor....389
Group 55: Cab Components....190
Specifications....1087
Decontaminate Spray Equipment....392
Remove and Install Boom Select Switch....393
Remove and Install Steering Mode Switch....394
Remove and Install Emergency Brake Control Switch....395
Remove and Install Key Switch....397
Remove and Install Light and Wiper Switch....398
Remove and Install Turn Signal Switch....399
Replace Horn Switch....400
Remove and Install Armrest Control Unit (ACU)....401
Remove and Install Throttle Control....402
Remove and Install Throttle Sensor....404
Remove and Install Multi-Function Lever Position Harness....406
Remove and Install Armrest Rocker Switches....410
Remove and Install Tread Adjust Switch....411
Replace Air Conditioning System On/Off Switch....412
Replace Blower Control Switch....413
Replace Dome Light....414
Replace Air Conditioning High/Low Pressure Switch....416
Replace Wiper Motor....418
Replace Windshield Washer Pump....420
Remove and Install Radio....421
Replace Speakers....422
Replace Antenna....423
Remove and Install Air Conditioning Temperature Control Switch....427
Group 60: Wiring Harness Routings....191
Engine Harness Routing....432
Chassis Harness Routing....434
Hood Harness Routing....436
Cab Harness Routing....437
Center Boom Harness Routing....439
Outer Boom Harness Routing....441
Section 50: Power Train....442
Group 00: Component Removal and Installation....442
Essential or Recommended Tools....993
Specifications....1087
Remove and Install Hydrostatic Drive Motor....447
Remove and Install Rear Tandem Drive Pump....451
Remove and Install Front Tandem Drive Pump....460
Remove and Install Planetary Hub....468
Remove, Install, and Adjust Hydrostatic Control Cable....473
Group 05: Hydrostatic Drive Repair....442
Essential or Recommended Tools....993
Service Equipment and Tools....958
Other Material....1022
Specifications....1087
Clean Vehicle of Hazardous Pesticides....484
Start-Up Procedure After Hydrostatic Repair....485
Flush Hydrostatic Drive System....488
Remove and Install Hydrostatic Pump Shaft Seal....490
Replace Hydrostatic Pump Cartridge Valves....494
Replace Hydrostatic Pump Charge Pressure Relief Valve....495
Repair Charge Pump....496
Remove and Install Hydrostatic Pump Control Valve....503
Remove and Install Control Valve Neutral Start Switch....509
Adjust Neutral Start Switch....511
Adjust Control Valve Eccentric Plug....514
Disassemble Hydrostatic Drive Pump....517
Inspect and Repair Hydrostatic Drive Pump....523
Assemble Hydrostatic Drive Pump....527
Disassemble and Assemble Hydrostatic Drive Motor....537
Disassemble and Assemble Hydrostatic Drive Motor Port Plate....549
Group 10: Planetary Hub Repair....442
Essential or Recommended Tools....993
Service Equipment and Tools....958
Other Material....1022
Specifications....1087
Disassemble Planetary Hub....559
Assemble Planetary Hub....573
Section 60: Steering and Brakes....594
Group 00: Component Removal and Installation....594
Other Material....1022
Specifications....1087
Remove and Install Steering Wheel....598
Remove and Install Steering Column....600
Remove and Install Steering Valve....602
Remove and Install Steering Input Device (SID) Sensor....605
Remove and Install Steering Cylinder....607
Remove and Install AutoTracTM SSU Control Unit....594
Remove, Adjust, and Install AutoTrac Wheel Angle Sensor....610
Remove and Install Service Brake Valve....614
Remove and Install Service Brake Caliper....617
Remove and Install Trailer Brake Valve....620
Remove and Install AutoTrac Valve....622
Remove and Install Emergency Steering Pump....624
Group 05: Steering....594
Other Material....1022
Specifications....1087
Repair Steering Cylinder....630
Bleed Steering System....632
Rear Wheel Adjustment....633
Group 10: Service Brakes....594
Specifications....1087
Inspect Service Brake System Components....643
Disassemble and Assemble Service Brake Caliper....645
Start-Up Procedure After Brake System Repair....647
Section 61: Suspension and Tread Adjust....648
Group 00: Component Removal and Installation....648
Essential or Recommended Tools....993
Other Material....1022
Specifications....1087
Remove and Install Air Spring Leveling System Control Valve....653
Remove and Install Leveling System Unloader Valve Switch....655
Remove and Install Air Spring Assemblies....656
Remove and Install Tread Adjust Valve Block....686
Remove and Install Hydraulic Tread Adjust Cylinders....661
Replace Tread Adjust Shim Pads....665
Replace Suspension Bushings and Seals....669
Group 05: Tread Adjust Valves....648
Essential or Recommended Tools....993
Specifications....1087
Service Parts Kit....685
Tread Adjust Valve Block....686
Replace Control Valve Coil(s)....687
Replace Tread Adjust Valve....690
Remove, Inspect, and Install Manifold Check Valve and Pilot Piston....692
Group 10: Tread Adjust Cylinders....648
Specifications....1087
Disassemble and Assemble Tread Adjust Cylinders....696
Section 70: Hydraulic System....698
Group 00: Component Removal and Installation....698
Essential or Recommended Tools....993
Specifications....1087
Remove and Install Auxiliary Drive Pump....703
Remove and Install Auxiliary Hydraulic Oil Cooler....707
Remove and Install Auxiliary Hydraulic Oil Cooler Fan....711
Remove and Install Hydraulic Oil Heat Exchanger....713
Remove and Install Priority Valve....715
Remove and Install Solution Pump Hydraulic Motor....717
Remove and Install Pressure Washer Hydraulic Valve....721
Remove and Install Hydraulic Reservoir....723
Remove and Install Hydraulic Pump Compensator Valve....731
Remove and Install Four-Wheel Steer Valve....733
Remove and Install Toe Control Valve....735
Remove and Install Combination Valve....737
Remove and Install Boom Control Valve Block....739
Remove and Install Boom Lift Cylinders....741
Remove and Install Variable Geometry Cylinder....743
Remove and Install Boom Inner Fold Cylinder....745
Remove and Install Boom Outer Fold Cylinder....747
Remove and Install Boom Tilt Cylinder....749
Remove and Install Pendulum Lock Cylinder....751
Remove and Install Accumulator....753
Remove and Install Attenuator....755
Remove and Install Ladder Cylinder....757
Remove and Install Ladder Control Valve....759
Group 05: Hydraulic Pump....698
Relieve Hydraulic System Pressure....764
Disassemble and Assemble Auxiliary Drive Pump....767
Group 10: Hydraulic Valves....698
Essential or Recommended Tools....993
Specifications....1087
Boom Control Valve General Information....774
Boom Control Valve Solenoid Identification....775
Disassemble, Inspect, and Assemble Boom Control Valve....776
Disassemble, Inspect, and Assemble Priority Valve....780
Disassemble and Assemble Four-Wheel Steer Valve....783
Disassemble and Assemble Combination Valve....785
Group 15: Hydraulic Reservoir....699
Specifications....1087
Clean Hydraulic Reservoir Strainers....789
Section 80: Solution Spray System....792
Group 00: Component Removal and Installation....792
Other Material....1022
Specifications....1087
Cleaning the Machine....798
Processing Residual Liquids....800
Auto Dilution (SCS)....801
Draining Solution Tank....803
Remove and Install Chemical Transport Compartment....805
Remove and Install Eductor System Venturi....807
Remove and Install Fast Fill Pump and Motor....810
Remove and Install Hand Wash Tank....818
Remove and Install Pneumatic Spray Nozzle Shut-Off Valve....820
Remove and Install Solution Valve Actuator....821
Solution Valve Actuator Locations....822
Remove and Install Solution Pressure Relief Valves....824
Remove and Install Solution Tank....826
Remove and Install Solution Tank Transfer Valve Assembly....832
Remove and Install Solution Pump....834
Remove and Install Suction Strainer Assembly....839
Remove and Install Pressure Strainer Assembly....841
Remove and Install Nozzle Holder (5-Way)....842
Remove and Install Spray Nozzle Air Valve....844
Remove and Install Nozzle Holder (Off-Center Nozzle)....845
Remove and Install Spray Nozzle Solenoid (Edge Nozzle)....847
Remove and Install Agitation Pressure Regulator....849
Remove and Install Flowmeter Assembly....851
Remove and Install Flowmeter Sensor....852
Replace Flowmeter Insert....853
Remove and Install Spray Line Valve....855
Remove and Install Rinse Tank....857
Remove and Install Pressure Washer Pump and Motor....866
Remove and Install Pressure Washer Hydraulic Motor....868
Group 05: Solution Tank....793
Repair Polyethylene Plastic....875
Group 10: Solution Pump....793
Other Material....1022
Specifications....1087
Disassemble and Assemble Solution Pump....883
Remove and Install Pump Oil Seal....903
Disassemble and Assemble Pump Accumulator....906
Group 15: Spray Nozzles....793
Disassemble and Assemble Nozzle Holder (5-Way)....910
Disassemble and Assemble Nozzle Holder (Single)....912
Disassemble and Assemble Spray Nozzle Air Valve....914
Group 20: Solution Control Valves....793
Essential or Recommended Tools....993
Specifications....1087
Disassemble and Assemble Fittings....918
Disassemble and Assemble Check Valve....920
Disassemble and Assemble Spray Line Valve....921
Disassemble and Assemble Agitation Pressure Regulator....923
Disassemble Solution Valves....925
Assemble Spray Rate Regulator Valve....930
Assemble 2- and 3-Way Valve....935
Assemble Pressure Recirculation Valve....939
Adjust 2-Way, 3-Way, and Pressure Recirculation Valve Actuators....943
Adjust Spray Rate Regulator Actuator....946
Group 25: Eductor....793
Eductor Assembly—Exploded View....953
Group 30: Fast Fill Pump....793
Service Equipment and Tools....958
Specifications....1087
Fast Fill Pump—Exploded View....960
Disassemble and Assemble Fast Fill Pump....961
Disassemble and Assemble Fast Fill Pump Motor....967
Section 81: Pneumatic System....974
Group 00: Component Removal and Installation....974
Remove and Install On Board Air Compressor....977
Remove and Install On Board Air Reservoir....979
Remove and Install On Board Air Dryer....981
Group 05: Component Repair....974
Specifications....1087
Pneumatic Fittings....985
Disassemble and Assemble On Board Air Dryer....986
Section 90: Operator's Station....990
Group 05: Cab....990
Essential or Recommended Tools....993
Specifications....1087
Remove and Install Cowl....995
Remove, Inspect, and Install Cab Interior Recirculating Air Filters....997
Remove, Inspect, and Install Exterior Cab Intake Air Filters....999
Remove and Install Headliner....1001
Remove and Install Cab Roof....1003
Remove and Install Fender Console....1007
Remove and Install Cab....1010
Group 10: Controls....990
Other Material....1022
Specifications....1087
Remove and Install Armrest....1024
Remove and Install Armrest Control Cover....1026
Remove and Install Multi-Function Lever....1028
Group 15: Air Conditioning System....990
Special Tools....1032
Specifications....1087
Torques for Tightening Refrigerant Hoses....1036
Safety At Work....1037
Handling Refrigerant....1038
In an Emergency....1039
Safety Equipment....1040
Storage of Refrigerant Containers....1041
R134A Refrigerant....1042
Air-Conditioning System - Safety at Work....1043
Air-Conditioning - Important....1045
Service Work on Air Conditioning System....1046
Discharge the System....1049
Evacuate the System....1051
Fill with Refrigerant Oil....1052
Instructions for Starting Up the DENSO Air-Conditioning Compressor....1054
Charge the System....1055
Leakage Test....1057
Remove and Install Compressor....1058
Checking Level in the Compressor....1060
Disassemble Compressor Clutch....1061
Checking Clutch Hub Clearance....1063
Checking the Compressor Manifold....1064
Remove and Install Condenser....1065
Replace Receiver-Drier....1067
Remove and Install the Evaporator and Expansion Valve....1069
Arrangement of Condensation Water Drain Hoses....1072
Group 20: Heating System....991
Remove and Install Heater Core....1075
Remove and Install Fan Motor Resistors....1077
Remove and Install Fan Motors....1079
Remove and Install Heater Valve....1081
Adjust Heater Valve Control Cable....1083
Group 25: Air Suspension Seat....991
Remove and Install Seat and Suspension....1085
Group 30: Cab Door and Windshield....991
Specifications....1087
Repair Cab Door Latch Assembly....1088
Cab Door Lock Adjustment....1090
Replace Windshield Glass or Seal....1092
Remove and Install Rear Window....1094
Remove and Install Front Lower Windows....1095
Remove and Install Side Windows....1096
Remove and Install Cab Doors....1098
Remove and Install Safety Exit Door....1103
Section 100: Boom Repair....1104
Group 05: Boom Repair....1104
Remove and Install Boom Shock Absorbers....1106
Remove and Install Spray Boom Suspension Springs....1107
Remove and Install Yaw Rocker Bumpers....1108
Section 199: Dealer Fabricated Tools....1112
Group 05: Dealer Fabricated Tools....1112
DFN21 Pump Support Fixture....1114
DFNX65-A1 Eccentric Plug Adjustment Tool....1115
DFNX65-A2 Sizing Arbor....1116
DFNXT12—Front and Rear Tandem Pump Removal Tool....1117
DFNXT14—Spindle Driver....1118
John Deere Demountable Self-Propelled Crop Sprayers 5430i Repair Service Manual (TM402219)
