Miller Nitro Sprayer 4000-Series 4215 4215HT 4240HT 4275 4315 4365 Repair & Maintenance Manual PDF (21-47116) - MMIL2147116.zip

Full service and repair documentation, complete with electrical wiring schematics, covering the Miller Nitro Sprayer 4000-Series Models — everything you need to service, troubleshoot, fix, and rebuild your machine the way a professional technician would.

Inside the Miller Nitro Sprayer 4000-Series Models workshop service repair manual, you'll find:

* 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.

21.47116 - Miller Nitro Sprayer 4000-Series Models Maintenance & Repair Manual.pdf

PRODUCT DETAILS:

Total Pages: 617 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

TABLE OF CONTENTS

CHAPTER 1 - GENERAL AND SAFETY INFORMATION

Safety Precautions.. . . . 1-3

Notes, Notices, Cautions, Warnings, and Dangers Definitions. . . . 1-3

General Safety Precautions. . . 1-4

Sprayer Safety Precautions. . . 1-5

SPRAYER OPERATIONS. . . . 1-5

SPRAYER SERVICE AND MAINTENANCE. . . . . 1-5

Chemicals and Hazardous Substances Safety Precautions. . . . . 1-5

HAZARDOUS SUBSTANCE ALERT. . . . . 1-5

Engine Safety Precautions. . . . 1-6

ENGINE OPERATION. . . . 1-6

Wheels and Tires Safety Precautions. . . . 1-7

Electrical Safety Precautions. . . . . 1-7

OPERATION OF ELECTRICAL COMPONENTS. . . . 1-7

Towing Safety Precautions. . . . 1-8

Moving a Downed Vehicle. . . . 1-8

Safety Sign and Decal Locations. . . . 1-11

SAFETY SIGNS. . . . . 1-11

Major Components Locations. . . . 1-15

Hoses/Fittings - General. . . . . 1-16

Application Basics. . . . 1-16

Bending, Motion, Routing. . . . 1-16

Hose and Fitting Care. . . . 1-16

Fittings Specifications. . . . 1-18

TIGHTENING HYDRAULIC FITTINGS. . . . . 1-18

TIGHTENING FLARE TYPE FITTINGS. . . . . 1-19

Hardware Torque Specifications. . . . 1-20

4000 Series Nitro Sprayer Models Pressure Settings. . . 1-27

Location of Electrical Relays, Breakers, and Fuses. . . . . 1-32

Miller Nitro Sprayer Hydraulic Oil Recommendation. . . . 1-34

Blaster Extended Antifreeze/Coolant. . . . 1-37

Nitro Sprayer Model Specifications. . . . . 1-38

Model 4215 / 4215HT. . . . 1-38

Model 4240HT. . . . 1-39

Model 4275.. . . 1-40

Page Number

Model 4315.. . . 1-41

Model 4365.. . . 1-42

CHAPTER 2 - CAB

General Notices, Cautions, Warnings, and Dangers For Cab Procedures. . . 2-3

Cab Air Bags. . . . . 2-4

REMOVAL.. . . . 2-4

INSTALLATION.. . . 2-4

Cab Filters.. . . . 2-4

CLEAN/CHANGE. . . . 2-4

Recirculation Air Filter. . . . . 2-4

Cab Air (Charcoal) Filter. . . 2-5

AC Recirculation Blower Motor. . . 2-5

REMOVAL.. . . . 2-5

INSTALLATION.. . . 2-6

AC Blower Motor. . . . . 2-6

REMOVAL.. . . . 2-6

INSTALLATION.. . . 2-6

AC Evaporator Heater. . . . 2-7

REMOVAL.. . . . 2-7

INSTALLATION.. . . 2-8

AC Actuator Water Valve. . . . 2-9

REMOVAL.. . . . 2-9

INSTALLATION. . . . . 2-10

AC Duct Work.. . . 2-11

REMOVAL.. . . 2-11

RH AC Vent. . . . . 2-11

LH AC Vent.. . . 2-11

INSTALLATION. . . . . 2-12

LH AC Vent.. . . 2-12

RH AC Vent. . . . . 2-12

Cab Interior Convenience Electrical Outlets Power Strip. . . 2-13

GENERAL INFORMATION. . . . . 2-13

Cab Interior Panels and Floor Mat. . . 2-14

REMOVAL.. . . 2-14

Floor Mat. . . . . 2-14

Front Interior Panel. . . 2-14

Overhead Console Panel. . . . . 2-14

Overhead Interior Light. . . 2-16

Headliner. . . . . 2-17

INSTALLATION. . . . . 2-18

Headliner. . . . . 2-18

Overhead Interior Light. . . 2-20

Overhead Console Panel. . . . . 2-21

Front Interior Panel. . . 2-22

Floor Mat. . . . . 2-22

Cab Roof.. . . . 2-23

REMOVAL.. . . 2-23

INSTALLATION. . . . . 2-23

Cab Steering Column Covers. . . . 2-24

REMOVAL.. . . 2-24

INSTALLATION. . . . . 2-24

Cab Windshield. . . . . 2-25

REPLACEMENT. . . . . 2-25

Cab Windshield Wiper Motor. . . . 2-25

REMOVAL.. . . 2-25

INSTALLATION. . . . . 2-25

Operator Control Console. . . 2-25

REMOVAL.. . . 2-25

INSTALLATION. . . . . 2-26

Operator Seat.. . . . 2-27

REMOVAL.. . . 2-27

INSTALLATION. . . . . 2-27

Operator Seat Suspension. . . 2-27

REMOVAL.. . . 2-27

INSTALLATION. . . . . 2-27

Training Seat.. . . .

REMOVAL.. . .

INSTALLATION. . . . .

AC/Heater Housing Cover. . .

REMOVAL.. . .

INSTALLATION. . . . .

AC Hoses.. . .

REMOVAL.. . .

INSTALLATION. . . . .

CHAPTER 3 - FRAME AND SUSPENSION

General Notices, Cautions, Warnings, and Dangers For Frame and Suspension Procedures. . . 3-3

Rear Deck and Platforms. . . . 3-4

REAR DECK. . . . . 3-4

Removal.. . . 3-4

Installation. . . . . 3-4

MID-PLATFORM. . . . . 3-5

Removal.. . . 3-5

Installation. . . . . 3-5

FRONT PLATFORM. . . . . 3-6

Removal.. . . 3-6

Installation. . . . . 3-6

Suspension Cylinders. . . . 3-7

SUSPENSION SYSTEM - GENERAL. . . . 3-7

SUSPENSION SYSTEM CHECK. . . . 3-9

Suspension System Leak Down Check. . . 3-9

SUSPENSION CYLINDERS ADJUSTMENT. . . . 3-9

BLEED AIR FROM SUSPENSION SYSTEM. . . 3-10

SUSPENSION CYLINDER 21.40741 REBUILD. . . . 3-11

Repair Parts Available. . . 3-13

A-Frame.. . . . 3-15

REMOVAL.. . . 3-15

INSTALLATION. . . . . 3-35

Ladder Assembly.. . . . 3-50

REMOVAL.. . . 3-50

INSTALLATION. . . . . 3-51

Hydraulic Ladder Lift Cylinder. . . 3-52

REMOVAL.. . . 3-52

INSTALLATION. . . . . 3-52

Air Tank. . . . . 3-53

REMOVAL.. . . 3-53

INSTALLATION. . . . . 3-53

Fuel Tank.. . . . 3-54

REMOVAL.. . . 3-54

INSTALLATION. . . . . 3-54

Hand Rinse Tank.. . . . 3-55

REMOVAL.. . . 3-55

DISASSEMBLY. . . . . 3-55

ASSEMBLY. . . . . 3-56

INSTALLATION. . . . . 3-56

CHAPTER 4 - ENGINE

General Notices, Cautions, Warnings, and Dangers For Engine Procedures. . . . 4-5

ENGINE TROUBLESHOOTING. . . 4-7

Engine Fault Codes - General. . . . . 4-8

Engine Fault Codes - QSB and QSL Engines. . . . . 4-9

Upper Fan Screen.. . . 4-23

REMOVAL.. . . 4-23

INSTALLATION. . . . . 4-23

Lower Fan Screen.. . . 4-24

REMOVAL.. . . 4-24

INSTALLATION. . . . . 4-24

Fan.. . . 4-25

REMOVAL.. . . 4-25

INSTALLATION. . . . . 4-25

Fan Motor.. . . . 4-26

REMOVAL.. . . 4-26

INSTALLATION. . . . . 4-26

Fan Shroud Assembly.. . . 4-27

REMOVAL.. . . 4-27

DISASSEMBLY. . . . . 4-28

ASSEMBLY. . . . . 4-28

INSTALLATION. . . . .

Cooling Package.. . . .

REMOVAL.. . .

INSTALLATION. . . . .

Individual Component of Cooling Package. . . . .

REMOVAL.. . .

INSTALLATION. . . . .

Engine Enclosure and Doors. . . .

REMOVAL.. . .

Engine Enclosure Doors. . . . .

Engine Top Covers. . .

Rear Engine Bay Panel. . . . .

Left Engine Bay Panel. . .

Right-hand Bottom and Top Engine Enclosure Covers. . . . .

Exhaust Shield.. . .

Right Engine Bay Panel. . . . .

INSTALLATION. . . . .

Right Engine Bay Panel. . . . .

Exhaust Shield.. . .

Right-hand Bottom and Top Engine Enclosure Covers. . . . .

Left Engine Bay Panel. . .

Rear Engine Bay Panel. . . . .

Engine Top Covers. . .

Engine Enclosure Doors. . . . .

Fuel Pump.. . .

REMOVAL.. . .

INSTALLATION. . . . .

Engine Mounts. . . . .

REMOVAL.. . .

Front Engine Mount. . . . .

Rear Engine Mount. . .

INSTALLATION. . . . .

Rear Engine Mount. . .

Front Engine Mount. . . . .

Air Conditioner Compressor Belt. . . . 4-50

REMOVAL.. . . 4-50

INSTALLATION. . . . . 4-50

Serpentine Belt.. . . 4-50

REMOVAL.. . . 4-50

INSTALLATION. . . . . 4-51

Engine Belly Door.. . . . 4-52

REMOVAL.. . . 4-52

INSTALLATION. . . . . 4-54

Air Conditioning Compressor. . . . 4-55

REMOVAL.. . . 4-55

INSTALLATION. . . . . 4-55

AC Receiver Dryer.. . . 4-56

REMOVAL.. . . 4-56

INSTALLATION. . . . . 4-56

Alternator.. . . . 4-57

REMOVAL.. . . 4-57

INSTALLATION. . . . . 4-57

Starter Motor.. . . . 4-58

REMOVAL.. . . 4-58

INSTALLATION. . . . . 4-59

Air Cleaner Filter Element. . . 4-60

REMOVAL.. . . 4-60

INSTALLATION. . . . . 4-61

Air Cleaner Assembly. . . . 4-62

REMOVAL.. . . 4-62

INSTALLATION. . . . . 4-62

Exhaust Assembly.. . . 4-63

REMOVAL.. . . 4-63

INSTALLATION. . . . . 4-64

Fan Hydraulic Pump. . . . . 4-65

REMOVAL.. . . 4-65

INSTALLATION. . . . . 4-65

Air Compressor. . . . . 4-66

REMOVAL.. . . 4-66

INSTALLATION. . . . . 4-67

Air Governor.. . . .

REMOVAL.. . .

INSTALLATION. . . . .

ADJUSTMENT. . . . .

Fuel-Water Separator.. . .

DRAIN.. . .

Fuel-Water Separator Hand Priming Pump. . . . .

REMOVAL.. . .

INSTALLATION. . . . .

AC Charging.. . . .

FIELD CHARGING. . . . .

ALTERNATE CHARGING TECHNIQUE. . . .

PRESSURE TEMPERATURE CHART. . . . .

CHAPTER 5 - DRIVE AND HYDRAULICS

General Notices, Cautions, Warnings, and Dangers For Drive and Hydraulics Procedures. . . . . 5-3

Troubleshooting.. . . 5-4

HYDRAULIC SYSTEM CLEANLINESS. . . . . 5-4

HYDRAULIC SYSTEM PRESSURE. . . . . 5-4

Front Steering Cover. . . . . 5-4

REMOVAL.. . . . 5-4

INSTALLATION.. . . 5-5

Tire.. . . 5-6

NITRO 4000 SERIES MAIN LIFT JACK P/N 21.43250. . . . . 5-6

TIRE REMOVAL. . . . . 5-7

TIRE INSTALLATION. . . . 5-8

Wheel Drive Motor Assembly. . . 5-10

REMOVAL.. . . 5-10

INSTALLATION. . . . . 5-11

Wheel Drive Motor Start Up/Air Bleed and Auxiliary Brake. . . . . 5-12

AIR BLEED. . . . . 5-12

Wheel Drive Motor Start Up/Air Bleed. . . 5-12

Auxiliary Foot Brake Air Bleed. . . 5-12

Hydrostatic Pump Adjustment. . . 5-13

Specifications By Model. . . . . 5-13

Auxiliary Hydraulic Pump. . . 5-20

REMOVAL.. . . 5-20

INSTALLATION. . . . . 5-20

Brake/Shifting Valve. . . . . 5-21

REMOVAL.. . . 5-21

INSTALLATION. . . . . 5-21

Hydraulic Oil Tank.. . . 5-22

REMOVAL.. . . 5-22

INSTALLATION. . . . . 5-23