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John Deere 4730 & 4830 Self Propelled Sprayer Repair Technical Manual TM2368 – PDF DOWNLOAD
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John Deere 4730 & 4830 Self Propelled Sprayer Repair Technical Manual TM2368 – PDF DOWNLOAD
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Description
John Deere 4730 & 4830 Self Propelled Sprayer Repair Technical Manual TM2368 – PDF DOWNLOAD
FILE DETAILS:
John Deere 4730 & 4830 Self Propelled Sprayer Repair Technical Manual TM2368 – PDF DOWNLOAD
Language : English
Pages : 734
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 4730 & 4830 Self Propelled Sprayer Repair Technical Manual TM2368 – PDF DOWNLOAD
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.
- Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment, service parts, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
- Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
- Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
TABLE OF CONTENTS:
John Deere 4730 & 4830 Self Propelled Sprayer Repair Technical Manual TM2368 – PDF DOWNLOAD
Contents........................................................................ 3 General Information......................................................... 6 Safety.................................................................. 7 Recognize Safety Information........................................ 7 Understand Signal Words............................................. 7 Perform Service Safely.............................................. 7 Wait Before Opening High-Pressure Fuel System....................... 8 Service Accumulator Systems Safely.................................. 8 Park Machine Safely................................................. 8 Servicing Electronic Control Units.................................. 9 Welding Near Electronic Control Units............................... 9 Keep Electronic Control Unit Connectors Clean....................... 9 Handle Fluids Safely—Avoid Fires.................................... 10 Prevent Battery Explosions.......................................... 10 Prepare for Emergencies............................................. 10 Protect Against High Pressure Spray................................. 11 Prevent Acid Burns.................................................. 11 Wear Protective Clothing............................................ 12 Handle Agricultural Chemicals Safely................................ 12 Avoid Contact with Agricultural Chemicals........................... 13 Clean Vehicle of Hazardous Pesticides............................... 13 Support Machine Properly............................................ 14 Service Machines Safely............................................. 14 Practice Safe Maintenance........................................... 15 Avoid Harmful Asbestos Dust......................................... 15 Work In Ventilated Area............................................. 16 Work in Clean Area.................................................. 16 Remove Paint Before Welding or Heating.............................. 16 Avoid Heating Near Pressurized Fluid Lines.......................... 17 Avoid High-Pressure Fluids.......................................... 17 Service Tires Safely................................................ 18 Service Cooling System Safely....................................... 18 Illuminate Work Area Safely......................................... 19 Replace Safety Signs................................................ 19 Use Proper Lifting Equipment........................................ 19 Use Proper Tools.................................................... 20 Construct Dealer-Made Tools Safely.................................. 20 Dispose of Waste Properly........................................... 20 Handle Electronic Components and Brackets Safely.................... 21 Live With Safety.................................................... 21 General Information..................................................... 23 Machine Specification............................................... 23 Dimensions.......................................................... 28 Dimensions—All Machines............................................. 29 Identification Numbers.............................................. 30 Sealants and Adhesives Cross-Reference Chart........................ 33 Face Seal Fittings Assembly and Installation—All Pressure Applic.... 34 Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standa.... 35 Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High P.... 36 SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard .... 37 SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pres.... 38 Four Bolt Flange Fittings Assembly and Installation—All Pressure.... 39 SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure A.... 39 SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Appli.... 40 External Hexagon Port Plug Torque Chart............................. 40 Identifying Zinc-Flake Coated Fasteners............................. 41 Metric Bolt and Screw Torque Values................................. 41 Unified Inch Bolt and Screw Torque Values........................... 42 Glossary of Terms................................................... 43 Preparing and Painting Sprayer Components........................... 44 Fuels and Lubricants.................................................... 45 Diesel Fuel......................................................... 45 Testing Diesel Fuel................................................. 45 Handling and Storing Diesel Fuel.................................... 46 Lubricity of Diesel Fuel............................................ 46 Heavy Duty Diesel Engine Coolant.................................... 47 Testing Diesel Engine Coolant....................................... 48 Supplemental Coolant Additives...................................... 48 Operating in Warm Temperature Climates.............................. 49 Additional Information About Diesel Engine Coolants and John Dee.... 50 Diesel Engine Break-In Oil.......................................... 51 Diesel Engine Oil................................................... 52 Extended Diesel Engine Oil Service Intervals........................ 53 Hydrostatic/Hydraulic Drive Oil..................................... 53 Planetary Hub Oil................................................... 54 Grease.............................................................. 54 Suspension and Steering Grease...................................... 54 Alternative and Synthetic Lubricants................................ 55 Lubricant Storage................................................... 55 Engine...................................................................... 57 Component Removal and Installation...................................... 59 Essential or Recommended Tools...................................... 59 Specifications...................................................... 60 John Deere Engine Repair—Use CTM.................................... 60 Clean Vehicle of Hazardous Pesticides............................... 61 Remove and Install Engine........................................... 61 Remove and Install Hood............................................. 70 Remove and Install Exhaust System................................... 72 Fuel, Air Intake, and Cooling Systems....................................... 73 Diesel Fuel System...................................................... 75 Specifications...................................................... 75 Remove Fuel Tank.................................................... 75 Clean and Inspect Fuel Tank......................................... 77 Replace Fuel Filter, Fuel Pump, and Bleed Fuel System............... 77 Air Intake System....................................................... 79 Specifications...................................................... 79 Inspect and Service Air Intake System............................... 79 Engine Cooling System................................................... 81 Essential or Recommended Tools...................................... 81 Specifications...................................................... 81 Test Radiator and Coolant Tank Cap.................................. 82 Remove and Install Radiator......................................... 83 Remove and Install Charge Air Cooler................................ 86 Inspect Belt Tensioner.............................................. 88 Remove and Install Fan Drive........................................ 89 Remove, Install, and Repair Engine Accessory Drive.................. 90 Fan Belt Routing.................................................... 94 Hydraulic Oil Cooler and Air Conditioning Condenser/Fuel Cooler......... 95 Specifications...................................................... 95 Other Material...................................................... 95 Remove Air Conditioning Condenser/Fuel Cooler....................... 95 Install Air Conditioning Condenser/Fuel Cooler...................... 95 Remove and Install Hydraulic Oil Cooler............................. 96 Leak Test Hydraulic Oil Cooler...................................... 96 Electrical.................................................................. 98 Batteries............................................................... 99 Prevent Battery Explosions.......................................... 99 Battery Safety...................................................... 99 Prevent Damage to Electrical Systems................................ 99 Checking Electrolyte Specific Gravity...............................100 Battery Replacement.................................................101 Charging Batteries..................................................102 Connecting Battery Cables...........................................103 Connector Repair........................................................105 Essential or Recommended Tools......................................105 Using High-Pressure Washers.........................................108 Connector Information...............................................109 Repair Procedure R-A................................................110 Repair Procedure R-B................................................114 Repair Procedure R-C................................................116 Repair Procedure R-D................................................119 Repair Procedure R-E................................................121 Repair Procedure R-F................................................123 Repair Procedure R-G................................................126 Repair Procedure R-I................................................127 Repair Procedure R-J................................................129 Repair Procedure R-K................................................134 Repair Procedure R-M................................................136 Repair Procedure R-N................................................138 Repair Procedure R-AE...............................................141 Repair Procedure R-AF...............................................143 Repair Procedure R-AG...............................................146 Repair Procedure R-AH...............................................148 Repair Procedure R-AI...............................................149 Repair Procedure R-AJ...............................................150 Repair Procedure R-AK...............................................153 Charging Circuit........................................................157 Repair Alternator—Use CTM77.........................................157 Exploded View—Alternator............................................158 Remove and Install Alternator.......................................159 Starting Circuit........................................................161 Specifications......................................................161 Repair Starter—Use CTM77............................................161 Remove and Install Starter Motor....................................161 Switches and Relays.....................................................163 Disconnect Electrical Circuit.......................................163 Replace Side Console Switches.......................................163 Replace A/C High/Low Pressure Switch................................164 Replace Dome Light Switch...........................................165 Replace Cab Door Light Switch.......................................165 Replace Ignition Switch.............................................166 Replace A/C Deicing Switch and Blower Motor Resistor................167 Replace Boom Fold/Level Switch......................................167 Load Center Fuses (S.N. —13 000)....................................168 Load Center Fuses (S.N. 13 001—)....................................169 Load Center Relays and Diodes.......................................170 Replace Battery Box Fuses...........................................171 Replace Remote Solution Pump Switch.................................172 Monitoring Systems and Sensors..........................................173 Other Material......................................................173 Specifications......................................................173 Disconnect Electrical Circuit.......................................173 Replace Turn Signal Indicator Bulbs.................................174 Replace Steering Column Mini-Pod....................................175 Replace Chassis Computer Unit/Spray Rate Control Unit (CCU/SRC).....176 Replace Radar Sensor................................................176 Replace Boom Height Control Unit (BHC)..............................178 Replace Hydraulic Oil Temperature Sensor............................178 Replace Boom Height Sensor..........................................180 Replace Boom Fold Cylinder Switch...................................181 Replace Wheel Speed Sensor..........................................182 Replace Fuel Level Sender...........................................182 Replace Solution Pressure Sensor....................................183 Remove and Install Flowmeter Sensor (Stainless Steel)...............183 Remove and Install Flowmeter Sensor (Plastic).......................184 Engine Control System...................................................185 Other Material......................................................185 Specifications......................................................185 Disconnect Electrical Circuit.......................................185 Replace Engine Control Unit (ECU)...................................186 Replace Engine Oil Pressure Sensor..................................187 Replace Engine Crank Speed Sensor...................................187 Replace Engine Coolant Temperature Sensor...........................188 Replace Air Filter Restriction Indicator Sensor.....................189 Lights..................................................................191 Replace and Adjust Field Lights.....................................191 Safety Rules When Replacing Halogen Bulbs...........................191 Hood Headlight Bulb Replacement and Adjustment......................191 Remove and Install Headlight Assembly...............................193 Convenience and Accessory Components....................................197 Replace Three-Pin Accessory Outlets.................................197 Replace Circulation Blower Motor....................................197 Remove Air Quality (AQS) Pressurizer Blower Motor...................198 Replace Wiper Motor.................................................200 Replace Windshield Washer Pump......................................201 Replace Seat Air Compressor Motor...................................201 Remove Radio and Speakers...........................................201 Wiring Harness Routing..................................................203 Engine Harness Routing..............................................203 Chassis Harness Routing (S.N. —2000)................................205 Chassis Harness Routing (S.N. 2001—)................................209 Boom Trac Pro System....................................................213 Decontaminate Spray Equipment.......................................213 Remove and Install Boom Trac ProTM Breakaway Sensor.................213 Remove and Install Boom Trac ProTM Inner Boom Sensor................215 Remove and Install Boom Trac ProTM Center Section Sensor............217 Remove and Install Boom Trac ProTM Roll Sensor......................219 Power Train Repair..........................................................221 Remove and Install Hydrostatic Components...............................223 Essential or Recommended Tools......................................223 Service Equipment and Tools.........................................224 Other Material......................................................225 Specifications......................................................226 Emergency Tow Procedure.............................................227 Start-Up Procedure After Hydrostatic Repair.........................231 Flushing Hydrostatic Drive System...................................232 Tightening Wheel Hardware...........................................233 Remove Hydrostatic Drive Pump.......................................233 Install Hydrostatic Drive Pump......................................237 Replace Hydrostatic Drive Pump Isolators............................241 Remove, Install, and Adjust Hydrostatic Control Cable...............242 Remove and Install Hydrostatic Drive Motor..........................249 Remove and Install Drive Shaft......................................251 Inspect Drive Shaft.................................................254 Remove Planetary Hub................................................254 Install Planetary Hub...............................................258 Hydrostatic Drive Repair................................................263 Essential or Recommended Tools......................................263 Service Equipment and Tools.........................................263 Other Material......................................................264 Specifications......................................................265 Clean Vehicle of Hazardous Pesticides...............................267 Remove and Install Hydrostatic Pump Shaft Seal......................268 Replace Hydrostatic Pump Cartridge Valves...........................273 Replace Hydrostatic Pump Charge Pressure Relief Valve...............274 Repair Charge Pump..................................................275 Remove and Install Hydrostatic Pump Control Valve...................280 Remove and Install Control Valve Neutral Start Switch...............282 Adjust Neutral Start Switch.........................................283 Adjust Control Valve Eccentric Plug.................................283 Disassemble Hydrostatic Drive Pump..................................285 Inspect and Repair Hydrostatic Drive Pump...........................289 Assemble Hydrostatic Drive Pump.....................................291 Disassemble and Assemble Hydrostatic Drive Motor....................298 Disassemble and Assemble Hydrostatic Drive Motor Port Plate.........306 Planetary Hub Repair....................................................309 Essential or Recommended Tools......................................309 Service Equipment and Tools.........................................311 Other Material......................................................312 Specifications......................................................313 Clean Vehicle of Hazardous Pesticides...............................314 Disassemble Planetary Hub—4730 (Front and Rear); 4830 (Front).......316 Assemble Planetary Hub—4730 (Front and Rear); 4830 (Front)..........328 Disassemble Planetary Hub—4830 (Rear)...............................345 Assemble Planetary Hub—4830 (Rear)..................................357 Steering and Brakes.........................................................377 Steering Column.........................................................379 Essential or Recommended Tools......................................379 Specifications......................................................379 Repair Steering Column (Standard and AutoTrac Equipped).............379 Bleed Steering System...............................................384 Steering Valve..........................................................385 Other Material......................................................385 Specifications......................................................385 Service Parts Kit...................................................385 Remove and Install Steering Valve...................................385 Repair Steering Valve...............................................388 Remove and Install Toe-Control Valves...............................395 AutoTrac™ Steering System...............................................397 Specifications......................................................397 Remove and Install AutoTrac™ Controller.............................398 Remove and Install AutoTrac™ Steering Control Valve.................398 Repair AutoTrac™ Steering Control Valve Assembly....................402 Remove and Install AutoTrac™ Wheel Angle Sensor.....................405 Steering Cylinder.......................................................407 Specifications......................................................407 Service Parts Kit...................................................407 Remove and Install Steering Cylinder................................408 Repair Steering Cylinder............................................408 Check Front Axle Toe-In.............................................413 Adjust Front Axle Toe-In............................................414 Service Brakes..........................................................415 Other Material......................................................415 Specifications......................................................415 Service Parts Kit...................................................415 Inspect Service Brake System Components.............................415 Remove and Install Service Brake Valve..............................416 Remove and Install Service Brake Caliper............................417 Disassemble and Assemble Service Brake Caliper......................419 Start-Up Procedure After Brake System Repair........................420 Park Brakes.............................................................421 Service Equipment and Tools.........................................421 Other Material......................................................421 Specifications......................................................421 Remove and Install Park Brake Valve.................................421 Park Brake Check....................................................422 Suspension and Tread Adjust Repair..........................................423 Suspension..............................................................425 Essential or Recommended Tools......................................425 Other Material......................................................426 Specifications......................................................427 Clean Vehicle of Hazardous Pesticides...............................427 Replace Suspension Bushings and Seals...............................428 Adjust Front and Rear Air Spring Assemblies.........................439 Remove and Install Air Spring Leveling System Control Valve.........440 Air Spring Leveling System Linkage..................................441 Tread Adjust Valves.....................................................443 Essential or Recommended Tools......................................443 Specifications......................................................443 Service Parts Kit...................................................443 Tread Adjust Valve Block............................................444 Remove and Install Tread Adjust Valve Block.........................445 Replace Vickers Control Valve Coil(s)...............................446 Replace Tread Adjust Valve..........................................447 Remove, Inspect and Install Manifold Check Valve and Pilot Pisto....448 Tread Adjust Cylinders..................................................451 Essential or Recommended Tools......................................451 Other Material......................................................451 Specifications......................................................451 Service Parts Kit...................................................451 Remove and Install Hydraulic Tread Adjust Cylinders.................452 Tread Adjust Cylinder Identification................................456 Disassemble and Assemble Tread Adjust Cylinders—Style A.............457 Disassemble and Assemble Tread Adjust Cylinder—Style B..............458 Tread Adjust Shim Pads..................................................467 Essential or Recommended Tools......................................467 Other Material......................................................467 Replacing Top Tread Adjust Shim Pads................................467 Replacing Bottom Tread Adjust Shim Pads.............................468 Hydraulic System............................................................471 Hydraulic Pump..........................................................473 Specifications......................................................473 Service Parts Kit...................................................473 Clean Vehicle of Hazardous Pesticides...............................473 Relieve Hydraulic System Pressure...................................474 Remove and Install Hydraulic Pump...................................476 Disassemble and Assemble Hydraulic Pump.............................478 Remove and Install Hydraulic Pump Compensator.......................480 Repair Hydraulic Pump Compensator...................................481 Hydraulic Valves........................................................483 Essential or Recommended Tools......................................483 Other Material......................................................483 Specifications......................................................484 Service Parts Kit...................................................484 Boom Valve Assembly.................................................485 Roll Bias Boom Valve (Optional).....................................486 Disassemble, Inspect and Assemble Roll Bias Boom Valve..............487 Remove and Install Boom Control Valve...............................488 Boom Control Valve General Information..............................489 Disassemble, Inspect and Assemble Boom Control Valve................490 Replace Priority Valve..............................................496 Disassemble, Inspect and Assemble Priority Valve....................497 Replace Load Sense Shuttle Valve....................................499 Remove and Install Combination Valve................................500 Repair Combination Valve............................................501 Remove and Install Traction Control Valve...........................502 Repair Traction Control Valve.......................................503 Remove and Install Reverse Boost Valve..............................504 Boom Hydraulic Cylinders................................................505 Other Material......................................................505 Specifications......................................................506 Service Parts Kit...................................................506 Hydraulic Cylinder and Boom Control Valve Fitting Torques...........507 Remove and Install Boom Lift Cylinders..............................507 Remove and Install Boom Leveling Cylinder...........................508 Adjusting Boom Leveling Cylinders...................................509 Remove and Install Boom Inner Fold Cylinder.........................510 Adjusting Inner Fold Cylinder.......................................511 Remove and Install Boom Outer Fold Cylinder.........................512 Adjusting Outer Fold Cylinder.......................................513 Adjusting Stop Bolt.................................................515 Remove and Install Roll Bias Cylinder...............................515 Outer Folding Cylinder and Leveling Cylinder Identification.........516 Leveling Cylinder One Way Orifice Identification....................517 Disassemble and Assemble Boom Lift Cylinder.........................517 Disassemble and Assemble Boom Leveling Cylinder—Style A.............518 Disassemble and Assemble Boom Leveling Cylinder—Style B.............520 Disassemble and Assemble Boom Inner Fold Cylinder...................528 Disassemble and Assemble Outer Folding Cylinder—Style A.............534 Disassemble and Assemble Outer Folding Cylinder—Style B.............537 Disassemble and Assemble Roll Bias Cylinder.........................545 Hydraulic Oil Cooler....................................................547 Hydraulic Oil Cooler................................................547 Hydraulic Reservoir.....................................................549 Specifications......................................................549 Remove Hydraulic Reservoir..........................................549 Install Hydraulic Reservoir.........................................550 Clean Hydraulic Reservoir Strainers.................................552 Accumulator.............................................................555 Service Equipment and Tools.........................................555 Specifications......................................................555 Remove and Install Accumulator......................................555 Charge Accumulator..................................................556 Retractable Ladder......................................................557 Service Parts Kit...................................................557 Remove and Install Ladder Cylinder..................................557 Remove and Install Ladder Control Valve.............................558 Solution Spray System.......................................................559 Nozzle Repair...........................................................561 Decontaminate Spray Equipment.......................................561 Clean Vehicle of Hazardous Pesticides...............................561 Cleaning SprayMaster™ 5-Position Nozzle Bodies—Standard Flow........562 Cleaning SprayMater™ 5-Position Nozzle Bodies—High Flow.............563 Solution Tank...........................................................565 Service Equipment and Tools.........................................565 Other Material......................................................565 Specifications......................................................565 Decontaminate Spray Equipment.......................................565 Flush Solution Tank and Spray System................................566 Remove and Install Solution Tank....................................566 Remove and Install Agitation Nozzles................................569 Solution Pump...........................................................571 Service Equipment and Tools.........................................571 Other Material......................................................571 Specifications......................................................571 Decontaminate Spray Equipment.......................................572 Remove Solution Pump and Motor......................................572 Solution Pump Exploded View.........................................574 Repair Solution Pump................................................574 Repair Solution Pump Hydraulic Motor................................579 Install Solution Pump and Motor.....................................584 Solution Control Valves.................................................585 Other Material......................................................585 Specifications......................................................585 Essential or Recommended Tools......................................585 Decontaminate Spray Equipment.......................................585 Disassemble and Assemble Fittings...................................586 Repair Check Valves and Strainers...................................587 Replace Solution Control Valves.....................................588 Remove and Install Flowmeter Assembly...............................589 Replace Flowmeter Insert............................................590 Recondition Flowmeter...............................................591 Calibrate Flowmeter.................................................594 Remove and Install Boom Section Shut-Off Valves.....................596 Replace Boom Section Shut-Off Valve Actuator........................599 Remove and Install Boom Section Shut-Off Valve Actuator Terminal....599 Rinse Tank..............................................................603 Essential or Recommended Tools......................................603 Specifications......................................................604 Remove and Install Rinse Tank Assembly..............................604 Repair Polyethylene Plastic.........................................606 Eductor.................................................................611 Decontaminate Spray Equipment.......................................611 Eductor Assembly....................................................612 Remove and Install Eductor System Venturi...........................614 Foam Marker System..........................................................615 Foam Marker System Repair...............................................617 Other Material......................................................617 On Board Air Foam Marker Schematic..................................618 Repair Foam Marker Tubes............................................619 Foam Control Box Relay Identification (S.N. —13 000)................619 Foam Control Box Relay Identification (S.N. 13 001—)................619 Repair Tank.........................................................619 Remove and Install Foam Tank (S.N. —13 000).........................620 Repair Foam Collectors..............................................621 Repair Foam Marker Quick Fill (S.N. —13 000)........................621 Fittings............................................................621 Disassemble, Inspect, and Assemble Foam Mixing Head (S.N. —13 00....622 Remove and Install Foam Mixing Chamber (S.N. 13 001—)...............623 On Board Air System.....................................................625 Specifications......................................................625 Remove and Install On Board Air Compressor..........................625 Remove and Install On Board Air Dryer...............................627 Repair On Board Air Dryer...........................................630 Operator Station............................................................635 Component Removal and Installation......................................637 Essential or Recommended Tools......................................637 Specifications......................................................637 Clean Vehicle of Hazardous Pesticides...............................637 Remove and Install Cab..............................................638 Controls................................................................643 Other Material......................................................643 Specifications......................................................643 Service Parts Kit...................................................643 Remove and Install Armrest..........................................644 Remove and Install Armrest Control Cover............................645 Remove and Install Multifunction Control Handle.....................646 Remove and Install Throttle Control.................................647 Remove and Install Throttle Sensor..................................647 Remove, Install, and Adjust Temperature Control Cable...............648 Air Conditioning System.................................................651 Essential or Recommended Tools......................................651 Other Material......................................................654 Service Parts Kits..................................................654 Specifications......................................................655 Hose and Tubing O-Ring Connection Torques...........................655 System Information..................................................656 Diagram - Air Conditioning System...................................658 Air Conditioning System Fittings—Reference Chart....................659 Discharge Air Conditioning System...................................661 Flush Compressor....................................................662 Flush Evaporator....................................................663 Flush Evaporator (Through Expansion Valve)..........................664 Flush Condenser.....................................................665 Purge Air Conditioning System.......................................666 Evacuate Air Conditioning System....................................666 Charge Air Conditioning System......................................667 Refrigerant Oil Information.........................................667 Check Refrigerant Oil Charge........................................668 Determine Correct Refrigerant Oil Charge............................668 Add Refrigerant Oil to System.......................................669 Add Oil to Pressurized System.......................................670 Remove and Install Compressor.......................................671 Test Volumetric Efficiency..........................................672 Test Shaft Seal Leakage.............................................674 Disassemble and Assemble Compressor Clutch..........................675 Check Clutch Hub Clearance..........................................676 Inspect Compressor Manifold.........................................676 Disassemble, Inspect and Assemble Compressor........................677 Remove and Install Compressor Relief Valve..........................681 Remove and Install Expansion Valve..................................681 Replace Receiver-Dryer..............................................682 Leak Test Hydraulic Oil Cooler/Air Conditioning Condenser...........683 Remove Air Quality System Module....................................683 Remove and Install Heater Core or Evaporator........................685 Leak Test Air Quality System Module.................................685 Install Air Quality System Module...................................686 Heating System..........................................................687 Remove Heater Control Valve.........................................687 Leak Test Heater Control Valve......................................688 Install Heater Control Valve........................................688 Air Suspension Seat.....................................................689 Other Material......................................................689 Service Parts Kit...................................................689 Remove Seat from Suspension.........................................689 Operator Seat—Exploded View.........................................692 Remove Air Seat Suspension System...................................693 Operator Seat Air Suspension Assembly—Exploded View.................694 Disassemble and Assemble Operator's Seat Air Suspension Assembly....695 Cab Door and Windshield.................................................699 Specifications......................................................699 Repair Cab Door Latch Assembly......................................700 Cab Door Adjustment—Step 1..........................................701 Cab Door Adjustment—Step 2..........................................702 Cab Door Adjustment—Step 3..........................................703 Cab Door Adjustment—Step 4..........................................703 Cab Door Adjustment—Step 5..........................................704 Replace Windshield Glass or Seal....................................704 Remove and Install Door Cylinder....................................706 Boom Repair.................................................................707 Boom Repair.............................................................709 Essential or Recommended Tools......................................709 Other Material......................................................709 Specifications......................................................709 Remove and Install Boom Center Roll Bearing.........................709 Remove and Install Boom Shock Absorbers and Rubber Stops............711 Remove and Install Boom Roll Suspension Springs.....................712 Remove and Install Boom Rear Anti-Yaw Link..........................712 Replace Boom Anti-Yaw Link Washers..................................713 Remove and Install Yaw Rocker Cushions..............................714 Dealer Fabricated Tools.....................................................717 Dealer Fabricated Tools.................................................719 DFN20 Solution Pump Seal Driver.....................................719 DFN21 Pump Support Fixture..........................................719 DFN22 Bearing Seat Driver...........................................719 DFN23 Hydrostatic Motor Seal Driver.................................720 DFNX65-A1 Eccentric Plug Adjustment Tool............................720 DFNX65-A2 Sizing Arbor..............................................721 DFNXT1—High Pressure Flange Wrench..................................722 DFNXT2—Agitation Nozzle Tool........................................723 DFRW151—Radiator Cap Adapter........................................724 DFNXT13—Rear Planetary Assembly Spacer..............................724 Page Number..................................................................... 3 Section 10.................................................................. 6 Group 05................................................................ 7 Group 10................................................................ 23 Group 15................................................................ 45 Section 20.................................................................. 57 Group 00................................................................ 59 Section 30.................................................................. 73 Group 10................................................................ 75 Group 15................................................................ 79 Group 20................................................................ 81 Group 25................................................................ 95 Section 40.................................................................. 98 Group 05................................................................ 99 Group 10................................................................105 Group 15................................................................157 Group 20................................................................161 Group 25................................................................163 Group 30................................................................173 Group 32................................................................185 Group 35................................................................191 Group 40................................................................197 Group 45................................................................203 Group 50................................................................213 Section 50..................................................................221 Group 05................................................................223 Group 10................................................................263 Group 15................................................................309 Section 60..................................................................377 Group 05................................................................379 Group 10................................................................385 Group 12................................................................397 Group 15................................................................407 Group 20................................................................415 Group 25................................................................421 Section 61..................................................................423 Group 05................................................................425 Group 10................................................................443 Group 15................................................................451 Group 20................................................................467 Section 70..................................................................471 Group 05................................................................473 Group 10................................................................483 Group 15................................................................505 Group 20................................................................547 Group 25................................................................549 Group 30................................................................555 Group 35................................................................557 Section 80..................................................................559 Group 05................................................................561 Group 10................................................................565 Group 15................................................................571 Group 20................................................................585 Group 25................................................................603 Group 30................................................................611 Section 81..................................................................615 Group 05................................................................617 Group 10................................................................625 Section 90..................................................................635 Group 05................................................................637 Group 10................................................................643 Group 15................................................................651 Group 20................................................................687 Group 25................................................................689 Group 30................................................................699 Section 100.................................................................707 Group 05................................................................709 Section 199.................................................................717 Group 05................................................................719
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