Complete service repair manual for John Deere 4630 Self-Propelled Sprayers (PIN Prefix 1YH), with all the service information to maintain, repair, and rebuild like professional mechanics.

John Deere 4630 Self-Propelled Sprayers 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.

TM106119 - John Deere Self-Propelled Sprayers 4630 Technical Manual (Repair).PDF
TM106119 - John Deere Self-Propelled Sprayers 4630 Technical Manual (Repair).epub

Total Pages: 1,016 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
      Fuels and Lubricants
   Engine
      Remove and Install Components
      Engine Cooling System
   Fuel and Air
      Remove and Install Components
      Diesel Fuel 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 Column
      Steering Valve
      Steering Cylinder
      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
      Boom Hydraulic Cylinders
      Hydraulic Oil Cooler
      Hydraulic Reservoir
      Accumulator
      Retractable Ladder
   Solution Spray System
      Component Removal and Installation
      Nozzle Repair
      Solution Tank
      Solution Pump
      Solution Control Valves
      Rinse Tank
      Eductor
      Flow Meter
   Foam Marker System
      Component Removal and Installation
      Foam Marker System Repair
      On Board Air System
   Operator Station
      Cab Component Removal and Installation
      Armrest
      Air Conditioning System
      Heating System
      Air Suspension Seat
      Cab Door and Windshield
   Boom Repair
      Component Removal and Installation
   Special Tools
      Dealer-Fabricated Tools

tm106119 - 4630 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

Park Machine Safely

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

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

Decontaminate Spray Equipment

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

Servicing Electronic Control Units

Welding Near Electronic Control Units

Keep Electronic Control Unit Connectors Clean

Handle Electronic Components and Brackets Safely

Live With Safety

Group 10: General Information

Machine Specification

Dimensions

Dimensions—All Machines

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

External Hexagon Port Plug Torque Chart

Identifying Zinc-Flake Coated Fasteners

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Glossary of Terms

Programming Control Units

Preparing and Painting Sprayer Components

Group 15: Fuels and Lubricants

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

Hydrostatic/Hydraulic Drive Oil

Planetary Hub Oil

Grease

Suspension and Steering Grease

Lubricant Storage

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 — Tier 3 and Stage III

Section 20: Engine

Group 00: Remove and Install Components

Other Material

Specifications

John Deere Engine Repair—Use CTM

Remove and Install Engine

Remove and Install Hood

Remove and Install Exhaust System

Group 05: Engine Cooling System

Specifications

Fan Belt Routing

Relieving Tension on the Drive Belt

Change the Drive Belt

Drain, Flush, and Fill Cooling System

Test Radiator and Coolant Tank Cap

Section 30: Fuel and Air

Group 00: Remove and Install Components

Specifications

Remove and Install Fuel Tank

Remove and Install Air Cleaner Housing

Remove and Install Radiator

Remove and Install Aftercooler

Remove and Install Fan Drive and Shroud

Remove and Install Air Conditioning Condenser

Remove and Install Fuel Cooler

Remove and Install Recovery Tank

Group 05: Diesel Fuel System

Specifications

Clean and Inspect Fuel Tank

Replace Fuel Filter, Fuel Pump, and Bleed Fuel System

Section 40: Electrical

Group 05: Batteries

Specifications

Battery Safety

Prevent Damage to Electrical Systems

Checking Electrolyte Specific Gravity

Charging Batteries

Connecting Battery Cables

Battery Replacement

Group 10: Connector Repair

Using High-Pressure Washers

Connector Information

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

Group 15: Charging Circuit

Specifications

Remove and Install Alternator

Group 20: Starting Circuit

Specifications

Remove and Install Starter Motor

Group 25: Fuses and Relays

Disconnect Electrical Circuit

Load Center Fuses

Load Center Relays and Diodes

Fuses and Relays in the Engine Compartment

Group 30: Lighting

Replace and Adjust Field Lights

Safety Rules When Replacing Halogen Bulbs

Hood Headlight Bulb Replacement and Adjustment

Remove and Install Headlight Assembly

Group 35: Chassis Control System

Specifications

Replace Radar Sensor

Replace Hydraulic Oil Temperature Sensor

Replace Wheel Speed Sensor

Replace Fuel Level Sender

Group 40: Engine Control System

Other Material

Specifications

Replace ECU (Engine Control Unit)

Replace Engine Crankshaft Position Sensor

Replace Engine Oil Pressure Sensor

Replace Engine Fuel Temperature Sensor

Replace Engine Manifold Air Temperature Sensor

Replace Engine Pump Position Sensor

Replace Water-In-Fuel Sensor

Replace Fuel Rail Pressure Sensor

Replace Engine Coolant Temperature Sensor

Replace Air Filter Restriction Switch

Group 45: Spray Rate Control System

Other Material

Specifications

Replace CCU-SRC (Chassis Control Unit - Spray Rate Control Unit)

Replace Solution Pressure Sensor

Group 50: Boom Control System

Replace Boom Height Sensor

Replace Boom Fold/Level Switch

Remove and Install Boom Trac Pro™ Center Section Sensor

Remove and Install Boom Trac Pro™ Inner and Outer Boom Sensors

Replace Boom Level Sensor

Replace Boom Fold Cylinder Switch

Group 55: Cab Components

Other Material

Specifications

Replace Side Console Switches

Replace Side Console Rotary Switch

Replace Boom Fold-Level Switch

Replace Key Switch

Replace Light Switch

Replace Turn Signal Switch

Replace Horn Switch

Replace Wiper Control Switch

Remove and Install Propulsion Control Harness

Remove and Install Throttle Control

Remove and Install Throttle Sensor

Remove and Install Armrest Rocker Switches

Remove and Install Armrest Toggle Switches

Replace Air Conditioning System On/Off Switch

Replace Air Conditioning Temperature Control Switch

Replace Blower Control Switch

Replace Dome Light

Replace Door Switch

Replace Air Conditioning High/Low Pressure Switch

Replace Wiper Motor

Replace Windshield Washer Pump

Replace Seat Air Compressor Motor

Remove and Install Radio

Replace Speakers

Replace Antenna

Replace SSU (Steering System Control Unit)

Group 60: Wiring Harness Routing

Engine Harness Routing

Cab Harness Routing

Chassis Harness Routing

Boom Center Harness Routing

Boom Wing Harness Routing

Guidance Harness Routing

Section 50: Power Train Repair

Group 00: Remove and Install Hydrostatic Components

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Hydrostatic Drive Pump

Replace Hydrostatic Drive Pump Isolators

Remove, Install, and Adjust Hydrostatic Control Cable

Remove and Install Control Valve Neutral Start Switch

Remove and Install Hydrostatic Drive Motor

Remove and Install Drive Shaft

Remove and Install Planetary Hub

Drain and Fill Planetary Hub

Group 05: Hydrostatic Drive Repair

Essential or Recommended Tools

Other Material

Specifications

Emergency Tow Procedure

Start-Up Procedure After Hydrostatic Repair

Start-Up Procedure After Oil Change or Filter Change

Flushing Hydrostatic Drive System

Remove and Install Hydrostatic Pump Control Valve

Tightening Wheel Hardware

Remove and Install Hydrostatic Pump Shaft Seal

Replace Hydrostatic Pump Cartridge Valves

Replace Hydrostatic Pump Charge Pressure Relief Valve

Repair Charge Pump

Adjust Neutral Start Switch

Adjust Control Valve Eccentric Plug

Disassemble Hydrostatic Drive Pump

Inspect and Repair Hydrostatic Drive Pump

Assemble Hydrostatic Drive Pump

Group 15: Planetary Hub Repair

Essential or Recommended Tools

Specifications

Planetary Hub—Exploded View

Disassemble Planetary Hub

Assemble Planetary Hub

Section 60: Steering and Brakes

Group 00: Component Removal and Installation

Other Material

Service Parts Kit

Specifications

Remove and Install Steering Wheel

Remove and Install Steering Column

Remove and Install Steering Valve

Remove and Install AutoTrac™ Steering Valve

Remove and Install Steering Input Device (SID) Sensor

Remove and Install Steering Cylinder (Wide Machine)

Remove and Install Steering Cylinder (Narrow Machine)

Remove and Install AutoTracTM SSU Control Unit

Remove and Install AutoTracTM Steering Electrohydraulic Control Valve

Remove and Install AutoTracTM Wheel Angle Sensor

Remove and Install Service Brake Valve

Remove and Install Service Brake Caliper

Group 05: Steering Column

Specifications

Bleed Steering System

Group 10: Steering Valve

Specifications

Service Parts Kit

Repair Steering Valve

Group 15: Steering Cylinder

Service Parts Kit

Specifications

Repair Steering Cylinder (Wide Machine)

Repair Steering Cylinder (Narrow Machine)

Check Front Axle Toe-In

Adjusting Front Axle Toe-In (Wide Machine)

Adjusting Front Axle Toe-In (Narrow Machine)

Group 20: Service Brakes

Other Material

Service Parts Kits

Specifications

Inspect Service Brake System Components

Disassemble and Assemble Service Brake Caliper

Start-Up Procedure After Brake System Repair

Section 61: Suspension and Tread Adjust

Group 00: Component Removal and Installation

Other Material

Specifications

Remove and Install Air Spring Leveling System Control Valve

Remove and Install Leveling System Unloader Valve Switch

Remove and Install Front and Rear Air Spring Assemblies

Remove and Install Air Spring Upper Mount

Remove and Install Air Spring Leveling System Linkage

Remove and Install Tread Adjust Valve Block

Remove and Install Hydraulic Tread Adjust Cylinders

Remove and Install Top Tread Adjust Shim Pads

Remove and Install Bottom Tread Adjust Shim Pads

Replace Suspension Bushings and Seals

Remove and Install Drag Links

Remove and Install Drag Link Casting (Front)

Remove and Install Drag Link Casting (Rear)

Group 05: Tread Adjust Valves

Specifications

Service Parts Kit

Tread Adjust Valve Block

Replace Control Valve Coil(s)

Replace Tread Adjust Valve

Remove, Inspect, and Install Manifold Check Valve and Pilot Piston

Group 10: Tread Adjust Cylinders

Other Material

Specifications

Service Parts Kit

Disassemble and Assemble Tread Adjust Cylinders

Section 70: Hydraulic System

Group 00: Component Removal and Installation

Specifications

Remove and Install Hydraulic Oil Cooler

Remove and Install Hydraulic Pump

Remove and Install Hydraulic Pump Compensator

Remove and Install Boom Control Valve

Remove and Install Boom Lift Cylinder

Remove and Install Boom Leveling Cylinder

Remove and Install Boom Inner Fold Cylinder

Remove and Install Boom Outer Fold Cylinder

Remove and Install Priority Valve

Remove and Install Combination Valve

Remove and Install Traction Control Valve

Remove and Install Shift Valve

Remove and Install Hydraulic Reservoir

Remove and Install Accumulator

Remove and Install Attenuator

Remove and Install Ladder Cylinder

Group 05: Hydraulic Pump

Service Parts Kit

Specifications

Relieve Hydraulic System Pressure

Disassemble and Assemble Hydraulic Pump

Repair Hydraulic Pump Compensator

Group 10: Hydraulic Valves

Other Material

Service Parts Kit

Specifications

Boom Valve Assembly

Boom Control Valve General Information

Disassemble, Inspect, and Assemble Boom Control Valve

Disassemble, Inspect, and Assemble Priority Valve

Repair Combination Valve

Repair Traction Control Valve

Repair Shift Valve

Group 15: Boom Hydraulic Cylinders

Other Material

Specifications

Service Parts Kit

Hydraulic Cylinder and Boom Control Valve Fitting Torques

Adjust Boom Stop Bolts

Adjusting Boom Outer Fold Cylinder

Disassemble and Assemble Boom Lift Cylinder

Disassemble and Assemble Boom Leveling Cylinder

Disassemble and Assemble Boom Inner Fold Cylinder

Disassemble and Assemble Boom Outer Fold Cylinder

Group 20: Hydraulic Oil Cooler

Specifications

Leak Test Hydraulic Oil Cooler

Group 25: Hydraulic Reservoir

Specifications

Clean Hydraulic Reservoir Strainers

Group 30: Accumulator

Specifications

Charge Accumulator

Group 35: Retractable Ladder

Other Material

Service Parts Kit

Disassemble and Assemble Retractable Ladder Cylinder

Section 80: Solution Spray System

Group 00: Component Removal and Installation

Other Material

Specifications

Remove and Install Solution Tank

Remove and Install Agitation Nozzles

Remove Solution Pump and Motor

Install Solution Pump and Motor

Remove and Install Flowmeter Assembly

Remove and Install Flowmeter Sensor

Remove and Install Boom Section Shut-Off Valves

Replace Boom Section Shut-Off Valve Actuator

Remove and Install Rinse Tank

Remove and Install Eductor System Venturi

Remove and Install AutoTrac™ Vision Sensor

Remove and Install AutoTrac™ RowSense™ Sensor

Group 05: Nozzle Repair

Cleaning SprayMaster™ 5-Position Nozzle Bodies—Standard Flow

Cleaning SprayMater™ 5-Position Nozzle Bodies—High Flow

Group 10: Solution Tank

Other Material

Specifications

Flush Solution Tank and Spray System

Group 15: Solution Pump

Service Equipment and Tools

Other Material

Specifications

Repair Solution Pump

Repair Solution Pump Hydraulic Motor

Group 20: Solution Control Valves

Other Material

Specifications

Disassemble and Assemble Fittings

Repair Check Valves and Strainers

Replace Solution Control Valves

Group 25: Rinse Tank

Repair Polyethylene Plastic

Group 30: Eductor

Eductor Assembly

Group 35: Flow Meter

Replace Flowmeter Insert

Recondition Flowmeter

Calibrate Flowmeter

Section 81: Foam Marker System

Group 00: Component Removal and Installation

Specifications

Other Material

Remove and Install Foam Marker Concentrate Tank

Remove and Install Control Box (With On Board Air)

Remove and Install Control Box (With 12-volt Compressor)

Remove and Install On Board Air Compressor

Remove and Install On Board Air Dryer

Replace Foam Mixing Chamber

Group 05: Foam Marker System Repair

Other Material

On Board Air (OBA) Foam Marker Schematic

Repair Control Box (With On Board Air)

Foam Marker System (With Internal 12-volt Compressor) Schematic

Repair Control Box (With 12-volt Compressor)

Repair Control Box Solenoid

Repair Foam Marker Tubes

Tube Fittings

Group 10: On Board Air System

Specifications

Service Parts Kit

Repair On Board Air Dryer

Section 90: Operator Station

Group 05: Cab Component Removal and Installation

Replace SSU Control Unit

Replace CCU-SRC Control Unit

Remove, Inspect, and Install Cab Interior Recirculating Air Filters

Remove, Inspect, and Install Exterior Cab Intake Air Filters

Remove and Install Headliner

Remove and Install Fender Console

Remove and Install Cowl

Remove and Install Cab Roof

Remove and Install Cab

Group 10: Armrest

Other Material

Service Parts Kits

Specifications

Remove and Install Armrest

Remove and Install Armrest Control Cover

Remove and Install Multifunction Control Handle

Group 15: Air Conditioning System

Other Material

Service Parts Kits

Specifications

Hose and Tubing O-Ring Connection Torques

System Information

Remove and Install Compressor

Remove and Install Compressor Relief Valve

Replace Receiver Dryer

Remove and Install the Evaporator and Expansion Valve

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

Check Refrigerant Oil Charge in Compressor

Determine Correct Refrigerant Oil Charge

Leak Test

Disassemble and Assemble Compressor Clutch

Check Clutch Hub Clearance

Inspect Compressor Manifold

Start Up Instructions for Air Conditioning Compressor

Adjust Thermostat Switch Control Cable

Group 20: Heating System

Remove and Install Fan Motor Resistors

Remove and Install Fan Motors

Remove and Install Heater Valve

Remove and Install Heater Core

Adjust Heater Valve Control Cable

Group 25: Air Suspension Seat

Other Material

Service Parts Kits

Remove Seat from Suspension

Remove Air Seat Suspension System

Operator Seat—Exploded View

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 Windshield

Remove and Install Rear Window

Remove and Install Front Lower Windows

Remove and Install Side Windows

Remove and Install Cab Doors

Remove and Install Safety Exit Door

Door Latch Installation and Adjustment

Section 100: Boom Repair

Group 00: Component Removal and Installation

Specifications

Remove and Install Boom Shock Absorbers

Remove and Install Boom Wear Plates and Plastic Sleeves

Remove and Install Boom Roll Suspension Springs

Remove and Install Boom Center Roll Bushings

Remove and Install Boom Inner Wing Leveling Bushings

Remove and Install Boom Inner Wing Fold Bushings

Remove and Install Boom Inner Wing Leveling Cylinder Bushings

Remove and Install Boom Inner Wing Fold Cylinder Bushings

Section 199: Special Tools

Group 05: Dealer-Fabricated Tools

DFN20 Solution Pump Seal Driver

DFN21 Pump Support Fixture

DFN22 Bearing Seat Driver

DFRW20—Compressor Holding Fixture

DFNX65-A1 Eccentric Plug Adjustment Tool

DFNX65-A2 Sizing Arbor

DFNXT2—Agitation Nozzle Tool

DFNXT11 Pump Removal Tool

DFNXT15 Planetary Assembly Spacer

John Deere 4630 Self-Propelled Sprayers Repair Service Manual (TM106119)