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
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John Deere 4640 | 4840 Tractor Service Manual...John Deere MODEL: 4640 & 4840 Chassis Only Volume 1 of 3 THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF JOHN
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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.
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
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
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
(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.
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)
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.
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
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
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