John Deere 5430i Demountable Self-Propelled Crop Sprayer Workshop Repair Manual TM402219 PDF - MJODTM402219.zip
The full factory service manual covering John Deere Demountable Self-Propelled Crop Sprayers model 5430i (PIN Prefix WZ & 1WZ), packed with every shop detail needed to service, fix, and overhaul the machine just like trained dealership technicians.
John Deere Demountable Self-Propelled Crop Sprayers 5430i workshop service & repair manual 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.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM402219 - John Deere 5430i Demountable Self-Propelled Crop Sprayer Technical Manual (Repair).PDF
TM402219 - John Deere 5430i Demountable Self-Propelled Crop Sprayer Technical Manual (Repair).epub
Total Pages: 1,111 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
Foreword
General Information
Safety
General Information
Fuels and Lubricants
Engine
Remove and Install Components
Fuel, Air Intake, and Cooling Systems
Component Removal and Installation
Diesel Fuel System
Engine Cooling System
Electrical System
Battery
Harness and Connector Repair
Charging Circuit
Starting Circuit
Fuses and Relays
Lighting
Chassis Control System
Engine Control System
Spray Rate Control System
Boom Control System
Cab Components
Wiring Harness Routings
Power Train
Component Removal and Installation
Hydrostatic Drive Repair
Planetary Hub Repair
Steering and Brakes
Component Removal and Installation
Steering
Service Brakes
Suspension and Tread Adjust
Component Removal and Installation
Tread Adjust Valves
Tread Adjust Cylinders
Hydraulic System
Component Removal and Installation
Hydraulic Pump
Hydraulic Valves
Hydraulic Reservoir
Solution Spray System
Component Removal and Installation
Solution Tank
Solution Pump
Spray Nozzles
Solution Control Valves
Eductor
Fast Fill Pump
Pneumatic System
Component Removal and Installation
Component Repair
Operator`s Station
Cab
Controls
Air Conditioning System
Heating System
Air Suspension Seat
Cab Door and Windshield
Boom Repair
Boom Repair
Dealer Fabricated Tools
TABLE OF CONTENTS....1
Section 10: General Information....18
Group 05: Safety....18
Recognize Safety Information....22
Understand Signal Words....23
Perform Service Safely....24
Wait Before Opening High-Pressure Fuel System....25
Service Accumulator Systems Safely....26
General Machine Operation Safety....27
Transport in the Field and on the Road....28
Park Machine Safely....30
Servicing Electronic Control Units....31
Welding Near Electronic Control Units....32
Keep Electronic Control Unit Connectors Clean....33
Handle Fluids Safely—Avoid Fires....34
Prevent Battery Explosions....195
Prepare for Emergencies....36
Protect Against High Pressure Spray....37
Prevent Acid Burns....38
Wear Protective Clothing....40
Handle Agricultural Chemicals Safely....41
Service and Operate Chemical Sprayers Safely....43
Avoid Contact with Agricultural Chemicals....45
Clean Vehicle of Hazardous Pesticides....484
Support Machine Properly....48
Service Machines Safely....49
Practice Safe Maintenance....50
Avoid Harmful Asbestos Dust....52
Work In Ventilated Area....53
Work in Clean Area....54
Remove Paint Before Welding or Heating....55
Avoid Heating Near Pressurized Fluid Lines....56
Avoid High-Pressure Fluids....57
Service Tires Safely....58
Service Cooling System Safely....59
Illuminate Work Area Safely....60
Replace Safety Signs....61
Use Proper Lifting Equipment....62
Use Proper Tools....63
Construct Dealer-Made Tools Safely....64
Decommissioning — Proper Recycling and Disposal of Fluids and Components....65
Handle Electronic Components and Brackets Safely....66
Live With Safety....67
Group 10: General Information....19
Machine Specification....72
Machine Dimensions....76
Face Seal Fittings Assembly and Installation—All Pressure Applications....79
Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures....80
Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications....82
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures....84
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications....86
Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications....88
SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications....89
SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications....90
External Hexagon Port Plug Torque Chart....91
Identifying Zinc-Flake Coated Fasteners....93
Metric Bolt and Screw Torque Values....94
Unified Inch Bolt and Screw Torque Values....96
Programming Control Units....98
Preparing and Painting Sprayer Components....101
Group 15: Fuels and Lubricants....19
Diesel Fuel....104
Handling and Storing Diesel Fuel....106
Lubricity of Diesel Fuel....107
Diesel Engine Coolant (engine with wet sleeve cylinder liners)....108
Testing Diesel Engine Coolant....110
Supplemental Coolant Additives....111
Operating in Warm Temperature Climates....112
Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER....113
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III....115
Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I....117
Extended Diesel Engine Oil Service Intervals — Non-Emissions Certified and Certified Tier 1 and Stage I....119
Hydrostatic/Hydraulic Drive Oil....120
Planetary Hub Oil....121
Grease....122
Suspension and Steering Grease....123
Alternative and Synthetic Lubricants....124
Lubricant Storage....125
Section 20: Engine....126
Group 00: Remove and Install Components....126
Essential or Recommended Tools....993
Specifications....1087
John Deere Engine Repair—Use CTM....371
Clean Vehicle of Hazardous Pesticides....484
Remove and Install Engine....132
Remove and Install Hood....141
Remove and Install Exhaust System....142
Section 30: Fuel, Air Intake, and Cooling Systems....144
Group 00: Component Removal and Installation....144
Specifications....1087
Remove and Install Air Cleaner Housing....147
Remove and Install Fan Drive and Shroud....148
Remove and Install Radiator....152
Remove and Install Aftercooler....166
Remove and Install Diesel Fuel Cooler....169
Remove and Install Expansion Tank....170
Remove and Install Fuel Tank....174
Group 05: Diesel Fuel System....144
Specifications....1087
Clean and Inspect Fuel Tank....179
Replace Fuel Filter, Fuel Pump, and Bleed Fuel System....180
Group 10: Engine Cooling System....144
Specifications....1087
Drain, Flush, and Fill Cooling System....183
Test Radiator and Coolant Tank Cap....186
Section 40: Electrical System....188
Group 05: Battery....188
Essential or Recommended Tools....993
Specifications....1087
Prevent Battery Explosions....195
Battery Safety....196
Prevent Damage to Electrical Systems....198
Check Electrolyte Specific Gravity....199
Charging Batteries....201
Connecting Battery Cables....203
Battery Replacement....204
Group 10: Harness and Connector Repair....188
Essential or Recommended Tools....993
Other Material....1022
Use Electrical Insulating Compound....216
Using High-Pressure Washers....217
Electrical System Visual Inspection....218
Basic Electrical Component Handling / Precautions for Vehicles Equipped with Computer Controlled Systems....219
Electrical Connector / Wiring Harness Handling and Repair....220
Installation of Repair Wire Assembly (RWA)....221
Repair Procedure R-A....230
Repair Procedure R-B....235
Repair Procedure R-C....239
Repair Procedure R-D....244
Repair Procedure R-E....247
Repair Procedure R-F....251
Repair Procedure R-G....255
Repair Procedure R-I....258
Repair Procedure R-J....261
Repair Procedure R-K....266
Repair Procedure R-M....269
Repair Procedure R-N....273
Repair Procedure R-AA....277
Repair Procedure R-AE....278
Repair Procedure R-AF....283
Repair Procedure R-AG....286
Repair Procedure R-AH....289
Repair Procedure R-AI....291
Repair Procedure R-AJ....294
Repair Procedure R-AK....299
Repair Procedure R-AL....302
Repair Procedure R-AM....306
Repair Procedure R-AN....309
Repair Procedure R-AO....312
Repair Procedure R-AP....315
Repair Procedure R-AQ....318
Group 15: Charging Circuit....189
Specifications....1087
Remove and Install Alternator....323
Group 20: Starting Circuit....189
Essential or Recommended Tools....993
Remove and Install Starter Motor....327
John Deere Starting Motor Repair—Use CTM....328
Group 25: Fuses and Relays....189
Replace Fuses and Relays....334
Group 30: Lighting....189
Safety Rules When Replacing Halogen Bulbs....340
Safety Instructions for Replacing a Halogen Bulb....341
Safety Instructions for Replacing Xenon (HID) Bulbs and Ballast Units....343
Hood Headlight Bulb Replacement and Adjustment....345
Remove and Install Headlight Assembly....349
Handling HID Light Bulbs Safely....350
Replacing Road Light Bulbs....351
Replace Roof Flood Light Halogen Bulb....354
Replace Rear Warning Light Bulbs....356
Replace Extremity Front Warning Light Bulb....357
Replacing Xenon (HID) Worklights and Ballast Units....359
Group 35: Chassis Control System....190
Specifications....1087
Replace Hydraulic Oil Temperature Sensor....363
Replace Wheel Speed Sensor....365
Replace Fuel Level Sender....366
Replace Chassis Control Unit (CCU) and Steering System Control Unit (SSU)....368
Group 40: Engine Control System....190
John Deere Engine Repair—Use CTM....371
Group 45: Spray Rate Control System....190
Specifications....1087
Remove and Install Auxiliary Fill Pressure Sensor....374
Remove and Install Solution Pressure Sensor....375
Remove and Install Spray Rate Control Unit....376
Remove and Install Solution Command System Electronic Power Module....378
Remove, Adjust, and Install Solution Pump Hydraulic Motor Speed Sensor....380
Group 50: Boom Control System....190
Remove and Install BoomTrac Sensor (If Equipped)....383
Replace Boom Hydraulic Control Unit (BHC)....384
Remove and Install Boom Inner Fold Position Sensor....385
Remove and Install Boom Outer Fold Position Switch....386
Remove and Install Pendulum Lock Position Sensor....387
Remove and Install Boom Tilt Sensor....388
Remove and Install Boom Height Sensor....389
Group 55: Cab Components....190
Specifications....1087
Decontaminate Spray Equipment....392
Remove and Install Boom Select Switch....393
Remove and Install Steering Mode Switch....394
Remove and Install Emergency Brake Control Switch....395
Remove and Install Key Switch....397
Remove and Install Light and Wiper Switch....398
Remove and Install Turn Signal Switch....399
Replace Horn Switch....400
Remove and Install Armrest Control Unit (ACU)....401
Remove and Install Throttle Control....402
Remove and Install Throttle Sensor....404
Remove and Install Multi-Function Lever Position Harness....406
Remove and Install Armrest Rocker Switches....410
Remove and Install Tread Adjust Switch....411
Replace Air Conditioning System On/Off Switch....412
Replace Blower Control Switch....413
Replace Dome Light....414
Replace Air Conditioning High/Low Pressure Switch....416
Replace Wiper Motor....418
Replace Windshield Washer Pump....420
Remove and Install Radio....421
Replace Speakers....422
Replace Antenna....423
Remove and Install Air Conditioning Temperature Control Switch....427
Group 60: Wiring Harness Routings....191
Engine Harness Routing....432