John Deere W230 (4LZ-7, 4LZ-8) Combine Workshop Repair Service Manual (TM702819) - MJODTM702819.zip
A full-service diagnostic and repair guide for the John Deere W230 (4LZ-7, 4LZ-8) Combine (SN.015000-), packed with workshop data so you can service, troubleshoot, fix, and rebuild your machine with the same skill as a professional technician.
The John Deere W230 (4LZ-7, 4LZ-8) Combine service manual covering diagnosis, repair, testing, operation, and maintenance contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
John Deere Combines W230 (4LZ-7, 4LZ-8) Diagnosis and Repair Service Manual (TM702819)
TM702819 - John Deere W230 (4LZ-7,4LZ-8) Combine (SN.015000-) Technical Manual (Diagnosis_Repair_Test_Operation_Service).PDF
TM702819 - John Deere W230 (4LZ-7,4LZ-8) Combine (SN.015000-) Technical Manual (Diagnosis_Repair_Test_Operation_Service).epub
Total Pages: 1,141 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
Identification and Specifications
Tune-Up and Adjustment
Fuels, Lubricants, and Coolants
Delivery and Storage Instructions
Engine
Engine
Cooling System
Fuel and Air Intake Systems
Fuel System
Air Intake System
Electrical System
Battery
Fuses and Relays
Operators Station
Sensors and Switches
Alternator and Voltage Regulator
Starting Motor and Starting Relay
Ground Drive
Variable Speed
Clutch
Transmission and Differential
Final Drive
Brakes, Steering and Rear Axle
Brakes
Steering
Rear Axle
Hydraulic System
Hydraulic Reservoir
Hydraulic Pumps
Hydraulic Valves
Hydraulic Cylinders
Accumulator
Hydrostatic Motor
Miscellaneous
Shafts and Bearings
Operator Station Repair
System Components
Cab
Feeder House
Feeder House-Removing and Installing
Feeder House-Adjustments
Threshing Separation and Grain Cleaning
Cylinder and Concave
Separator Drive
Beater
Cleaning
Straw Walkers and Walker Tine Separator
Residue Disposal
Elevator, Grain Tank, and Unloading
Elevators and Augers
Electrical Diagnostic
General References
Theory of Operation
Schematics
Diagnostics
Electrical Components - Connectors
Electrical Components
Hydraulic Diagnostics
Hydraulic System Specification
Theory of Operation
Schematics
Diagnostics
Hydraulic Components
Using Instruction
Symbol Reference
Hydraulic-A Component
Hydraulic-C Components
Hydraulic-F Component
Hydraulic-G Components
Hydraulic-M Component
Hydraulic-O Components
Hydraulic-P Components
Hydraulic-R Components
Hydraulic-V Components
Hydraulic-X Components
TABLE OF CONTENTS................1
Section 10: General Information................23
Group 05: Safety................23
Recognize Safety Information................27
Follow Safety Instructions................28
Understand Signal Words................29
Driving the Machine................30
Parking and Leaving the Machine................31
Keep Riders Off Machine................32
Avoid Electrical Power Lines................33
Handle Fuel Safely—Avoid Fires................34
Install All Guards................35
Service Cooling System Safely................36
Prevent Battery Explosions................37
Handling Batteries Safely................38
Prevent Acid Burns................40
Avoid Heating Near Pressurized Fluid Lines................42
Wear Protective Clothing................43
Use Proper Lifting Equipment................44
Stay Clear of Rotating Drivelines................45
Tightening Wheel Retaining Bolts/Nuts................46
Keep Hands Away From Knives................47
Cleaning Grain Tank and Removal of Blockages Safely................48
Stay Clear of Harvesting Units................49
Unloading Auger Transport Position................50
Stay Away From Straw Chopper................51
Handle Fluids Safely—Avoid Fires................52
Prepare for Emergencies................53
Avoid High-Pressure Fluids................54
Park Machine Safely................55
Support Machine Properly................56
Service Machines Safely................57
Work In Ventilated Area................58
Illuminate Work Area Safely................59
Protect Against Noise................60
Work in Clean Area................61
Use Proper Tools................62
Decommissioning — Proper Recycling and Disposal of Fluids and Components................63
Remove Paint Before Welding or Heating................64
Use Safety Lights and Devices................65
Live With Safety................66
Servicing Electronic Control Units................67
Welding Near Electronic Control Units................68
Group 10: Identification and Specifications................691
Specifications................691
Combine Dimensions................79
Identification Numbers................80
Metric Bolt and Screw Torque Values................82
Unified Inch Bolt and Screw Torque Values................84
Face Seal Fittings Assembly and Installation—All Pressure Applications................86
Metric Face Seal Fitting Torque Chart Standard Pressure Applications................87
Group 15: Tune-Up and Adjustment................24
Storing Belts................90
Inspect Belts................91
Remove and Install Belts................94
Align Sheaves................96
Chain Maintenance................97
Safety Cotter Pin................98
Drive Chains—Connecting Link................99
Group 20: Fuels, Lubricants, and Coolants................24
Diesel Fuel................102
Hydraulic Oil................104
Gear Oil................105
Transmission................106
Gear Oil Information................107
Multipurpose Grease................108
Diesel Engine Coolant (engine with wet sleeve cylinder liners)................109
Group 25: Delivery and Storage Instructions................25
Combine Temporary Storage Instructions................112
Prepare Combine For Railroad Delivery................113
Pre-Delivery Inspection................114
Section 20: Engine................116
Group 05: Engine................116
Essential Tools................118
John Deere Engine Repair—Use CTM................119
Remove and Install Engine................120
Group 10: Cooling System................116
Specifications................691
Engine Coolant................129
Cooling System Theory of Operation................467
Common Problems of Cooling Systems................131
Remove and Install Rotary Screen................132
Remove and Install Radiator................133
Radiator Assembly—Exploded View................135
Rotary Screen Assembly—Exploded View................136
Disassemble and Assemble Rotary Screen Drive................138
Screen Vacuum—Exploded View................140
Screen Vacuum Adjustment................142
Check and Adjust Radiator................143
Check Radiator Cap................144
Cooling System Operation................145
Section 30: Fuel and Air Intake Systems................146
Group 05: Fuel System................146
Do Not Modify the Fuel System................148
Specifications................691
Remove and Install Fuel Prefilter With Electric Fuel Pump................150
Remove Fuel Tank Frame................151
Remove and Install Fuel Tank................154
Fuel System—Exploded View................155
Fuel Filter—Exploded View................156
Check Injection Nozzles................157
Purge Fuel from Injection Nozzles................158
Group 10: Air Intake System................146
Specifications................691
Turbocharger Theory of Operation................467
Air Intake System—Exploded View................163
Air Intake and Filter Maintenance................164
Intake and Exhaust Components—Exploded View................168
Turbocharger Components................169
Remove and Install Turbocharger................171
Check Turbocharger................173
Check Radial Bearing Clearance of Turbocharger................178
Check Axial Clearance of Turbocharger................179
Pre-Lubricate Turbocharger................180
Section 40: Electrical System................181
Group 05: Battery................181
Essential or Recommended Tools................201
Multimeter—General Information................202
Servicing Batteries................187
Prevent Damage to Electrical Systems................189
Checking Battery Fluid Level................190
Checking Battery Charge................192
Charging Batteries................193
Preventing Battery Damage................195
Remove and Install Battery................197
Using a Booster Battery................199
Group 10: Fuses and Relays................181
Essential or Recommended Tools................201
Multimeter—General Information................202
Description of Fuses and Relays................203
Remove and Install Auxiliary Fuse................205
Remove and Install Starter Fuse................207
Remove and Install Backup Lights and Alarm Relay................209
Remove and Install Heater Relay................210
Group 15: Operators Station................181
Instruments and Controls Identification................213
Remove and Install Marker Light Switch................214
Remove and Install Work Light Switch................215
Remove and Install Throttle Switch................216
Remove and Install Murphy Gauge................218
Remove and Install Indicator Panel................220
Remove and Install Speedometer................222
Remove and Install Beacon Light and Unloading Auger Light Switch................224
Remove and Install Turn-Signal Switch................226
Remove and Install Key Switch................228
Remove and Install Reel Speed Switch................230
Remove and Install Field Light Switch................232
Remove and Install Fuel Gauge................234
Remove and Install Horn Switch................236
Remove and Install Horn................836
Remove and Install Threshing Speed Gauge................239
Remove and Install Wiper Switch................241
Remove and Install Radio................242
Remove and Install Radio Speaker................243
Remove and Install Dome Light................244
Group 20: Sensors and Switches................182
Specifications................691
Remove and Install Air Filter Restriction Switch................247
Remove and Install Backup Alarm Switch................248
Remove and Install Backup Alarm................250
Remove and Install Battery Disconnect Switch................251
Remove and Install Straw Walker Plug Switch................253
Remove and Install Brake Fluid Level Alarm Switch................254
Remove and Install Brake Light Switch................255
Remove and Install Chopper Plug Switch................256
Remove and Install Threshing Speed Sensor................257
Remove and Install Engine Crank Sensor................258
Remove and Install Fuel Level Sensor................259
Remove and Install Fuel Pressure Sensor................260
Remove and Install Fuel Temperature Sensor................261
Remove and Install Full Grain Tank Switch................262
Remove and Install Ground Speed Sensor................263
Remove and Install Hydraulic Oil Filter Pressure Alarm Switch................264
Remove and Install Manifold Air Temperature Sensor................265
Remove and Install Oil Pressure Sensor................266
Remove and Install Separator Safety Switch................267
Remove and Install Tine Separator Plugged Switch................268
Remove and Install Water-in-Fuel Sensor................269
Group 25: Alternator and Voltage Regulator................182
Remove and Install Alternator................272
Alternator Voltage Regulator................274
Group 30: Starter Motor and Starter Relay................183
Starter Motor................276
Remove and Install Starter Relay................277
Section 50: Ground Drive................279
Group 05: Variable Speed................279
Other Material................376
Specifications................691
Upper Variable Drive Sheave Troubleshooting................284
Checking Lower Unit................285
Upper Drive Sheave Alignment................286
Upper Variable Drive Sheave Damage Preventives................287
Disassemble and Assemble Power Take-Off Assembly................288
Disassemble and Assemble Upper Variable Sheave................290
Lower Transmission Drive Maintenance and Operation................297
Lower Transmission Drive Belt Adjustment................299
Disassemble and Assemble Lower Transmission Drive................301
Group 10: Clutch................279
Specifications................691
Disassemble and Assemble Clutch................316
Hydraulic Clutch Valve—Troubleshooting................320
Hydraulic Clutch Schematic................321
Remove and Install Hydraulic Clutch Valve................322
Hydraulic Clutch Valve—Exploded View................324
Remove and Install Hydraulic Clutch Cylinder................325