John Deere R4040i Demountable Self-Propelled Crop Sprayer Diagnostics & Tests Service Manual (TM407519) PDF - MJODTM407519.zip
In-depth Diagnosis & Tests guide for the John Deere Demountable Self-Propelled Crop Sprayer R4040i, packed with the workshop knowledge needed to service, troubleshoot, and rebuild the machine the way trained technicians do.
The Diagnosis & Tests manual for the John Deere Demountable Self-Propelled Crop Sprayer R4040i covers:
* 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.
TM407519 - John Deere R4040i Demountable Self-Propelled Crop Sprayer Technical Manual (Diagnosis & Tests).PDF
Total Pages: 2,121 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
Diagnostic Trouble Codes (DTC)
Armrest Control Unit (ACU)
Boom Hydraulic Control (BHC) Unit
Chassis Control Unit (CCU)
Chassis Control Unit - Vehicle Load Center (CCU VLC)
Cab Load Center (CLC)
Engine Control Unit (ECU) - L34
Vehicle Navigation - StarFire (iTC)
Primary Display Unit (PDU)
Spray Rate Control (SRC) Unit
AutoTrac Control Unit (SSU)
Cab Load Center
Electrical
Accessing Diagnostic Codes and Addresses
GS2 Display Diagnostic Information
Schematic
Electrical Component Information
Electrical Assemblies
Sensors
Motors
Resistors
Switches
Electronically Actuated Mechanical Devices
Lights
Fuses
Charging
Monitoring Devices
Relays
Interconnects and Ground Points
Observable Symptoms
Fuel, Air Intake, Exhaust, and Cooling
Electrical
Engine
Drivetrain
Steering and Brakes
Hydraulics and Pneumatics
Solution System
Heating, Ventilating, and Air Conditioning System
Engine Diagnostics
Fuel, Air Intake, Exhaust, and Cooling System Components
Exhaust Components
Cooling Components
Fuel Components
Air Intake Components
Electronic Control Units
Schematic
Programming Electronic Control Units
Control Unit Addresses
Drivetrain
Operational Checks
Schematic
Diagnostic Tests and Adjustments
Drivetrain Component Information
Attenuator and Accumulator
Diagnostic Receptacle
Cylinder, Actuator, or Piston
Check Valve
Filter
Valve Block, Assembly, or Gearcase
Cooler
Motor
Orifice
Pump
Reservoir or Tank
Valve
Solenoid Valve
Steering and Brakes
Schematic
Diagnostic Test and Adjustments
Heating, Ventilating, and Air Conditioning System
Schematic - HVAC
Diagnostic Tests and Adjustments
Heating, Ventilating, and Air Conditioning Component Information
HVAC Component Information
Special Tools
Service Tools and Kits
Steering and Brakes Component Information
Hydraulics and Pneumatics
Hydraulics Component Information
Solution System
TABLE OF CONTENTS...1
Section 210: General Information...76
Group 05: Safety...76
Recognize Safety Information...79
Understand Signal Words...80
Follow Safety Instructions...81
Handle Fluids Safely—Avoid Fires...82
Prevent Battery Explosions...83
Prepare for Emergencies...84
Handling Batteries Safely...85
Handle Agricultural Chemicals Safely...87
Service and Operate Chemical Sprayers Safely...89
Avoid Contact with Agricultural Chemicals...91
Clean Vehicle of Hazardous Pesticides...93
Park Machine Safely...94
Support Machine Properly...95
Wear Protective Clothing...96
Work in Clean Area...97
Service Machines Safely...98
Work In Ventilated Area...99
Illuminate Work Area Safely...100
Replace Safety Signs...101
Use Proper Lifting Equipment...102
Avoid High-Pressure Fluids...103
Avoid Static Electricity Risk When Refueling...104
Wait Before Opening High-Pressure Fuel System...106
Service Accumulator Systems Safely...107
Remove Paint Before Welding or Heating...108
Avoid Heating Near Pressurized Fluid Lines...109
Keep ROPS Installed Properly...110
Service Tires Safely...111
Follow Tire Recommendations...112
Avoid Harmful Asbestos Dust...113
Practice Safe Maintenance...114
Use Proper Tools...115
Construct Dealer-Made Tools Safely...116
Decommissioning — Proper Recycling and Disposal of Fluids and Components...117
Live With Safety...118
Servicing Electronic Control Units...1760
Welding Near Electronic Control Units...1761
Keep Electronic Control Unit Connectors Clean...1762
Precautions for Welding...122
Clean Exhaust Filter Safely...124
Group 10: General References...77
Trademarks...129
Glossary of Terms...131
Machine Specifications...133
General Information - Inch Bolt and Cap Screws, Torque Values...137
General Information - Metric Bolt and Cap Screws, Torque Values...139
General Information - Hydraulic System Inch Fittings, Torque Values...141
General Information - Hydraulic System Metric Fittings, Torque Values...142
General Information - Electrical System, Component Identification Table...143
General Information - Electrical System, How to Read a Diagnostic Schematic...145
General Information - Electrical System, Symbols in Schematic, Wiring and Harness Diagrams...147
General Information - Electrical System, Troubleshooting Unsolved Problems...149
General Information - Electrical System, Worksheet for Circuit/Harness Test...150
General Information - Electrical System, Visual Check...152
General Information - Electrical System, Electrical Circuit Malfunctions...153
General Information - Electrical System, Seven-Step Test Procedure...158
General Information - Hydraulic System, Symbols in Circuit Diagrams...160
Section 211: Diagnostic Trouble Codes (DTC)...166
Group ACU: Armrest Control Unit (ACU)...166
ACU 000237.02 - Data Erratic, Intermittent or Incorrect...166
ACU 000237.14 - VIN Security Not Enabled...166
ACU 000237.31 - VIN Messages Null or Missing...166
ACU 000974.02 - Data Erratic, Intermittent or Incorrect...166
ACU 000974.03 - Hand Throttle Voltage Above Normal, or Shorted to High Source...166
ACU 000974.04 - Hand Throttle Voltage Below Normal, or Shorted to Low Source...166
ACU 001079.02 - Data Erratic, Intermittent or Incorrect...166
ACU 001079.03 - Voltage Above Normal, or Shorted to High Source...166
ACU 001079.04 - Voltage Below Normal, or Shorted to Low Source...166
ACU 001080.02 - Data Erratic, Intermittent or Incorrect...166
ACU 001080.03 - Voltage Above Normal, or Shorted to High Source...166
ACU 001080.04 - Voltage Below Normal, or Shorted to Low Source...166
ACU 002000.09 - Abnormal Update Rate...166
ACU 522803.02 - Data Erratic, Intermittent or Incorrect...166
ACU 523486.02 - Data Erratic, Intermittent or Incorrect...166
ACU 523953.02 - Data Erratic, Intermittent or Incorrect...166
Group BHC: Boom Hydraulic Control (BHC) Unit...166
BHC 000158.00 - Switched System Voltage High...166
BHC 000158.01 - Switched System Voltage Low...166
BHC 000237.02 - VIN Data Does Not Match Other Controllers...166
BHC 000237.14 - VIN Security Not Enabled...166
BHC 000237.31 - VIN Messages Missing...166
BHC 000630.02 - Checksum failure for the EEPROM...166
BHC 002071.09 - Abnormal Update Rate...166
BHC 522316.03 - Boom Center Frame Position Sensor Voltage Above Normal or Shorted to High Source...166
BHC 522316.04 - Center Frame Position Sensor Voltage Below Normal or Shorted to Low Source...166
BHC 522316.13 - Center Frame Position Sensor Calibration Fault...166
BHC 522372.03 - Right Inner Boom Sensor Voltage Above Normal, or Shorted to High Source...166
BHC 522372.04 - Right Inner Boom Sensor Voltage Below Normal, or Shorted to Low Source...166
BHC 522372.13 - Right Inner Boom Sensor Out of Calibration...167
BHC 522378.03 - Left Inner Boom Sensor Voltage Above Normal, or Shorted to High Source...167
BHC 522378.04 - Left Inner Boom Sensor Voltage Below Normal, or Shorted to Low Source...167
BHC 522378.13 - Left Inner Boom Sensor Not Calibrated...167
BHC 523460.03 - Boom Roll Lock Out Sensor Short Circuit...167
BHC 523460.04 - Boom Roll Lock Out Sensor Voltage Below Normal, or Shorted to Low Source...167
BHC 523460.13 - Boom Roll Lock Sensor Out Of Calibration...167
BHC 523461.03 - Center Frame Roll Sensor Voltage Above Normal or Shorted to High Source...167
BHC 523461.04 - Center Frame Roll Sensor Voltage Below Normal or Shorted to Low Source...167
BHC 523461.13 - Boom Roll Bias Sensor Out of Calibration...167
BHC 5234630.05 - Boom Roll Bias Left Mode Current Below Normal or Open Circuit...167
BHC 523463.06 - Boom Roll Bias Left Mode Current Above Normal or Grounded Circuit...167
BHC 523464.05 - Boom Roll Bias Right Mode Current Below Normal or Open Circuit...167
BHC 523464.06 - Boom Roll Bias Right Mode Current Above Normal or Grounded Circuit...167
BHC 523465.14 - Left Outer Boom Fold Mode Special Instructions...167
BHC 523466.14 - Left Outer Boom Fold Mode Special Instructions...167
BHC 523467.14 - Left Inner Boom Fold Mode Special Instructions...167
BHC 523468.14 - Left Inner Boom Unfold Mode Special Instructions...167
BHC 523469.14 - Right Inner Boom Unfold Mode Special Instructions...167
BHC 523470.14 - Right Inner Boom Fold Mode Special Instructions...167
BHC 5234741.14 - Right Outer Boom Fold Mode Special Instructions...167
BHC 523472.14 - Right Outer Boom Unfold Mode Special Instructions...167
BHC 523477.05 - Center Frame Lower Valve Coil Current Below Normal or Open Circuit...167
BHC 523477.06 - Center Frame Lower Valve Coil Current Above Normal or Grounded Circuit...167
BHC 523478.05 - Center Frame Raise Valve Coil Current Below Normal or Open Circuit...167
BHC 523478.06 - Center Frame Raise Valve Coil Current Above Normal or Grounded Circuit...167
BHC 523479.05 - Left Boom Tilt Down Valve Coil Current Below Normal or Open Circuit...167
BHC 523479.06 - Left Boom Tilt Down Valve Coil Current Above Normal or Grounded Circuit...167
BHC 523480.05 - Right Boom Tilt Down Valve Coil Current Below Normal or Open Circuit...167
BHC 523480.06 - Right Boom Tilt Down Valve Coil Current Above Normal or Grounded Circuit...167
BHC 523481.05 - Left Boom Tilt Up Valve Coil Current Below Normal or Open Circuit...167
BHC 523481.06 - Left Boom Tilt Up Valve Coil Current Above Normal or Grounded Circuit...167
BHC 523482.05 - Right Boom Tilt Up Valve Coil Current Below Normal or Open Circuit...167
BHC 523482.06 - Right Boom Tilt Up Valve Coil Current Above Normal or Grounded Circuit...168
Group CCU: Chassis Control Unit (CCU)...168
CCU 000096.03 - Fuel Level Voltage Above Normal Range Indicating Open Circuit, Failed Sensor, or Short to High...168
CCU 000096.17 - Low Fuel Level...168
CCU 000237.02 - VIN Numbers Do Not Match Between Control Units...168
CCU 000237.31 - VIN Numbers Are Missing...168
CCU 000619.05 - Park Brake Actuator Current Below Normal or Short Circuit...168
CCU 000619.06 - Park Brake Actuator Current Above Normal or Grounded Circuit...168
CCU 000628.02 - CCU Unit Calibration Failed...168
CCU 000630.02 - Calibration Memory Data Erratic, Intermittent, or Incorrect...168
CCU 000697.05 - Front Left Wheel Motor Solenoid Valve Current Below Normal or Open Circuit...168
CCU 000697.06 - Front Left Wheel Motor Coil Current Above Normal or Short Circuit...168
CCU 000698.05 - Front Right Wheel Motor Valve Coil Current Below Normal or Open Circuit...168
CCU 000698.06 - Front Right Wheel Motor Coil Current Above Normal or Short Circuit...168
CCU 000699.05 - Rear Left Wheel Motor Valve Coil Current Below Normal or Open Circuit...168
CCU 000699.06 - Rear Left Wheel Motor Coil Current Above Normal or Short Circuit...168
CCU 000700.05 - Rear Right Wheel Motor Valve Coil Current Below Normal or Open Circuit...168
CCU 000700.06 - Rear Right Wheel Motor Coil Current Above Normal or Short Circuit...168
CCU 001079.03 - Voltage Above Normal, or Shorted to High Source...168
CCU 001079.04 - Voltage Below Normal, or Shorted to Low Source...168
CCU 001086.18 - Air Brake Pressure Low...168
CCU 001238.14 - Traction Control Override Switch Special Instructions...168
CCU 001592.02 - Left Front Wheel Angle Sensor Fault...168
CCU 001592.13 - Left Front Wheel Angle Sensor Calibration Fault...168
CCU 001593.02 - Right Front Wheel Speed Sensor Fault...168
CCU 001594.02 - Left Front Wheel Speed Sensor Fault...168
CCU 001595.02 - Right Rear Wheel Speed Sensor Fault...168
CCU 001638.00 - Temperature Extremely High...168
CCU 001638.03 - Hydraulic Oil Temperature Sensor Circuit Voltage High...168
CCU 001638.04 - Hydraulic Oil Temperature Sensor Circuit Voltage Low...168
CCU 001638.16 - Hydraulic Oil Temperature Out of Specified Operation Range...168
CCU 002602.01 - Hydraulic Oil Level Low...168
CCU 002602.18 - Hydraulic Oil Level Low...169
CCU 002614.00 - Steering Axle Lubrication Pressure Data Valid but Above Normal Operational Range - Most Severe Level...169
CCU 002614.03 - Steering Axle Lubrication Pressure Voltage Above Normal, or Shorted to High Source...169
CCU 002614.04 - Steering Axle Lubrication Pressure Voltage Below Normal, or Shorted to Low Source...169
CCU 520432.14 - Ladder Position Driver Special Instructions...169
CCU 520444.05 - Hydraulic Reverse Boost Valve Actuator Driver Current Below Normal or Open Circuit...169
CCU 520802.03 - Left Rear Wheel Angle Voltage Above Normal, or Shorted to High Source...169
CCU 520802.04 - Left Rear Wheel Angle Voltage Below Normal, or Shorted to Low Source...169
CCU 520802.07 - Left Rear Wheel Angle Mechanical System not Responding or Out of Adjustment...169
CCU 520802.13 - Left Rear Wheel Angle Out of Calibration...169
CCU 520802.14 - Left Rear Wheel Angle Re-Phase Rear Wheels...169
CCU 520802.31 - Left Rear Wheel Angle Not Available or Condition Exists...169
CCU 520803.03 - Right Rear Wheel Angle Voltage Above Normal, or Shorted to High Source...169
CCU 520803.04 - Right Rear Wheel Angle Voltage Below Normal, or Shorted to Low Source...169
CCU 520803.07 - Right Rear Wheel Angle Mechanical System not Responding or Out of Adjustment...169
CCU 520803.13 - Right Rear Wheel Angle Out of Calibration...169
CCU 520803.14 - Right Rear Wheel Angle Re-Phase Rear Wheels...169
CCU 520803.31 - Right Rear Wheel Angle Not Available or Condition Exists...169
CCU 522260.02 - Wheel Speed Sensors - Primary or Secondary Data Erratic, Intermittent, or Incorrect...169
CCU 522792.05 - Rear Steer Valve Right Current Below Normal...169
CCU 522792.06 - Rear Steer Valve Right Current Above Normal...169
CCU 522793.05 - Rear Steer Valve Left Current Below Normal...169
CCU 522793.06 - Rear Steer Valve Left Current Above Normal...169
CCU 523777.05 - Emergency Steering Fault...169
CCU 523789.31 - Front Left Wheel Angle Sensor Missing...169
CCU 524016.04 - Battery Voltage Below Normal, or Shorted to Low Source...169
Group CCU-VLC: Chassis Control Unit - Vehicle Load Center (CCU VLC)...169
CCU VLC 000158.00 - Keyswitch Battery Potential Data Above Normal Operational Range...169
CCU VLC 000158.01 - Keyswitch Battery Potential Data Above Operational Range...169
CCU VLC 000158.17 - Keyswitch Battery Potential Data Below Normal Operating Range...170
CCU VLC 000158.18 - Keyswitch Battery Potential Data Below Normal Operating Range...170
CCU VLC 000628.02 - Program Memory Data Erratic, Intermittent, or Incorrect...170
CCU VLC 001079.03 - Sensor Supply Voltage Over Voltage...170
CCU VLC 001079.04 - Sensor Supply Voltage Below Voltage...170
CCU VLC 001542.04 - ECU Power Supply Voltage #2 Below Normal...170
CCU VLC 001550.05 - Air Conditioner Compressor Current Below Normal...170
CCU VLC 001550.06 - Air Conditioning Compressor Current Above Normal...170
CCU VLC 002030.06 - Load Center Output Current High...170
CCU VLC 002055.09 - CAN Messages From Lighting Operator Control Unit (RLC) Missing...170
CCU VLC 002348.05 - Road Lights High Beam Current Below Normal or Open Circuit...170
CCU VLC 002348.06 - Road Lights High Beam Current Above Normal or Grounded Circuit...170
CCU VLC 002350.05 - Road Lights High Beam Current Below Normal or Open Circuit...170
CCU VLC 002350.06 - Road Lights Low Beam Current Above Normal or Grounded Circuit...170
CCU VLC 002354.05 - Outer Hood Work Light Current Below Normal or Open Circuit...170
CCU VLC 002354.06 - Outer Hood Work Light Current Above Normal or Grounded Circuit...170
CCU VLC 002372.05 - Current Below Normal or Open Circuit...170
CCU VLC 002372.06 - Current Above Normal or Grounded Circuit...170
CCU VLC 522310.05 - Key Switch - ELX Driver Current Below Normal or Open Circuit...170