Complete service repair manual for John Deere Self-Propelled Sprayers 4920, with all the shop information to maintain, diagnose, and service like professional mechanics.

John Deere Self-Propelled Sprayers 4920 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.

TM2124 - John Deere 4920 Self-Propelled Sprayers Technical Manual (Repair).PDF
TM2124 - John Deere 4920 Self-Propelled Sprayers Technical Manual (Repair).epub

Total Pages: 1,112 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
      Diesel Fuel System
      Engine Cooling System
      Coolers and Air Conditioning Condenser
   Electrical
      Batteries
      Connector Repair
      Charging Circuit
      Starting Circuit
      Fuses and Relays
      Spray Rate Control System
      Chassis Control System
      Engine Control System
      Lighting
      Cab Components
      Wiring Harness Routing
      Boom Trac Pro™ System
   Power Train Repair
      Remove and Install Hydrostatic Components
      Hydrostatic Drive Repair
      Planetary Hub Repair
   Steering and Brakes
      Steering Column
      Steering Valve
      Steering Cylinder
      Brakes
      AutoTrac Steering System
   Suspension and Tread Adjust Repair
      Suspension
      Tread Adjust Valves
      Tread Adjust Cylinders
      Tread Adjust Shim Pads
   Hydraulic System
      Hydraulic Pump
      Hydraulic Valves
      Boom Hydraulic Cylinders
      Hydraulic Reservoir
      Accumulator
   Solution Spray System
      Nozzle Repair
      Solution Tank
      Solution Pump-Standard
      Solution Pump-High Flow
      Solution Control Valves
      Rinse Tank
      Eductor
   Foam Marker System
      Foam Marker System Repair
      On Board Air System
   Dry Box Conversion
      Liquid System
   Operator Station
      Component Removal and Installation
      Air Conditioning System
      Heating System
      Air Suspension Seat and Armrest
      Cab Door and Windshield
   Boom Repair
      Boom Repair
      Full Boom Breakaway
   Dealer Fabricated Tools

tm2124 - 4920 Self-Propelled Sprayer Repair

Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Perform Service Safely

Wait Before Opening High-Pressure Fuel System

Service Accumulator Systems Safely

Servicing Electronic Control Units

Welding Near Electronic Control Units

Keep Electronic Control Unit Connectors Clean

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Protect Against High Pressure Spray

Prevent Acid Burns

Wear Protective Clothing

Handle Agricultural Chemicals Safely

Service and Operate Chemical Sprayers Safely

Avoid Contact with Agricultural Chemicals

Clean Vehicle of Hazardous Pesticides

Support Machine Properly

Service Machines Safely

Practice Safe Maintenance

Avoid Harmful Asbestos Dust

Work In Ventilated Area

Work in Clean Area

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Avoid High-Pressure Fluids

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

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

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Group 15: Fuel and Lubricants

Diesel Fuel

Testing Diesel Fuel

Handling and Storing Diesel Fuel

Lubricity of Diesel Fuel

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Testing Diesel Engine Coolant

Supplemental Coolant Additives

Operating in Warm Temperature Climates

Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER

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

Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I

Hydrostatic/Hydraulic Drive Oil

Grease

Suspension and Steering Grease

Planetary Hub Oil

Extended Diesel Engine Oil Service Intervals — Non-Emissions Certified and Certified Tier 1 and Stage I

Alternative and Synthetic Lubricants

Lubricant Storage

Section 20: Engine

Group 05: Component Removal and Installation

Engine Repair—Use CTM86 or CTM255

Essential or Recommended Tools

Other Material

Specifications

Clean Vehicle of Hazardous Pesticides

Remove and Install Engine

Hood Position for Operating Engine

Position Hood Forward

Remove and Install Hood

Remove and Install Exhaust Pipe

Remove and Install Auxiliary Drive Belt

Auxiliary Drive Belt Routing

Remove and Install Drive Shaft

Inspect Drive Coupler

Section 30: Fuel, Air Intake, and Cooling Systems

Group 05: Diesel Fuel System

Service Equipment and Tools

Other Material

Specifications

Relieve Fuel System Pressure

Replacing Fuel Filters

Bleeding the Fuel System

Remove and Install Air Cleaner Filters

Clean and Inspect Fuel Tank

Remove Fuel Tank

Remove and Install Fuel Level Sensor

Remove and Install Turbocharger

Group 10: Engine Cooling System

Essential or Recommended Tools

Specifications

Clean Vehicle of Hazardous Pesticides

Test Radiator and Coolant Tank Cap

Remove and Install Radiator/Aftercooler

Remove and Install Fan Drive Assembly

Inspect Fan Belt Tensioner

Group 15: Coolers and Air Conditioning Condenser

Essential or Recommended Tools

Specifications

Remove Air Conditioning Condenser/Fuel and Oil Cooler

Install Air Conditioning Condenser/Fuel and Oil Cooler

Leak Test Hydraulic Oil Cooler

Section 40: Electrical

Group 05: Batteries

Prevent Battery Explosions

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

Connector Information

Connector Identification and Functions

Using High-Pressure Washers

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 32 and 48 Way CINCH Connectors

Group 15: Charging Circuit

Repair Alternator—Use CTM77

Disconnect Electrical Circuit

Exploded View—Alternator

Remove and Install Alternator

Group 20: Starting Circuit

Essential or Recommended Tools

Repair Starter—Use CTM77

Remove and Install Starter Motor

Replace Fusible Link

Replace Starter Circuit Relay

Group 25: Fuses and Relays

Disconnect Electrical Circuit

Load Center Fuses

Load Center Relays and Diodes

Auxiliary Load Center Fuses and Relays

Boom Relay Identification

Foam Control Box Relay Identification

Group 30: Spray Rate Control System

Other Material

Specifications

Disconnect Electrical Circuit

Replace Spray Rate Control Unit (SRC)

Replace Solution Pressure Sensor

Calibrating Pressure Sensor

Replace Boom Outer Wing Position Sensor

Replace Boom Height Sensor

Replace Boom Inner Wing Position Sensor

Boom Sensors Calibrate

Remove and Install Flowmeter Sensor

Group 31: Chassis Control System

Specifications

Replace Hydraulic Oil Temperature Sensor

Replace Chassis Computer Unit (CCU)

Replace Wheel Speed Sensor

Calibrating Wheel Speed Sensor

Replace Tread Adjust Sensor

Group 32: Engine Control System

Other Material

Specifications

Replace Engine Control Unit (ECU)

Replace Engine Crank Position Sensor

Replace Engine Oil Pressure Switch

Replace Engine Coolant Temperature Sensor

Replace Air Filter Restriction Switch

Replace Fuel Temperature Sensor

Replace Air Intake Temperature Sensor

Group 35: Lighting

Safety Rules When Replacing Halogen Bulbs

Replace and Adjust Field Lights

Hood Head Light Bulb Replacement and Adjustment

Remove and Install Headlight Assembly

Group 40: Cab Components

Side Console Switches

Replace Side Console Switches

Replace Dome Light Switch

Replace Cab Door Light Switch

Replace Starting Aid Switch

Replace Ignition Switch

Replace A/C Deicing Switch and Blower Motor Resistor

Replace Boom Fold/Level Switch

Replace Turn Signal Indicator Bulbs

Replace Steering Column Mini-Pod

Replace Three-Pin Accessory Outlets

Replace Circulation Blower Motor

Remove Air Quality (AQS) Pressurizer Blower Motor

Replace Wiper Motor

Replace Windshield Washer Pump

Remove Radio and Speakers

Remove and Install Propulsion Sensor

Remove and Install Propulsion Control Harness

Remove and Install Throttle Control

Remove and Install Throttle Sensor

Remove and Install Armrest Rocker Switches

Group 45: Wiring Harness Routing

Engine Harness Routing

Installation and Routing of Neutral Start Harness

Solution System Harness Routing

Chassis Harness Routing

CAN Terminator Locations

Group 50: Boom Trac Pro™ System

Decontaminate Spray Equipment

Remove and Install Boom Trac ProTM Breakaway Sensor

Remove and Install Boom Trac ProTM Inner Boom Sensor

Remove and Install Boom Trac ProTM Center Section Sensor

Remove and Install Boom Trac ProTM Roll Sensor

Remove and Install Boom Trac ProTM Flowmeter Sensor

Section 50: Power Train Repair

Group 05: Remove and Install Hydrostatic Components

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Emergency Tow Procedure

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—Rear Pump Only

Remove and Install Hydrostatic Drive Pumps—Both Pumps

Remove and Install Hydrostatic Drive Motor

Remove and Install Planetary Hub

Remove and Install Filter Base on Hydrostatic Pump

Remove, Install and Adjust Hydrostatic Control Cable

Remove and Install Hydrostatic Drive Pump Control Valve

Install Control Valve Lever and Bracket

Bench Adjust Neutral Start Switch

Group 10: Hydrostatic Drive Repair

Service Equipment and Tools

Specifications

Replace Hydrostatic Drive Motor Shaft Seal

Repair Hydrostatic Drive Motor

Replace Hydrostatic Drive Pump Shaft Seal

Repair Hydrostatic Drive Pump

Flush Procedure for Failed Wheel Motor

Group 15: Planetary Hub Repair

Essential or Recommended Tools

Service Equipment and Tools

Specifications

Clean Vehicle of Hazardous Pesticides

Planetary Hub—Exploded View

Disassemble Planetary Hub

Assemble Planetary Hub

Section 60: Steering and Brakes

Group 05: Steering Column

Specifications

Repair Steering Column

Bleed Steering System

Group 10: Steering Valve

Specifications

Remove Steering Valve

Repair Steering Valve

Group 15: Steering Cylinder

Other Material

Service Parts Kit

Specifications

Remove and Install Steering Cylinder (S.N. —4000)

Remove and Install Steering Cylinder with Toe Control Valve (S.N. 4001—)

Disassemble and Assemble Steering Cylinder (S.N. —4000)

Disassemble and Assemble Steering Cylinder (S.N. 4001—)

Remove and Install Steering Arm

Check Front Axle Toe-In

Adjust Front Axle Toe-In

Group 20: Brakes

Essential or Recommended Tools

Other Material

Specifications

Inspect Service Brake System Components

Disassemble, Inspect and Assemble Service Brake Linkage

Brake Valve Fittings Adjustment

Remove and Install Service Brake Valve

Remove and Install Brake Rotor

Remove and Install Service Brake Caliper

Disassemble and Assemble Service Brake Caliper

Installation of Brake Hose Clamps

Start-Up Procedure After Brake System Repair

Group 25: AutoTrac Steering System

Specifications

Remove and Install AutoTrac Controller

Remove and Install AutoTrac Steering Control Valve

Repair AutoTrac Steering Control Valve Assembly

Section 61: Suspension and Tread Adjust Repair

Group 05: Suspension

Essential or Recommended Tools

Other Material

Specifications

Clean Vehicle of Hazardous Pesticides

Front Suspension—Exploded View

Rear Suspension—Exploded View

Remove and Install Air Spring Assembly

Replace Air Spring Assembly Valve

Remove and Install Suspension/Drive Mount Housing

Replace Suspension/Drive Mount Housing Seals and Bushings

Replace Front Axle Knee Bushings

Adjust Front and Rear Air Spring Assemblies

Remove and Install Air Spring Leveling System Control Valve

Group 10: Tread Adjust Valves

Essential or Recommended Tools

Specifications

Service Parts Kit

Tread Adjust Valve Block

Remove and Install Tread Adjust Valve

Replace Control Valve Coil(s)

Replace Tread Adjust Valve

Remove, Inspect and Install Manifold Check Valve and Pilot Piston

Group 15: Tread Adjust Cylinders

Service Parts Kit

Specifications

Remove and Install Tread Adjust Cylinders

Disassemble and Assemble Tread Adjust Cylinders

Group 20: Tread Adjust Shim Pads

Essential or Recommended Tools

Other Material

Specifications

Replace Tread Adjust Shim Pads

Adjust Tread Adjust Shims

Section 70: Hydraulic System

Group 05: Hydraulic Pump

Other Material

Specifications

Service Parts Kit

Clean Vehicle of Hazardous Pesticides

Relieve Hydraulic System Pressure

Remove and Install Hydraulic Pump Compensator

Disassemble and Assemble Hydraulic Pump Compensator

Remove and Install Hydraulic Pump

Disassemble and Assemble Hydraulic Pump

Group 10: Hydraulic Valves

Essential or Recommended Tools

Other Material

Specifications

Service Parts Kit

Boom Control Valve General Information

Boom Control Valve Solenoid Identification

Remove and Install Boom Control Valve

Disassemble, Inspect and Assemble Boom Control Valve

Remove and Install Priority Valve

Disassemble, Inspect and Assemble Priority Valve

Remove and Install Combination Valve

Repair Combination Valve

Remove and Install Ladder Valve

Remove and Install Park Brake Valve

Group 15: Boom Hydraulic Cylinders

Specifications

Boom Cylinder Orifice Locations

Remove and Install Boom Lift Cylinders

Disassemble and Assemble Boom Lift Cylinders

Remove and Install Boom Leveling Cylinders

Disassemble and Assemble Boom Leveling Cylinders

Remove and Install Boom Inner Fold Cylinders

Disassemble and Assemble Boom Inner Fold Cylinders

Adjust Boom Inner Fold Cylinder

Remove and Install Boom Outer Fold Cylinders

Disassemble and Assemble Boom Outer Fold Cylinders

Remove and Install Boom Breakaway Fold Cylinders

Disassemble and Assemble Boom Breakaway Fold Cylinders

Remove and Install Boom Roll Lock Cylinder

Disassemble and Assemble Roll Lock Cylinder

Group 20: Hydraulic Reservoir

Specifications

Remove and Install Hydraulic Reservoir

Clean Hydraulic Reservoir Strainers

Group 25: Accumulator

Service Equipment and Tools

Specifications

Service Accumulator Systems Safely

Remove and Install Accumulator

Charge Accumulator

Section 80: Solution Spray System

Group 05: Nozzle Repair

Decontaminate Spray Equipment

Clean Vehicle of Hazardous Pesticides

Cleaning SPRAY MASTER SPRAY MASTER is a trademark of Deere & Company 5-Position Nozzle Bodies

Group 10: Solution Tank

Specifications

Other Material

Decontaminate Spray Equipment

Flush Solution Tank and Spray System

Remove and Install Solution Tank

Remove and Install Agitation Nozzles

Positioning Agitation Nozzles

Group 15: Solution Pump—Standard

Service Equipment and Tools

Other Material

Specifications

Decontaminate Spray Equipment

Remove and Install Solution Pump

Solution Pump Exploded View

Repair Solution Pump

Repair Solution Pump Hydraulic Motor

Group 16: Solution Pump—High Flow

Other Material

Specifications

Decontaminate Spray Equipment

Remove and Install Solution Pump and Motor

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

Decontaminate Spray Equipment

Disassemble and Assemble Fittings

Repair Check Valves and Strainers

Exploded View— Flowmeter Assembly

Replace Flowmeter

Remove and Install Boom Section Shut-Off Valves

Diagnose and Repair Boom Shut-Off Valves

Remove and Install Rinse Water Control Valve Assembly

Remove and Install Solution Control Valves

Repair Solution Control Valves

Group 25: Rinse Tank

Essential or Recommended Tools

Specifications

Remove and Install Rinse Tank Assembly

Repair Polyethylene Plastic

Group 30: Eductor

Decontaminate Spray Equipment

Eductor Assembly

Remove and Install Eductor System Venturi

Section 81: Foam Marker System

Group 05: Foam Marker System Repair

Repair Foam Marker Tubing

Repair Tank

Remove and Install Foam Tank

Repair Foam Collectors

Repair Foam Marker Quick Fill

Fittings

Remove and Install Foam Mixing Head

Disassemble, Inspect and Assemble Foam Mixing Head

Group 10: On Board Air System

Other Material

Specifications

Remove and Install On Board Air Compressor

Remove and Install On Board Air Dryer

Replace Air Dryer Desiccant Filter

Repair On Board Air Dryer

Section 82: Dry Box Conversion

Group 10: Liquid System

Introduction

Specifications

Work in Clean Area

Empty Tank and Boom Plumbing—Decontaminate Spray Equipment

Remove Liquid System

Install Liquid System

Section 90: Operator Station

Group 05: Component Removal and Installation

Essential or Recommended Tools

Specifications

Clean Vehicle of Hazardous Pesticides

Remove and Install Cab

Group 15: Air Conditioning System

Essential or Recommended Tools

Other Material

Service Parts Kits

Specifications

Hose and Tubing O-Ring Connection Torques

System Information

Diagram - Air Conditioning System

Air Conditioning System Fittings—Reference Chart

Discharge Air Conditioning System

Flush Compressor

Flush Evaporator

Flush Evaporator (Through Expansion Valve)

Flush Condenser

Purge Air Conditioning System

Evacuate Air Conditioning System

Charge Air Conditioning System

Refrigerant Oil Information

Check Refrigerant Oil Charge

Determine Correct Refrigerant Oil Charge

Add Refrigerant Oil to System

Add Oil to Pressurized System

Remove and Install Compressor

Test Volumetric Efficiency

Test Shaft Seal Leakage

Disassemble and Assemble Compressor Clutch

Check Clutch Hub Clearance

Inspect Compressor Manifold

Disassemble, Inspect and Assemble Compressor

Remove and Install Compressor Relief Valve

Remove and Install Expansion Valve

Replace Receiver-Dryer

Remove Air Quality System Module

Remove and Install Heater Core or Evaporator

Leak Test Air Quality System Module

Install Air Quality System Module

Group 20: Heating System

Remove Heater Control Valve

Leak Test Heater Control Valve

Install Heater Control Valve

Remove, Install, and Adjust Temperature Control Cable

Group 25: Air Suspension Seat and Armrest

Other Material

Remove and Install Armrest

Remove and Install Armrest Control Cover

Remove Multifunction Control Handle

Remove Seat from Suspension

Operator Seat—Exploded View

Remove Air Seat Suspension System

Operator Seat Air Suspension Assembly—Exploded View

Disassemble and Assemble Operator's Seat Air Suspension Assembly

Group 30: Cab Door and Windshield

Specifications

Remove and Install Cab Door Latch Assembly

Remove and Install Cab Door Latch Jaw Assembly

Remove and Install Cab Door Interior Release Handle

Cab Door Adjustment—Step 1

Cab Door Adjustment—Step 2

Cab Door Adjustment—Step 3

Cab Door Adjustment—Step 4

Cab Door Adjustment—Step 5

Replace Windshield Glass or Seal

Remove and Install Door Cylinder

Section 100: Boom Repair

Group 05: Boom Repair

Essential or Recommended Tools

Specifications

Inner Wing

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 10: Full Boom Breakaway

Specifications

Relieve Full Boom Breakaway System Pressure

Remove and Install Full Boom Breakaway Cylinder

Remove Full Boom Breakaway Accumulator

Remove and Install Full Boom Breakaway Valve

Repair Full Boom Breakaway Valve

Section 199: Dealer Fabricated Tools

Group 05: Dealer Fabricated Tools

DFNXT6 Hydrostatic Pump Removal Tool

DFNXT7—Agitation Nozzle Tool

DFN20 Solution Pump Seal Driver—Standard Solution Pump

DFN21 Pump Support Fixture—Standard Solution Pump

DFRG6—Electric Fuel Priming Pump

DFRW151—Radiator Cap Adapter

John Deere Self-Propelled Sprayers 4920 Repair Service Manual (TM2124)