John Deere 4640 | 4840 Tractor Service Manual...John Deere MODEL: 4640 & 4840 Chassis Only Volume 1...

John Deere

MODEL:

4640 & 4840 Chassis Only Volume 1 of 3

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF JOHN DEERE OR IT'S SUCCESSORS. JOHN DEERE AND IT'S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

JD-S-TM1183

http://www.jensales.com/products/john-deere-tractor-service-manual-4640-tractor-4840-tractor.html

1

4640 AND 4840 TRACTORS TECHNICAL MANUAL

TM-1183 (OCT-8S)

CONTENTS-REPAIR SECTIONS

SECTION 10-GENERAL Group ~O-Specifications and Special Tools Group 05-Predelivery, Delivery, and After-Sale

Services Group 10-Tune-Up Group 15-Lubrication Group 20-Separation

SECTION 20-ENGINE REPAIR Group OO-Specifications and Special Tools Group 05-Cylinder Head, Valves, and Camshaft Group 1 O-Cylinder Block, Liners, Pistons and Rods Group 15-Crankshaft, Main Bearings, and Flywheel Group 20-Lubricating System Group 25-Cooling System

SECTION 30-FUEL AND AIR REPAIR Group OO-Specifications and Special Tools Group 05-Air Intake System Group 10-Diesel Fuel System Group 15-Control Linkage

SECTION 40-ELECTRICAL REPAIR Group OO-Specifications and Special Tools Group 05-Harness Replacement Group 10-Charging Circuit Group 15-Starting Circuit Group 20-Lighting Circuits Group 25-lnstrument and Accessory Circuits Group 30-Power Front-Wheel Drive

SECTION 50-POWER TRAIN REPAIR Group OO-Specifications and Special Tools Group 05-Perma-Clutch Group 10-Quad-Range Planetary Group 15-Quad-Range Transmission Group 20-Power Shift Transmission Group 25-Power Take-Off Group 30-Differential Group 35-Final Drive Group 40-Power Front-Wheel Drive

SECTION 60-STEERING/BRAKES REPAIR Group OO-Specifications and Special Tools Group 05-Power Steering Group 10-Power Brakes

SECTION 70-HYDRAULIC REPAIR Group OO-Specifications and Special Tools Group 05-Miscellaneous Hydraulic Components Group 10-Hydraulic Pumps Group 15-Rockshaft and Implement Hitches Group 20-Selective Control Valve, Breakaway

Coupler and Remote Cylinder

SECTION SO-MISCELLANEOUS Group OO-Specifications and Special Tools Group 05-Front Axles Group 10-Wheels

SECTION gO-OPERATOR STATION REPAIR Group OO-Specifications and Special Tools Group 05-Air Conditioning System Group 10-Heating System Group 15-Seat Group 20-Miscellaneous Components

Continued on next page

All information, illustrations and specifications contained in this technical manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

TM-1183 (OCT-85) LITHO IN U.S.A. Tractors - 4640 and 4840


2

CONTENTS~~OPERATION AND TEST SECTIONS

SECTION 220-ENGINE OPERATION AND TESTS Group ~O-Specifications and Special Tools Group 05-System Operation Group i0-System Tests and Diagnosis

SECTION 230-FUEL/AIR OPERATION AND TESTS Group ~O-Specifications and Special Tools Group 05-Air Intake System Group i0-Diesel Fuel System Group i5-Control Linkage

SECTION 240-ELECTRICAL OPERATION AND TESTS

Group ~O-Specifications and Special Tools Group 05-General Information and Diagrams Group 06-Electrical System Diagnosis Group 10-DELCOTRON Charging Circuit Group 12-JOHN DEERE Charging Circuit Group i5-Starting Circuit Group 20-Lighting Circuits Group 25-lnstrument and Accessory Circuits Group 3D-Power Front-Wheel Drive Group 35-Electrical Remote Control and Outlet

Socket

SECTION 250-POWER TRAIN OPERATION AND TESTS

Group ~O-Specifications and Special Tools Group 05-Quad-Range System Operation Group 10-Quad-Range Test and Diagnosis Group 15--Power Shift System Operation Group 20-Power Shift Tests and Diagnosis Group 25-Differential and Final Drive Group 3D-Power Front-Wheel Drive

TM-1183 (OCT-85) LITHO IN U.S.A.

SECTION 260-STEERING/BRAKES OPERATION AND TESTS

Group DO-Specifications and Special Tools Group 05-Power Steering Group 10-Power Brakes

SECTION 270-HYDRAULIC OPERATION AND TESTS

Group ~O-Specifications and Special Tools Group 05-Hydraulic System Operation Group 10-Hydraulic System Tests Group i5-Miscellaneous Hydraulic Components Group 20-Hydraulic Pumps Group 25-Rockshaft and Implement Hitches Group 3D-Selective Control Valve, Breakaway

Coupler, and Remote Cylinder

SECTION 290-0PERATOR STATION OPERATION AND TESTS

Group ~O-Specifications and Special Tools Group 05-Air Conditioning System Group 10-Heating System

Tractors - 4640 and 4840


General Specifications and Special Tools 10-00-1

Section 10 GENERAL

CONTENTS OF THIS SECTION

Page Page

GROUP OO-SPECIFICATIONS GROUP 15-LUBRICATION General Tractor Specifications. . . . . . . . .. 10-00-1 Predelivery . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-00-4 Tune-Up ............................. 10-00-5 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-00-5 Separation. . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-00-6 Special Tools ......................... 10-00-7

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-15-1 Engine ............................... 10-15-2 Transm iss ion-Hydraulic System . . . . . . . .. 10-15-3 Front Wheel Bearings. . . . . . . . . . . . . . . . .. 10-15-5 Grease Fittings. . . . . . . . . . . . . . . . . . . . . . .. 10-15-6

GROUP 20-SEPARATION GROUP 05-PREDELIVERY, DELIVERY,

AND AFTER-SALE SERVICES Dealer Predelivery Service . . . . . . . . . . . .. 10-05-1 Inspection Checks. . . . . . . . . . . . . . . . . . .. 10-05-11 Dealer Service . . . . . . . . . . . . . . . . . . . . . .. 10-05-13 After Sale Inspection ................. 10-05-14

GROUP 10---..,. TUNE-UP Preliminary Engine Testing ............. 10-10-1 Engine Tune-Up ...................... 10-10-1 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-10-7 General .............................. 10-10-7

Removing SOUND-GARD® Body without Control Support. . . . . . . . . . . . . . . . . . . .. 10-20-1

Removing SOUNO-GARD Body with Control Support. . . . . . . . . . . . . . . . . . . .. 10-20-5

Separating Engine from Clutch Housing .................... 10-20-10

Removing Front End. . . . . . . . . . . . . . . . .. 10-20-14 Removing Engine .................... 10-20-18 Separating Clutch Housing from

Power Shift Transmission Case ...... 10-20-21 Separating Clutch Housing from

QUAD-RANGPM Transmission Case. 10-20-24 Removing Rear Axle Housing ......... 10-20-26

Group 00 SPECIFICATIONS AND SPECIAL TOOLS

GENERAL TRACTOR SPECIFICATIONS 4640

HORSEPOWER (Factory observed PTO horsepower at 2200 rpm) 155 hp (116 kW)

ENGINE: Type

Slow idle speed Working speed range Bore and stroke Displacement Compression ratio Firing order Valve clearance

Intake Exhaust

Injection pump timing Lubrication system

TM-1183 (Jun-80) Litho in U. S.A.

6-cylinder, in-line, valve-in-head, diesel, turbocharged, intercooled 800 rpm 1500 to 2200 rpm 4.56 x 4.75 in. (116 x 121 mm) 466 cu. in. (7.6 L) 14.9 to 1 1-5-3-6-2-4

0.018 in. (0.46 mm) 0.028 in. (0.71 mm) TDC force-feed, pressurized with full-flow filter

4840

180 hp (134 kW)

6-cylinder, in-line, valve-in-head, diesel, turbocharged, intercooled 800 rpm 1500 to 2200 rpm 4.56 x 4.75 in. (116 x 121 mm) 466 cu. in. (7.6 L) 14.9 to 1 1-5-3-6-2-4

0.018 in. (0.46 mm) 0.028 in. (0.71 mm) TDC force-feed, pressurized with full-flow filter



General

Fig. 9-Testing Pressure Cap

(f) Install each pressure cap on radiator tester, and pump pressure up to limit of pressure cap. Low pressure cap should maintain 6.25 to 7.50 psi (0.4 to 0.5 bar) (0.4 to 0.5 kg/cm2), and high pressure cap should maintain 14 to 17 psi (0.9 to 1.2 bar) (0.9 to 1.2 kg/cm2). If either cap is defective, replace it.

Diesel Fuel System

Fig. 10-Fuel Filter Drain Plugs

1. Check fuel filters for water or sediment. If any is present, remove drain plugs and drain it out. Caution customer about importance of proper fuel storage.

NOTE: Fuel filters must be replaced periodically to prevent excessive restriction. During a tune-up is a good time to perform this service.

TM-1183 (Feb-78) Litho in U.S.A.

Tune-Up 10-10-5

A-Sediment Bowl B-Hand Primer

Fig. 11-Fuel Transfer Pump

2. Check sediment bowl (A, Fig. 14) on fuel transfer pump. If water or sediment is present, clean it out. Close valve on bottom of fuel tank before removing sediment bowl.

3. If either fuel filters or sediment bowl is drained, bleed air from system. Loosen hand primer (8) and pump until most of air bubble disappears.

Fig. 12-Fuel Tank Drain Plug

4. Loosen or remove fuel tank drain plug, and drain any water or sediment from tank.

5. Check entire fuel system for leaks. Correct as necessary.

6. Check injection pump timing as instructed in Group 05 of this section.

7. Check engine idle speeds as instructed in Group 05 of this section. Slow idle speed should be 780 to 820 rpm, and fast idle speed should be 2325 to 2425 rpm.



General Separation 10-20-5

REMOVING SOUND-GARD BODY WITH CONTROL SUPPORT

R 27410N

Fig. 12-Removing Sound-Gard Body With Control Support

Removal

1. (Not Illustrated). Disconnect battery ground cable.

2. (Not Illustrated). On tractors equipped with a heater, drain the cooling system.

Fig. 13-Removing Muffler, Screens and Cowling

3. Remove muffler.

TM-1183 (Feb-l8) Litho in U.S.A.

4. Remove air intake stack.

5. Remove left and right-hand grill screens.

6. Remove left and right-hand side shields.

7. Remove hood.

8. Remove left and right-hand cowling.

9. (Not Illustrated). Remove floor mat.

Fig. 14-Removing Battery Box Covers and Riser Panels



Engine Repair Specifications and Special Tools 20-00-1

Section 20 ENGINE REPAIR


Group 00 - SPECIFICATIONS AND SPECIAL TOOLS

Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 20-00-2 Special Tools ......................... 20-00-4

GROUP 05 - CYLINDER HEAD, VALVES AND CAMSHAFT

Preliminary Valve Checks . . . . . . . . . . . . .. 20-05-1 Checking Valve Clearance ............. 20-05-1 Checking Valve Lift. . . . . . . . . . . . . . . . . . .. 20-05-2 Cylinder Head and Valves .............. 20-05-3

Access. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-05-3 Rocker Arm Assembly ................. 20-05-3

Removal ....... . . . . . . . . . . . . . . . . . . .. 20-05-3 Inspection and Repair . . . . . . . . . . . . . .. 20-05-3 Assembly and Installation ............ 20-05-4

Valves, Valve Springs, Valve Rotators, and Wear Caps. . . . . . . . . . . . . . . . . . . .. 20-05-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-05-4 Inspection and Repair . . . . . . . . . . . . . .. 20-05-4

Valve Springs .................... 20-05-4 Valves, Rotators and Wear Caps ... 20-05-4 Valve Guides. . . . . . . . . . . . . . . . . . . .. 20-05-5 Valve Seats ...................... 20-05-6

Cylinder Head ........................ 20-05-8 Assembly .......................... 20-05-8 Installation. . . . . . . . . . . . . . . . . . . . . . . . .. 20-05-8

Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-05-9 Checking Camshaft End Play ........ 20-05-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-05-9 Inspection and Repair . . . . . . . . . . . . .. 20-05-10

Camshaft Gear . . . . . . . . . . . . . . . . . . 20-05-10 Thrust Plate. . . . . . . . . . . . . . . . . . . .. 20-05-10 Bushings and Journals . . . . . . . . . .. 20-05-10 Lobes .......................... 20-05-11

Assembly ......................... 20-05-11 Installation. . . . . . . . . . . . . . . . . . . . . . . .. 20-05-11

GROUP 10 - CYLINDER BLOCK, LINERS, PISTONS AND RODS

Diagnosing Malfunctions ............... 20-10-1 Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-1 0-1

Access. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-1 0-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-10-2 Inspection and Repair . . . . . . . . . . . . . .. 20-10-2

Piston Rings and Ring Grooves . . .. 20-10-2 Piston Head, Ring Lands and Piston

Skirt. . . . . . . . . . . . . . . . . . . . . . . . . .. 20-10-3 Piston Pins. . . . . . . . . . . . . . . . . . . . . .. 20-10-4

TM-1183 (Apr-8t) Litho in U.S.A.

Connecting Rods. . . . . . . . . . . . . . . . . . . . .. 20-10-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-10-4 Inspection and Repair . . . . . . . . . . . . . .. 20-10-4

Connecting Rod Bearings. . . . . . . . .. 20-10-5 Cylinder Liners

Removal, Inspection, and Repair ..... 20-10-5 Deglazing Cylinder Liners. . . . . . . . .. 20-10-7

Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-10-7 Inspection and Repair ............. 20-10-7 Installation ....................... 20-10-8 Liners ........................... 20-10-8 Pistons and Connecting Rods ...... 20-10-8

GROUP 15 - CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL

Diagnosing Malfunctions . . . . . . . . . . . . . .. 20-15-1 Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-15-1 Inspection and Repair ................. 20-15-1

Damper Pulley. . . . . . . . . . . . . . . . . . . . .. 20-15-1 Front Wear Sleeve . . . . . . . . . . . . . . . . .. 20-15-2 Crankshaft Gear . . . . . . . . . . . . . . . . . . .. 20-15-2 Flywheel .... . . . . . . . . . . . . . . . . . . . . . .. 20-15-2 Clutch Shaft Pilot Bearing (Power Shift) 20-15-3 Clutch Shaft Pilot Bushing and Adapter

(Quad-Range) .................... 20-15-3 Rear Crankshaft Oil Seal, Housing and

Wear Sleeve .. . . . . . . . . . . . . . . . . . .. 20-15-4 Main Bearings . . . . . . . . . . . . . . . . . . . . .. 20-15-4 Thrust Bearings ..................... 20-15-5 Crankshaft Journals . . . . . . . . . . . . . . . .. 20-15-6

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-15-6 Main Beari ngs and Crankshaft. . . . . . .. 20-15-6 Rear Wear Sleeve .. . . . . . . . . . . . . . . .. 20-15-7 Rear Oil Seal and HOusing ........... 20-15-7 Crankshaft Gear, Front Wear Sleeve

and Oil Seal. . . . . . . . . . . . . . . . . . . . .. 20-15-8

GROUP 20 - LUBRICATION SYSTEM Diagnosing Malfunctions ............... 20-20-1 Removql, Inspection and Repair ........ 20-20-1

Oil Filter Housing ................... 20-20-1 Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . .. 20-20-1 Oil Pumps. . . . . . . . . . . . . . . . . . . . . . . . .. 20-20-2 Tachometer Drive ................... 20-20-5

Assembly and Installation . . . . . . . . . . . . .. 20-20-6 Oil Cooler By-Pass Valve. . . . . . . . . . .. 20-20-6 Oil Pumps .......................... 20-20-6 Tachometer Drive ................... 20-20-9



20-00-2 Specifications and Special Tools Engine Repair

CONTENTS-(Continued)

GROUP 25 - COOLING SYSTEM Water Pump Diagnosing Malfunctions ............... 20-25-1 Access ............................. 20-25-2 Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-25-1 Inspection and Repair ............... 20-25-3

Inspection and Repair ............... 20-25-1 Assembly .......................... 20-25-4 Radiator Caps. . . . . . . . . . . . . . . . . . .. 20-25-1 Overflow Valve . . . . . . . . . . . . . . . . . .. 20-25-2

Water Manifold and Thermostats. . . . . . .. 20-25-6 Inspection and Repair ............... 20-25-6

Fan Belts ........................ 20-25-2 Installation. . . . . . . . . . . . . . . . . . . . . . . . .. 20-25-6 Coolant Conditioner Filter . . . . . . . . . . . . .. 20-25-6


SPECIFICATIONS Item New Part Specification Wear Tolerance

Cylinder Head, Valves, and Camshaft

Valve clearance Intake valve .......................... 0.018 in. (0.46 mm) Exhaust valve ......................... 0.028 in. (0.71 mm)

Valve lift at specified clearance Intake valve .......................... 0.412 to 0.442 in. (10.5 to 11.2 mm) Exhaust valve ......................... 0.413 to 0.443 in. (10.5 to 11.2 mm)

Valve springs - compressed Valve closed .......................... 1.81 in. at 54 to 62 Ibs.

(45.9 mm at 240.2 to 275.8 N) Valve open . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.36 in. at 133 to 153 Ibs.

(35.5 mm at 591.6 to 680.5 N) Valve face angle ........................ 30° Valve face 0.0 .......................... 1.710 to 1.720 in. (43.4 to 43.7 mm) Valve guide 1.0 .......................... 0.3745 to 0.3755 in. (9.51 to 9.54 mm) Valve stem 0.0 .. ........................ 0.3715 to 0.3725 in. (9.44 to 9.46 mm) Valve stem-to-guide clearance ............ 0.0020 to 0.0040 in. (0.05 to 0.10 mm) .............. 0.0060 in.

(0.15 mm) Valve seat width ......................... 0.0830 to 0.0930 in. (2.11 to 2.37 mm) Valve seat concentricity with guide ........ 0.0020 in. (0.05 mm) Valve seat angle ........................ 30° Valve face above head ................... 0.0240 to 0.0380 in. (0.62 to 0.96 mm) .... 0.0060 in. (1.52 mm)

recessed Camshaft end play ...................... 0.0025 to 0.0085 in. (0.06 to 0.22 mm) .. " 0.0150 in. (0.38 mm) Camshaft thrust plate thickness ........... 0.1860 to 0.1890 in. (4.72 to 4.80 mm) .... 0.1820 in. (4.62 mm) Camshaft bushing journal 0.0 .. ........... 2.3745 to 2.3755 in. (60.31 to 60.34 mm) Camshaft bushing 1.0 .................... 2.3775 to 2.3795 in. (60.39 to 60.50 mm) Camshaft bushing-to-journal clearance ..... 0.0020 to 0.0050 in. (0.05 to 0.13 mm) .... 0.0060 in. (0.15 mm) Cylinder head-to-block - Initial ........... 105 ft-Ibs. (142 N·m) (14.2 kgm)

Second ......... 117 to 143 ft-Ibs (158 to 193 N·m) (15.8 to 19.3 kgm) Final ........... 135 to 165 ft-Ibs (183 to 224 N·m) (18.3 to 22.4 kgm)

Rocker arm shaft clamps. . . . . . . . . . . . . . .. 45 to 65 ft-Ibs (61 to 88 N·m) (6.1 to 8.8 kgm) Intake manifold to cylinder head .......... 35 ft-Ibs (47 N·m) (4.7 kgm) Intake cover-to-intake manifold ............ 20 ft-Ibs (27 N·m) (2.7 kgm) Camshaft thrust plate .................... 20 ft-Ibs (27 N·m) (2.7 kgm) Camshaft gear .......................... 85 ft-Ibs (115 N·m) (11.5 kgm) Timing gear cover ....................... 30 ft-Ibs (41 N·m) (4.1 kgm)

TM-1183 (Apr-81) Litho in US.A. Tractors - 4640 and 4840


Fuel and Air Repair Specifications and Special Tools 30-00-1

Section 30 FUEL AND AIR REPAIR


GROUP 00 - SPECIFICATIONS AND SPECIAL TOOLS

Specifications

Page

Air Intake System ...................... 00-2 Diesel Fuel System .................... 00-3 Control Linkage. . . . . . . . . . . . . . . . . . . . . . .. 00-3 Special Tools .......................... 00-4

GROUP 05 - AIR INTAKE SYSTEM Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-1 AiResearch T-04B Turbo-

charger .............................. , 05-3 Schwitzer 3LM Turbo

charger .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-11 Intercooler and Intake Manifold ........... 05-17 Ether Starting Aid . . . . . . . . . . . . . . . . . . . . . .. 05-20

TM-1183 (Aug-77) Litho in U.S.A.

Page GROUP 10 - DIESEL FUEL SYSTEM

Fuel Tank ............................... 10-1 Fuel Supply Pump ...................... " 10-3 Fuel Check Valve .. . . . . . . . . . . . . . . . . . . . . .. 10-3 Fuel Filter .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-4 Bleeding Fuel System .................... 10-6 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . .. 10-6 Aneroid ............................. " .. 10-10 Hydraulic Aneroid Activator ............... 10-11 Injection Nozzles ........................ 10-12 Overflow Valve (4840 Tractor) . . . . . . . . . . .. 10-22

GROUP 15 - CONTROL LINKAGE Speed Control Linkage. . . . . . . . . . . . . . . . . . .. 15-1 Foot Throttle Linkage . . . . . . . . . . . . . . . . . . . .. 15-3



30-10-4 Diesel Fuel System

FUEL CHECK VALVE-Continued

Removal

R 2681lN

A-Connector B-Check Valve

C-O-Rings D-Valve Body E-Pipe Nipple

Fig. 6-Cross-sectional View of Fuel Check Valve Assembly

Disconnect the fuel inlet pipe and unscrew connector (A, Fig. 6). Check valve (B) will fall out of housing when connector is removed.

To remove valve body (D), take off the fuel filter elements. Separate the filter body (11, Fig. 10) from its support (1). Unscrew valve body from filter body.

Repair

The check valve is not designed to be repaired. Before replacing the valve, inspect to make sure that there is no foreign material which may be keeping valve open. Use compressed air to remove foreign material from valve and valve body.

Installation

Apply a light coating of Permatex to pipe nipple threads (E), and attach valve body to filter body. Mount filter body on its support. Install filter elements.

Position new O-rings (C) on check valve and connector. Install valve and connector in valve body. Connect fuel pipe, and bleed the fuel system (page 10-6).

TM-1183 (Aug-77) Litho in U.S.A.

Fuel and Air Repair

FUEL FILTER

General Information

A-Inlet B-Outlet C-Air Vent D-Second Stage

Filtering Media

E-First Stage Filtering Media

F-Drain G-Sediment Bowl ISM -Supply Pump

Pressure

Fig. 7-Fuel Flow Through Filter

Two fuel filter elements (B, Fig. 8) are used on the 4640 and 4840 Tractors to prevent dirty fuel from reaching the injection pump and injection nozzles. Both fuel filter elements are mounted in parallel on a common filter body.

The filter elements will require occasional replacement (in pairs) to maintain an adequate flow of fuel to the injection pump. The frequency of this service will vary according to the cleanliness of available fuel and the care used in storage.

Replacing Filter Elements

To change the filter elements (B, Fig. 8), close the fuel shut-off valve at bottom of fuel tank.

Remove drain plugs (D) and drain filter.

Release the filter element retaining spring (C) and pull off element.

NOTE: The spring may be released by pressing inward on the outside finger tab (A, Fig. 9) until the top hook of the spring can be disengaged. Disengage the top hook by pulling upward on the inside finger tab.



Electrical Repair Specifications and Special Tools 40-00-1

Section 40 ELECTRICAL REPAIR


Page

GROUP OO-SPECIFICATIONS AND SPECIAL TOOLS

General Information ................... 40-00-2 Charging Circuit ....................... 40-00-3 Starting Circuit ........................ 40-00-3 Lighting Circuits. . . . . . . . . . . . . . . . . . . . . .. 40-00-4 Instrument and Accessory Circuits ...... 40-00-4 Power Front-Wheel Drive .............. 40-00-5 Special Tools ......................... 40-00-6

GROUP 05-HARNESS REPLACEMENT General Information ................... 40-05-1 Right-Hand Lighting Harness

(ROLL-GARD) ...................... 40-05-1 Right-Hand Lighting Harness

(SOUND-GARD) . . . . . . . . . . . . . . . . . . .. 40-05-4 SOUND-GARD Body Harness .......... 40-05-4 Removing Connector Body. . . . . . . . . . . .. 40-05-5

GROUP 10-DELCOTRON CHARGING CIRCUIT

Removal ............................. 40-10-1 Disassembly .......................... 40-10-1 Repair ............................... 40-10-2 Assembly ............................. 40-10-6 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-10-6

GROUP 12-JOHN DEERE CHARGING CIRCUIT

Removal ............................. 40-12-1 Disassem bly . . . . . . . . . . . . . . . . . . . . . . . . .. 40-12-1 Repair ........ . ..................... 40-12-2 Assembly ............................. 40-12-6 Installation ............................ 40-12-8

Page

GROUP 15-STARTING CIRCUIT General Information ................... 40-15-1 Solenoid .............................. 40-15-1 Starting Motor Removal ................ 40-15-2 Disassembly and Repair ............... 40-15-3 Assembly ............................. 40-15-9 Installation ..... " ..................... 40-15-9

GROUP 20-LlGHTING CIRCUITS Testing Flood Lamp Relays ............ 40-20-1 Testing Turn Signal Controller .......... 40-20-2 Testing Light Switch ................... 40-20-2 Bulb Replacement ..................... 40-20-3

GROUP 25-INSTRUMENT AND ACCESSORY CIRCUITS

Instrument Cluster ..................... 40-25-1 Radio and Tape Player ................ 40-25-4 Right-Hand Wiper Motor ............... 40-25-5 Left-Hand Wiper Motor ................ , 40-25-6

GROUP 30-POWER FRONT-WHEEL DRIVE Power Shift Transmission Switches ..... 40-30-1 QUAD-RANGE Transmission

Switches . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-30-2

TM-1183 (Jun-80) Litho in U.S.A. Tractors - 4640 and 4840


Power Train Repair Specifications and Special Tools 50-00-1

Section 50 POWER TRAIN REPAIR


Page


Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . .. 00-3 Special Tools ........................... 00-13

GROUP 5 - PERMA-CLUTCH (4640 only) Pressure Regulating Valve Housing .......... 5-1 Clutch Operating Assembly .................. 5-3 Clutch Pack ............................... 5-9 Adjustment

Clutch Valve Operating Rod ............... 5-8 Clutch Pack . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-11

GROUP 10 - QUAD-RANGE PLANETARY (4640 only)

Removal ................................ 1 0-1 Disassembly ............................. 10-4

Control and Shift Valve . . . . . . . . . . . . . . . .. 10-5 Repair and Assembly

Clutch and Brake ...................... 10-6 Planetary. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 0-8

GROUP 15 - QUAD-RANGE TRANSMISSION (4640 only)

Removal Shifter 15-1 Transmission Drive Shaft ... . . . . . . . . . . .. 15-2 Differential Drive Shaft .................. 15-3 Counters haft. . . . . . . . . . . . . . . . . . . . . . . . . .. 15-3

Transmission Drive Shaft Disassembly and Repair. . . . . . . . . . . . . . .. 15-4 Assembly ............................. 15-5

Countershaft Repair ...................... 15-7 Shaft Installation and Adjustment

Counters haft . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-8 Differential Drive Shaft .................. 15-8 Transmission Drive Shaft .............. 15-11

Range and Speed Selector Assembly Removal ... . . . . . . . . . . . . . . . . . . . . . . . . .. 15-13 Disassembly and Repair. . . . . . . . . . . . . .. 15-14 Installation and Adjustment. . . . . . . . . . . .. 15-16

TM-1183 (Oct-78) Litho in U.S.A.

Page

GROUP 20 - POWER SHIFT TRANSMISSION Torsional Damper ........................ 20-1 Clutch Pack

Removal and Disassembly. . . . . . . . . . . . .. 20-2 Transmission Pump .................... 20-3 Assembly and Repair ................... 20-4

Planetary Pack Removal and Disassembly. . . . . . . . . . . . .. 20-8 Repair and Assembly ................... 20-9 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16

Reduction Train, Differential Drive Shaft, Park Pawl & Tow Disconnect

Removal ............................. 20-17 Repair, Assembly and Adjustment ...... 20-19

Pressure Regulating and Pedal Valve .. . . . 20-20 Control and Shift Valve .. . . . . . . . . . . . . . . .. 20-23 Speed Selector ......................... 20-25 Adjustments

Oil Pressure Regulating Valve. . . . . . . . .. 20-27 Pedal Valve .. . . . . . . . . . . . . . . . . . . . . . . .. 20-27 Pedal Height ......................... 20-28 Speed Selector ....................... 20-28

GROUP 25 - PTO Perma-Clutch PTO ....................... 25-1 Power Shift PTO . . . . . . . . . . . . . . . . . . . . . . . .. 25-4

GROUP 30 - DIFFERENTIAL Removal

Perma-Clutch Differential ............... 30-1 Power Shift Differential ................. 30-2

Repair .................................. 30-3 Installation and Adjustment. . . . . . . . . . . . . . .. 30-5 Differential Lock Valve

Removal .............................. 30-6 Disassembly and Repair ................ 30-7 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30-8



50-00-2 Specifications and Special Tools Power Train Repair

CONTENTS OF THIS SECTION-Continued

Page

GROUP 35 - FINAL DRIVE Removal ................................ 35-1 Disassembly and Repair .................. 35-2 Assembly and Adjustment ................. 35-5

Adjusting Bearings . . . . . . . . . . . . . . . . . . . .. 35-7 Rolling Drag Torque ................... 35-11

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 35-13

TM-1183 (Oct-78) Litho in U.S.A.

GROUP 40 - POWER FRONT-WHEEL DRIVE (4640 only)

Removal

Page

Control Valve . . . . . . . . . . . . . . . . . . . . . . . . .. 40-1 Planetary. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-2 Wheel Manifold and Motor . . . . . . . . . . . . .. 40-2

Repair Control Valve .......................... 40-3 Pivot Pin and Bushing. . . . . . . . . . . . . . . . .. 40-6 Motor Housing . . . . . . . . . . . . . . . . . . . . . . . .. 40-6

Installation and Adjustment Wheel Bearing Adjustment. . . . . . . . . . . . .. 40-7 Brake Piston Housing .................. 40-9 Planetary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10

Oil Manifold Repair . . . . . . . . . . . . . . . . . . . . . . 40-11 Wheel Motor

Disassembly .......................... 40-11 Repair and Assembly .................. 40-12 Adjustments .......................... 40-12



Steering/Brakes Repair Specifications and Special Tools 60-00-1

Section 60 STEERING/BRAKES REPAIR



Specifications Power Steering ................... " 60-00-1 Power Brakes ...................... 60-00-2

Special Tools ......................... 60-00-3

GROUP 05 - POWER STEERING Steering Column and Metering Pump

Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 60-05-1 Disassembly and Inspection .......... 60-05-3 Steering Column .................... 60-05-3 Metering Pump ..................... 60-05-4

Steering Pump and Column Assembly ... 60-05-4 Steering Valve Repair ............. " 60-05-6 Removal ........................... 60-05-7 Disassembly and Inspection .......... 60-05-7 Assembly .......................... 60-05-7

Steering Motor Repair Steering Motor Access ............... 60-05-8 Disassembly ........................ 60-05-9 Inspection ......................... 60-05-11 Assembly ......................... 60-05-12

GROUP 10 - POWER BRAKES Pistons, Plates, and Disks

Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 60-10-1 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 60-10-1 Assembly and Installation. . . . . . . . . . .. 60-10-2

Brake Valve Removal ........................... 60-10-2 Disassembly ........................ 60-10-3 Inspection .......................... 60-10-3 Assem bly .......................... 60-10-4 Installation and Adjustment. . . . . . . . . .. 60-10-5

Brake Accumulator .................... 60-10-6


SPECIFICATIONS

Power Steering

Friction spring-Free length ....................................................... 0.735 in. (18.67 mm) -Compressed .................................................... 0.52 in. at 81 to 99 Ibs.

(13.2 mm at 360 to 440 N) Steering motor piston 0.0 ......................................... 2.621 to 2.623 in. (66.70 to 66.75 mm) Steering motor piston sleeve 1.0 .................................... 2.625 to 2.626 in. (66.79 to 66.81 mm) Feedback piston pin

Length .......................................................................... 2.58 in. (65.6 mm) 0.0 . ..................................................... 0.7357 to 0.7363 in. (18.719 to 18.734 mm)

Feedback piston pin bore 1.0 ................................... 0.7365 to 0.7375 in. (18.739 to 18.765 mm) Feedback piston pin spring

-Free length .................................................................. 1.16 in. (29.464 mm) -Compressed ............................................................... 0.74 in. at 45 to 55 Ibs.

(18.8 mm at 200 to 244 N) Feedback piston 0.0 .............................................. 1.499 to 1.500 in. (38.14 to 38.17 mm) Feedback piston bushing

1.0 ............................................................ 1.501 to 1.506 in. (38.27 to 38.32 mm) 0.0 ...................................................... 1.8515 to 1.8525 in. (47.110 to 47.135 mm)

TM-1183 (Jun-80) Litho in U.S.A. Tractors - 4640 and 4840


John Deere 4640 | 4840 Tractor Service Manual...John Deere MODEL: 4640 & 4840 Chassis Only Volume 1...

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Transcript of John Deere 4640 | 4840 Tractor Service Manual...John Deere MODEL: 4640 & 4840 Chassis Only Volume 1...