John Deere Tractor 4040 4240 TM1181 SM 011080 - Text

4040 & 4240
Tractors
JOHN DEERE
TM1181 (NOV
UTHOIN
88)
U.S.A. (REVJSErf)
4040 AND TRACTORS
4240
TECHNICAL MANUAL
TM-1181 (SEP-77)
CONTENTS REPAIR SECTIONS
SECTION 10 GENERAL SECTION 50 POWER TRAIN REPAIR (Continued)
Group 00 Specifications and Special Tools Group 15 Creeper Planetary
Group 05 Predelivery, Delivery, and After-Sale Group 20Quad-Range Planetary and Shifter
Services Assembly
Group 10 Tune-Up Group 25 Power Transmission
Shift
Group 15 Lubrication Group 30 Dual-Speed PTO

Group 20 Separation Group 35 Differential
Group 40 Drive
Final
SECTION 20 ENGINE REPAIR Group 45 Power Front-Wheel Drive
Group 00 Specifications and Special Tools
Group 05 Cylinder Head, Valves, and Camshaft SECTION 60 STEERING/BRAKES REPAIR
Group 10 Cylinder Block, Pistons, and
Liners,
Group 00 Specifications and Special Toofs
Rods Group 05 Power Steering
Group 15 Crankshaft, Main Bearings, and Group 10 Power Brakes
Flywheel
Group 20 Lubricating System SECTION 7C^HYDRAULIC REPAIR
Group 25 Cooling System Group 00Specifications and Special Tools
Group 05Miscellaneous Hydraulic Components
SECTION 30 FUEL AND AIR REPAIR Group 10 Hydraulic Pumps
Group 00 Specifications and Special Toofs Group 15 Rockshaft and Implement Hitcher
Group 05Air Intake System Group 20Selective Control Valve and Remote
Group 10 Diesel Fuel System Cylinder
Group 15Control Linkage
SECTION 80 MISCELLANEOUS
SECTION 40 ELECTRICAL REPAIR Group 00 Specifications and Special Tools
Group 00Specifications and Special Tools Group 05 Front Axles
Group 05 Harness Replacement Group 10 Wheels
Group 10Charging Circuit
Group 15 Starting Circuit SECTION 90-OPERATOR STATION REPAIR
Group 20 Lighting Circuits Group 00Specifications and Special Tools
Group 25 Instrument and Accessory Circuits Group 05 Conditioning System
Air
Group 30 Power Front-Wheel Drive Group 10 Heating System

Group 15 Seat
SECTION 50 POWER TRAIN REPAIR Group 20 Miscellaneous Components

Group 00 Specifications and Special Tools (Continued on page 2)
Group 05 Perma-Clutch
Group 1
Syncro Range Transmission (Also
8-Speed Portion of Quad-Range and
Creeper)
AH 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-1181 (Sep-77) Litho in USA. Tractors - 4040 and 4240

CONTENTSOPERATION AND TESTS SECTIONS
SECTION 220 ENGINE OPERATION AND TESTS SECTION 260STEERING/BRAKES OPERATION
Group 00 Specifications and Special Tools AND TESTS I
Group 05 System Operation Group 00 Specifications and Special Tools
Group 10 System Tests and Diagnosis Group 05 Power Steering
Group 10 Power Brakes
SECTION 230 FUEL/AIR OPERATION AND
TESTS SECTION 270 HYDRAULIC OPERATION AND

Group 00 Specifications and Special Tools TESTS

Group 05 Air Intake System Group 00Specifications and Special Toots
Group 10 Diesel Fuel System Group 05 Hydraulic System Operation

Group 15 Control Linkage Group 10 Hydraulic System Tests
Group 15 Miscellaneous Hydraulic Components
SECTION 240 ELECTRICAL OPERATION AND Group 20 Hydraulic Pumps
TESTS Group 25 Rockshaft and Implement Hitches
Group 00Specifications and Special Tools Group 30 Selective Control Valve and Remote
Group 05General information and Diagrams Cylinder
Group 10Charging Circuit
Group 15 Starting Circuit SECTION 290OPERATOR STATION
Group 20 Lighting Circuits OPERATION AND TESTS
Group 25 Instrument and Accessory Circuits
Group 00 Specifications and Special Tools
Group 30 Power Front-Wheel Drive
Group 05 Air Conditioning System
Group 35 Remote Control and Outlet
Electrical Group 10 Heating System
Socket
SECTION 250 POWER TRAIN OPERATION AND

TESTS
Group 00Specifications and Special Tools
Group 05 Perma-CIutch Systems Operation
Group 10 Perma-Clutch Systems Tests
Group 15 Power Transmission Operation
Shift
Group 20 Power Transmission Tests
Shift
Group 25 and
Differential Drive
Final
Group 30 Power Front-Wheel Drive
TM-1181 (Sep-77) Litho in U.S.A. Tractors - 4040 and 4240

1
General Specifications and Special Tools 10-00-1
Section 10
I
GENERAL
CONTENTS OF THIS SECTION
Page Page
GROUP 00 SPECIFICATIONS GROUP 15 LUBRICATION
Genera! Tractor Specifications 10-00-1 Lubricants 10-15-1
Predelivery 10-00-4 Engine 10-15-2
Tune-Up 10-00-5 Transmission-Hydraulic System 10-15-3
Lubrication 10-00-5 Hi-Crop Final Drive Housings 10-15-5
Separation 1 0-00-6 Front Wheel Bearings 10-15-6
Special Tools 10-00-7 Grease Fittings 10-15-6
GROUP 05 PREDELIVERY, DELIVERY, GROUP 20 SEPARATION

AND AFTER-SALE SERVICES Removing SOUND-GARD Body without
Dealer Predelivery Service 10-05-1 Control Support 10-20-1
inspection Checks 10-05-1 Removing SOUND-GARD Body with
Dealer Service 10-05-13 Control Support 10-20-5
After-Sale Inspection 10-05-14 Separating Engine from
Clutch Housing 10-20-10 |
GROUP 10TUNE-UP Removing Front End 10-20-14

!
Preliminary Engine Testing 10-10-1 Removing Engine 10-20-18

Engine Tune-Up 10-10-1 Separating Clutch Housing from
Operation 10-10-7 Power Shift Transmission Case 10-20-21
General 10-10-7 Separating Clutch Housing from
QUAD-RANGE Transmission Case . 10-20-24
Removing Rear Axle Housing 10-20-26
Group 00
SPECIFICATIONS AND SPECIAL TOOLS
GENERAL TRACTOR SPECIFICATIONS
4040 4240
HORSEPOWER (Factory observed PTO

horsepower at 2200 rpm) 90 hp (67 kW) 110 hp (82 kW)
ENGINE:
Type 6-cylinder, in-line, valve-in-head, 6-cylinder, in-line, valve-in-head,
diesel diesel
Slow idle speed 800 rpm 800 rpm
Working speed range 1500 to 2200 rpm 1500 to 2200 rpm
Bore and stroke 4.25 x 4.75 in. (108 x 121 mm) 4.56 X4.75 in. (116 x 121 mm)
Displacement 404 cu. in. (6.6 L) 466 cu. in. (7.6 L)
Compression ratio 16.7 to 1 17.0 to 1
Firing order 1-5-3-6-2-4 1-5-3-6-2-4
Valve clearance
Intake 0.018 in. (0.46 mm) 0.018 in. (0.46 mm)
Exhaust 0.028 in. (0.71 mm) 0.028 in. (0.71 mm)
Injection pump timing TDC TDC
Lubrication system force-feed, pressurized with force-feed, pressurized with
full-flow filter full-flow filter
TM-1181 (Jun-80) Litho in U.S.A. Tractors - 4040 and 4240

10*00-2 Specifications and Special Tools General
4040 4240
FUEL SYSTEM
Type direct injection direct injection
Injection pump type distributor distributor (
Air cleaner dry type with safety element dry type with safety element
COOLING SYSTEM
Type dual-pressure with centrifugal pump dual pressure with centrifugal pump
Temperature control duaJ heavy duty thermostats dual heavy duty thermostats
CAPACITIES
Fuel tank 37 U.S. gal. (140 L) 46 U.S. gal. (176 L)
Cooling system 24 U.S. qts. (23 L) 30 U.S. qts. (26 L)
Crankcase (with change)
filter 17 U.S. qts. (16 L} 17 U.S. qts. (16 L)
Transmission-hydraulic system
(Drain and fill):
Power Shift Transmission 11.0 U.S. gal. (41.6 L) 11.0 U.S. gal. (41.6 L)
QUAD-RANGE or Syncro-Range
Transmission 13.0 U.S. gal. (49.2 L) 13.0 U.S. gat. (49.2 L)
Add for power front- wheel drive 4.0 U.S. gal. (15.1 L) 4.0 U.S. gal. (15.1 L)
(Dry, production fill):
Power Shift Transmission 15.9 U.S. gallons (60.3 L) 15.9 U.S. gallons (60.3 L)
QUAD-RANGE or Syncro-Range
Transmission 15.9 U.S. gal. (60.3 L) 15.9 U.S. gal. (60.3 L)
Add for power front- wheel drive 5.0 U.S. gallons (1B.9 L) 5.0 U.S. gal. (18.9 L)
POWER SHIFT TRANSMISSION:

Type planetary gears, hydrauficaily pianetary gears, hydraulicalfy
actuated wet disk clutches actuated wet disk clutches
and brakes and brakes
Gear selections 8 forward and 4 reverse 8 forward and 4 reverse
Shifting hydraulic, on-the-go and under load hydraulic, on-the-go and under load
QUAD-RANGE TRANSMISSION
Type 2-speed, power-shifted planetary 2-speed, power-shifted planetary
and 8-speed synchronized and 8-speed synchronized
16 forward and 6 reverse 16 forward and 6 reverse
Gear selections hydraulicaliy-operated, muftiple- hydraulicaJly-operated, muttiple-
Perma-Ciutch disk wet clutch dtsk wet clutch
SYNCRO-RANGE TRANSMISSION
Type synchronized, constant mesh synchronized, constant mesh
Gear seJections B forward and 2 reverse 8 forward and 2 reverse
Shifting 4 stations; synchronized 4 stations; synchronized
forward speed shifting within forward speed shifting within
stations stations
CREEPER TRANSMISSION
Type 8-speed Syncro-Range plus 2- 8-speed Syncro-Range plus 2-
speed collar-shifted planetary speed collar-shifted planetary
Gear selections 13 forward and 4 reverse 13 forward and 4 reverse
Shifting same as Syncro-Range plus same as Syncro-Range plus
collar shift between ranges collar shift between ranges
POWER TAKE-OFF:
Type fully independent, duaJ-speed fully independent, dual-speed
Speeds (2200 engine rpm) 1000 rpm or independent 540 and 1000 rpm 1000 rpm or independent 540 and 1000 rpm
Size 1-3/8 in. (35 mm) 1-3/8 in. (35 mm)
Clutch hydraulicaliy-operated, multiple- hydrauficaffy-operated, m ultipfe-
disk wet clutch disk wet clutch
POWER FRONT-WHEEL DRIVE:

Type hydraulic motor with planetary hydraulic motor with planetary
gear reduction, constant torque gear reduction, constant torque
and variable speed and variable speed
Controls solenoid-operated valves, synchro- solenoid-operated vaJves, synchro-
nized with transmission controls nized with transmission controls

4040 4240
HYDRAULIC SYSTEM:
Type closed-center, constant-pressure closed-center, constant-pressure
Standby pressure 2250 psi (155 bar) (155 kg/cm2) 2250 psi (155 bar) (155 kg/cm2)
BRAKES:
Type hydraulically-operated wet disk hydraulically-operated wet disk
ELECTRICAL SYSTEM:
Type 12-volt, negative ground 12-volt, negative ground
Batteries two, 6-voIt, 5D group, 800 amps two, 6-voIt, 5D group, 800 amps
cold cranking, 376 minutes reserve cold cranking, 376 minutes reserve
capacity capacity
Alternator 72-amp with SOUND-GARD body, 72-amp with SOUND-GARD body,

61 -amp without 61-amp without
TIRES AND THREADS: see page 05-6 in this section see page 05-6 in this section
DIMENSIONS:
Wheelbase 104.0 in. (2 642 mm) 105.7 in. (2 709 mm)
Overall length 153.2 in. (3 892 mm) 156.6 in. (3 977 mm)
Height to muffler cover*
Tractors with SOUND-GARD body 119.8 in. (3 040 mm) 123.0 in. (3 122 mm)
Tractors without SOUND-GARD
body 111.8 in. (2 837 mm) 115.0 in. (2 918 mm)
Height to top of SOUND-GARD Body* 109.3 in. (2 775 mm) 114.1 in. (2 895 mm)
Overall width (regular axle) 90 in. (2 277 mm) 90 in. (2 277 mm)
Width at fender 82 in. (2 082 mm) 82 in. (2 082 mm)
Width at roof 54.4 in. (1 382 mm) 54.4 in. (1 382 mm)
Turning radius 134 in. (3 400 mm) 146 in. (3 700 mm)
SHIPPING WEIGHT** 9630 lbs. (4370 kg) 10,900 lbs. (4975 kg)
*4040 Tractor equipped with 18.4-34 rear tires and 9.5L-15 front tires. 4240 Tractor equipped with 18.4-38 rear tires and 10.00-16 front tires.
**Equipped for average field service, without fuel and ballast. Add approximately 1000 lbs. (450 kg) if equipped with power front-wheel drive.
Subtract 900 lbs. (400 kg) if not equipped with SOUND-GARD Body.
GROUND SPEEDS
Speeds in the following charts are in miles per hour, with kilometers per hour in parenthesis. Speeds are for a 4040 Tractor with 1 8.4-34 tires or
a 4240 Tractor with 18.4-38 tires.
POWER SHIFT TRANSMISSION
Gear 1500 rpm 2200 rpm 1500 rpm 2200 rpm

1 1.1 (1.8) 1.7 (2.7) 1.2 (1.9) 1.8 (2.9)
2 1.6 (2.6) 2.4 (3.9) 1.7 (2.7) 2.5 (4.0)
3 2.5 (4.0) 3.7 (6.0) 2.6 (4.2) 3.8 (6.2)
4 3.2 (5.2) 4.7 (7.6) 3.4 (4.9) 4.9 (7.9)
5 4.2 (6.8) 6.1 (9.8) 4.4(7.1) 6.5 (10.5)
6 5.4 (8.7) 7.9 (12.7) 5.7(9.2) 8.3 (13.4)
7 7.1 (11.4) 10.5(16.9) 7.6 (12.2) 11.2 (18.0)
8 11.9 (19.2) 17.5 (28.2) 12.9 (20.7) 18.9 (30.4)
1R 1.3(2.1) 1.9 (3.1) 1.5 (2.4) 2.2 (3.5)
2R 1.9 (3.1) 2.8 (4.5) 2.1 (3.4) 3.1 (5.0)
3R 2.9 (4.7) 4.3(6.9) 3.2(5.1) 4.7 (7.6)
4R 3.8 (6.1) 5.5 (8.9) 4.1 (6.6) 6.0 (9.7)

10-00-4 Specifications and Special Tools General
GROUND SPEEDSContinued
4040 4240
Gear 1500 rpm 2200 rpm 1500 rpm 2200 rpm
A 1 1.3(2.1) 1.9 (3.1) 1.4(2.2) 2.0 (3.2)
2 1.6(2.6) 2.4 (3.7) 1.8 (2.9) 2.6 (4.2)
3 2.1 (3.4) 3.1 (5.G) 2.3 (3.7) 3.4 (5.4)
4 2.7 (4.3) 4.0 (6.4) 2.9 (4.7) 4.3 (6.9)
1R 2.1 (3.4) 3.0 (4.8) 2.2 (3.5) 3.2 (5.2)
2R 2.6 (4.2) 3.9 (6.3) 2.8 (4.5) 4.1 (6.6)
B 1 3.0 (4.8) 4.4 (7.1) 3.2 (5.1) 4.7 (7.6)
2 3.8 (6.1) 5.6 (9.0) 4.0 (6.5) 5.9 (9.5)
3 4.9 (7.9) 7.2 (11.6) 5.3 (8.5) 7.7 (12.4)
4 6.3 (10.1) 9.2 (14.8) 6.7 (10.8) 9.8 (15.8)
1R 4.8 (7.7) 7.0 (11.3) 5.1 (8.2) 7.5(11.9)
2R 6.1 (9.8) 8.9 (14.3) 6.5 (10.5) 9.5 (15.3)
C 1 3.5 (5.6) 5.2 (8.4) 3.8 (6.1) 5.5 (8.9)
2 4.5 (7.2) 6.6 (10.6) 4.8 (7.7) 7.0(11.3)
3 5.8 (9.3) 8.6 (13.8) 6.2 (10.0) 9.2 (14.7)
4 7.4(11.9) 10.9 (17.5) 7.9 (12.7) 11.6(18.6)
1R 5.6 (9.0) 8.3 (13.4) 6.0 (9.7) 8.9 (14.2)
2R 7.2 (11.6) 10.5 (16.9) 7.7 (12.4) 11.2(18.0)
D 1 5.4 (8.7) 8.0 (12.9) 5.8 (9.3) 8.5 (13.7)
2 6.9 (11.1) 10.1 (16.3) 7.3 (11.7) 10.8 (17.4)
3 9.0 (14.4) 13.2 (21.2) 9.6 (15.4) 14.0 (22.6)
4 11.4(18.3) 16.7 (26.9) 12.2 (19.6) 17.8 (28.7)
1 1.3 (2.1) 1.9 (3.1) 1.4(2.2) 2.0 (3.2)

2 2.1 (3.4) 3.0 (4.8) 2.2 (3.5) 3.2 (5.2)
3 2.7 (4.3) 4.0 (6.4) 2.9 (4.7) 4.2 (6.8)
4 3.5 (5.6) 5.1 (8.2) 3.7 (6.0) 5.4 (8.7)
5 4.3 (7.0) 6.3 (10.2) 4.6 (7.4) 6.8 (10.9)
6 5.7 (9.1) 8.3 (13.4) 6.1 (9.8) 8.9 (14.3)
7 7.3 (11.8) 10.7 (17.3) 7.8 (12.5) 11.5 (18.5)
8 11.9 (19.2) 17.5 (28.2) 12.8 (20.6) 18.8 (30.3)
1R 2.6 (4.2) 3.8 (6.3) 2.8 (4.5) 4.1 (6.6)
2R 4.2 (6.8) 6.2 (10.0) 4.5 (7.2) 6.6 (10.6)
With optional Creeper engaged

1 0.3 (0.5) 0.4 (0.7) 0.3 (0.4) 0.4 (0.6)
2 0.4 (0.7) 0.6(1.0) 0.4 (0.7) 0.6(1.0)
3 0.5 (0.9) 0.8 (1.3) 0.5 (1.0) 0.8(1.4)
4 0.8 (1.2) 1.1 (1.8) 0.8 (1.2) 1.1 (1.8)
5 0.9 (1.4) 1.3 (2.1) 1.0 (1.6) 1.3(2.2)

1R 0.5 (0.9) 0.8 (1.3) 0.5 (0.8) 0.8 (1.2)
2R 0.9 (1.4) 1.3 (2.1) 0.9 (1.5) 1.3 (2.2)
(Specifications and design subject to change without notice.)

PREDELIVERY, DELIVERY, AND AFTER-SALE SERVICES

Specification
(tem
Toe-in 1/8 to 3/8 inch (3 to 9 mm)
Injection pump timing T C
Engine speeds
Slow idle 780 to 820 rpm
Fast idle
2325 t0 2425 f P m
Rated speed at full load 2200 r P m
Torque ft - |bs Nm kQ m
SOUND-GARD Body or Four-Post ROLL-GARD mounting bolts 150 200 20

Front axle-to-knee bolts:
Narrow front axle 320 435 44
Regular or wide front axle 370 500 50
Hi-Crop 445 600 60
Front wheel-to-hub bolts 100 135 14
Special bolts on rear hubs 300 410 41
Steel wheel-to-hub bolts 240 325 33

Rim clamp-to-wheel bolts 1 70 230 23
Rockshaft lift arm retaining bolts 300 410 41
Other nuts and cap screws:
Three Six
Plain Head* Radial Dashes* Radial Dashes*
Bolt Diameter
ft-lbs Nm kgm ft-lbs Nm kgm ft-lbs Nm kgm
1/4 mm) 6 8 0.8 10 14 1.4 14 19 1.9

in. (6.35
(7.93 mm) 13 18 1.8 20 27 2.7 30 41 4.1
5/16 in.
3/8 in. (9.53 mm) 23 31 3.1 35 47 4.7 50 70 /.U
7/16 in. (11.11 mm) 35 47 4.7 55 75 7,5 80 110 11
85 115 12 120 160 16

1/2 in. (12.70 mm) 55 75 7.5
9/16 in. (14.29 mm) 75 100 10 130 175 18 175 240 24
5/8 in. (15.88 mm) 105 140 14 170 230 23 240 325 33
(19.05 mm) 185 250 25 300 410 41 425 575 58
3/4 in.
7/8 in. (22.23 mm) 160 220 22** 445 600 60 685 930 93
34** 670 900 90 1030 1400 140
1 in. (25.40 mm) 250 340
*The types of bolts and cap screws are identified by 6-Dash Head: tempered steel extra high -strength
head markings as follows: bolts and cap screws.
Plain Head: regular machine bolts and cap screws. **Machine bolts and cap screws 7/8-inch and larger
3-Dash Head: tempered steel high-strength bolts are sometimes formed hot rather than cold, which
and cap screws. accounts for the lower torque.

TUNE-UP
Item Specification
PTO horsepower
4040 90 hp (67 kW)
4240 1 10 hp (82 kW)
Compression 370 to 400 psi (25.5 to 27.6 bar)

dosing vacuum
Air cleaner indicator switch 24 to 26 in. (60 to 65 mbar)
Thermostat opening temperature 160 to 180F (71 to 82C)
Radiator cap pressure release
Low pressure cap 6.25 to 7.50 psi (0.4 to 0.5 bar)
High pressure cap 14 to 1 7 psi (0.9 to 1 .2 bar)
Engine speeds
Slow idte 780 to 820 rpm
Fast idle , 2325 to 2425 rpm
Rated speed at full load 2200 rpm
LUBRICATION
Engine crankcase oil capacity 1 7 U.S. quarts (1 6 L)
(Drain and fill):
Power Shift Transmission 1 1 .0 U.S. gal. (41 .6 L)

QUAD-RANGE or Syncro-Range Transmission 13.0 U.S. gal. (49.2 L)
Add for power front-wheel drive 4.0 U.S. gal. (15.1 L)
(Dry, production fill):
Power Shift Transmission 1 5.9 U.S. gal. (60.3 L)

QUAD-RANGE or Syncro-Range Transmission 15.9 U.S. gal. (60.3 L)
Add for power front-wheel drive 5.0 U.S. gal. (1 8.9 L)
Service intervals
Check engine oil level Every 10 hours
Change engine oil Every 100 hours
Replace engine oil filter Every 200 hours
Clean crankcase breather filter Every 200 hours
Check transmission-hydraulic system oil level Every 200 hours
Replace transmission-hydraulic system oil filter (Quad-Range) Every 200 hours
Replace transmission-hydraulic system oil filters (Power Shift) Every 600 hours
Change transmission-hydraulic oil Every 1200 hours
Clean main hydraulic pump screen Every 1200 hours
Clean and repack front wheel bearings Every 1200 hours
Lubricate grease fittings
Front axle pivot pins, steering spindles, tie rods (10 fittings) Every 10 hours
Wide-swing drawbar rollers (if equipped) Every 10 hours
Front wheel bearings (only in extremely wet conditions) Every 10 hours
3-point hitch : Every 200 hours
Load control shaft bushings Every 200 hours
Rear axle bearings Every 00 hours
Vacuum (full speed, full load, clean air filters)
4040 7.5 to 8.5 in. (19 to 21 mbar)
4240 9 to 10 in. (22 to 25 mbar)

SEPARATION
ITEM SPECIFICATION
Fan belt tension New Belt

Single belt 130-140 lbs. (578-622 N)
Dual belt 95-104 lbs. (423^67 N)
After Run In
All belts 85-94 lbs. (378-423 N)
ITEM TORQUE
Sound-Gard Body retaining cap screws 150 ft-lbs (203 Nm) (20.3 kgm)
Roll-Gard (4-post) mounting cap screws 150 ft-lbs (203 Nm) (20.3 kgm)
Engine-to-clutch housing cap screws 1/2 in. 85 ft-lbs (115 Nm) (1 1 .5 kgm)
3/4 in.300 ft-lbs (406 Nm) (40.6 kgm)
Clutch housing-to-engine cap screws 300 ft-lbs (406 Nm) (40.6 kgm)
Hydraulic pump support-to-engrne cap screws 85 ft-lbs (1 15 Nm) (1 1 .5 kgm)
Hydraulic pump coupler lock nuts 30 ft-lbs (41 Nm) (4,1 kgm)
Hydraulic pump drive coupling 35 ft-ibs (47 Nm) (4.7 kgm)
Side frames-to-engine 5/8 in.275 ft-lbs (373 Nm) (37.3 kgm)
3/4 in.425 ft-lbs (578 Nm) (57.8 kgm)
Clutch housing-to-transmission case cap screws
5/8 in. 170 ft-lbs (230 Nm) (23 kgm)
3/4 in.300 ft-lbs (406 Nm) (40.6 kgm)
Oil filter inlet pipe elbow cap screws 45 ft-lbs (61 Nm) (6,1 kgm)
Axle housing-to-transmission case cap screws 170 ft-lbs (230 Nm) (23 kgm)
Hi-Crop drive shaft houslng-to-finai drive gear housing 275 ft-lbs (373 Nm) (37.3 kgm)
Radiator hose damps (clean and dry) 36 in-lbs (4 Nm) (0.4 kgm)
Transmission pump elbow-to-clutch housing cap screws 45 ft-lbs (61 Nm) (6.1 kgm)
Oil pan-to-clutch housing cap screws 85 ft-lbs (1 15 Nm) (1 1 .5 kgm)
Hose clamps 30 in-lbs (3.4 Nm) (0.3 kgm)
TM-1181 (Feb-78) Lhho in U.S.A. Tractors - 4040 and 4240

10-00-8 Specifications and Special Toots General
SPECIAL TOOLS
Predelivery, Delivery, and After-Sale TOOL USE
Services
JDG-18 Snap Ring Tool Remove and install snap rings
on ends of rear axles
Fig. 1-JDG-18 Snap Ring Tool"
JDE-S1-1 Engine Rotation Turn engine to TOC to check

Tool and JDE-81-4 Timing injection pump timing
Pin
A-^JDE-81-1 Engine Rotation Tool*

B-ÎDE-81-4 Timing Pin*
Fig. 2-Toois Required for Checking Timing
JDE-28 Adapter and Hand Check engine speeds

Tachometer
AJDE-28 Adapter* B Hand Tachometer

Fig. 3-TooIs Required for Checking
Engine Speeds
TM-1181 (Feth78) Litho in U.S.A. Tractors - 4040 and 4240

Tune-Up TOOL USE
JDE-81-1 Engine Rotation Turn engine to TDC to check

Tool and JDE-81-4 Timing injection pump timing
Pin
JDE-28 Adapter and Hand Check engine speeds

Tachometer
ARG2377 Dry Element Clean primary element of

CJeaning Gun air cleaner
Fig. 4-AR62377 Dry Element Cleaning Gun
D-05022ST Water Vacuum Measure air intake vacuum

Gauge
Fig. 5-D-05022ST Water Vacuum Gauge*

(Formerly JDST-11)
TM-1181 (Sep-77) Litho in US. A Tractors - 4040 and 4240

TOOL NUMBER USE
BT-11-52 Radiator Tester Pressure test cooling system

and radiator caps
Fig. 6-BT-11-52 Radiator Tester*
Separation
Brown Body Lift To remove Sound-Gard Body.
Fig. 7-Brown Body Lift
JDG-21 Fork To remove Sound-Gard Body

Lift Adapters
Fig. 8-Fork Lift Adapters

Separation Continued
TOOL NUMBER USE
JDG-10-2 To support Sound-Gard Body
after removal.
%-fmzm.
Fig. 9-Sound-Gard Body Stand*
A-D-05007ST To support tractor in various

Splitting Stand separations.
B-D-05149ST
Attachments
R 23088^*
Fig, 10-Sptitting Stand*
JDG-12-1 To support front end of tractor

Splitting Stand
;R Z6$Wtt
Fig. 11-Spfftting Stand*

10-00-12 Specifications and Special Test General
TOOL NUMBER USE
A-JDE-63 Engine To remove engine

Lift Brackets
B-JDG-23 Engine
Lift Sling
Fig. 12-Bngtne Removal Tools*
D-05001ST To support engine during re-

Repair Stand pair
Fig. 13-Engine Repair Stand*
*Toois marked with an asterisk can be ordered from

Service Tools, Box 314, Owatonna MN 55060,
TM-1181 (Sep-77) Lttho in U.S.A. Tractors - 4040 and 4240

General Predelivery, Delivery, and After-Sale Services 10-05-1
Group 05
PREDELIVERY, DELIVERY, AND
AFTER-SALE SERVICES
The John Deere delivery receipt, when properly
filled out and signed by the dealer and customer,
verifies that predelivery and delivery services were
satisfactorily performed, When delivering the tractor, L_ ^y8P^ mK^m îlUHi- """'.ilLA .'.'>%):
give the customer his copy of the delivery receipt and

operators manual. Be sure to explain their purpose to
him.
Because of the shipping factors involved, plus extra

touches necessary to promote customer sat-
finishing
isfaction, there are certain predelivery services that
must be performed by the dealer. These services are
listed in the first of two sections on the predelivery
form, which is attached to the tractor. The second
29779
section is a list of factory inspections that must be
verified by the dealer. Fig. 2-Wide Swing Drawbar Grease Fittings
Fili the form in completely and sign it. Send copy to 2. If tractor is equipped with a wide-swing drawbar
the factory and file the original with the shop order for (Fig. 2)apply several shots of John Deere High Tem-
T
the job. This will certify that the proper predelivery perature Grease or its equivalent to drawbar rollers.
service has been completed.
DEALER PREDELIVERY SERVICE

Using the first part of the predelivery form along with
the following illustrated procedures, perform all ser-
vices listed and check each job off as it is completed.
Lubricate Grease Fittings

Grease all fittings with John Deere AT30408 High
Temperature Grease (1 lb. [0.45 kg] can) or its equiv-
alent. TY6281 is the same John Deere High Temper-
ature Grease in a 14 02. (0.39 kg) cartridge. Lubricant
must be an extreme-pressure grease with non-soap
base and NGLl No. 2 consistency, and must meet John
Deere JDM J13 E4 specifications.
Fig. 3-Hi-Crop Rear Axle Grease Fitting
3. On Hi-Crop tractors, apply several shots of John

Deere High Temperature Grease or its equivalent to
grease fittings on ends of rear axles.
Fig. 1 -Grease Fittings
1. Apply several shots of grease to tie rods, pivot

pins, and the steering spindles (10 fittings).

10-05-2 Predelivery, Delivery, and After-Sale Services General
Lubricate Grease Fittings Continued
iarSt
Fig. 4-Radius Rod Pivot Grease Fitting
4. On Hi-Crop tractors, apply several shots of John

Deere High Temperature Grease or its equivalent to
grease fittings. Fig. 6-Rear Axte Grease Pfug
6.Grease the rear axle bearings by removing the

pipe plug on each end of the axle housing, installing a
grease fitting and applying John Deere High Temper*
ature Grease or its equivalent at each fitting. Apply
grease until grease appears at seals, or a maximum of
25 shots.
Install Ether Aid Solenoid Wiring (if

equipped)
Fig. 5-Load Control Shaft Bushing Grease

Fitting
5. Apply several shots of John Deere High Tem-

perature Grease or its equivalent to each load control
shaft bushing.
Fig. 7'Bectric Starting Aid Connector
Connect starting aid wiring to starting aid solenoid (if
equipped}.

Align Muffler and Air Stack Head Lamps
|p HI .<,. jW% i
..";.
jp
Z:H. 13
MML ^ B-:.;
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ipnfr*** 1
:
in
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:
:;;.
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S!iH r
il;
; r 3{*::*:;I':K:'::: : r r ";,:-i:H: I:
;
r;r t;I;TTi;'F. 'L -T: EEIIFi ;Et- !
liIIIP:Dll:i'SilS3llli!ll3l
lllili
I'-"'''
5
-" MKSSff*
- ' ;
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ill lS: .S;;B!lll^
:
FJ3. 8-Muffler and Air Stack
R33823
necessary, align muffler and
If air stack so they are
perpendicular to tractor hood. A Points Directly in Front of Lamps
B^-Small Zones of Bright Light
Adjust All Lamps Fig. 10-Checking Head Lamp Positions
1 . Park tractor on level ground, 25 feet (8 m) from a

wall
2. Measure height of lamps above ground, and

place a strip of masking tape on wall at same height.
3. Sight across steering wheel and hood ornament

to locate tractor centerline. Mark this spot, and mea-
sure out one foot (300 mm) in each direction. This
locates a spot directly in front of each lamp.
4. Turn light switch to "H" and dimmer switch to low

beam,
Fig. 9-Ught Switch 5. Locate small zone of bright light projected by

each lamp. Top of bright zone should be five inches
Make sure lights work properly in the following po- (130 mm) lower than lamp, and left edge of zone
sitions: should be five inches (130 mm) to left of lamp. Cover
other lamp if necessary.
OFF - To turn off lights.
W - To turn on the warning lamps.

H - To turn on the dual-beam head lamps, warning
lamps, and red tail lamps.
F - To turn on the dual-beam head lamps and flood
lamps.
&#&&*-
Fig. 1 1-Head Lamp Adjusting Nut
6. To readjust a bulb, loosen nut behind bulb. Hold

lamp in correct position, and tighten securely.
TM-1181 (Jun-80) Litho in USA. Tractors - 4040 and 4240

.
10-05-4 Predelivery, Delivery and After-Sate Services General
Remove SMV Plastic Cover
|RS0053A1|
Fig. 12-Ptastic Cover
Remove plastic cover from SMV emblem.

A Rim Clamp Cap Screws B Special Bolts
Remove Rockshaft Lift Arm Retaining Fig. 15-Rear Wheel Cap Screws
Wire
3. Torque rim clamp cap screws (A, Fig. 15) to 170
ft-lbs (230 N-m) (23 kgm).
4. Torque special bolts (B) to 300 ft-lbs (410 N-m)

(41 kgm).
13-Retaining Wire
Remove retaining wire from rockshaft lift arms.
Torque Wheel Hardware To Specifications
Fig. 16-Hear Wheel Bolts
5. Torque wheel bolts to 300 ft-lbs (410 N-m) (41

kgm) (10-bolt wheel), 240 ft-lbs (325 N-m) (33 kgm)
(9-bolt wheel with retaining ring) or 85 ft-lbs (110 N-m)
(11 kgm) (9-bolt wheel without retaining ring).
R 29578 Ik- '^J;.'-' 1

^
AÂxle Cap Screws B Front Wheel Cap Screws
Fig. 14-Front Axle Cap Screws
1 Torque axle cap screws (A, Fig. 14) to 320 ft-lbs

(435 N-m) (44 kgm) (Narrow Axle), 370 ft-lbs (500
N-m} (50 kgm) (Regular or Wide Axle) or 445 ft-lbs
(600 N-m) (60 kgm) (Hi-Crop).

2. Torque front wheel cap screws to 100 ft-lbs (135
N-m) (14 kgm).
TM-1181 (Jun-80) Utho in U.S.A. Tractors - 4040 and 4240

Check Tire Pressure Adjust Wheel Spacing

Make sure tire pressure meets the specifications in Front Tread
the chart below.
Front axle is adjustable in four-inch (100 mm) steps
Ply Maximum
within the ranges shown below.
Tire
Size Rating Pressure
FRONT TREAD RANGE
Front Tires Front
7.5L-15 6 44 psi (3.1 bar) Tire Size Narrow Axle Regular Axle Wide Axle
7.50-16 6 40 psi (2.8 bar)
7.5L-15 50 to 76" 54 to 84" 60 to 94"
7.50-18 6 36 psi (2.5 bar)
(1.27 to 1.93 m) (1.37 to 2.13 m) (1.52 to 2.39 m)
7.50-20 6 32 psi (2.2 bar) 7.50-16 50 to 75" 54 to 84" 60 to 93"
9.5L-15 6 32 psi (2.2 bar) {1.27 to 1.91 m) (1.37 to 2.13 m) (1,52 to 2.36 m)
10.00-16 6 24 psi (1.7 bar) 7,50-18 50 to 75" 54 to 83" 60 to 93"
(1.27 to 1.91 m) (1.37 to 2,11 m) {1.52 to 2.36 m)
11.00-16 8 24 psi (1.7 bar)
9.5L-15 51 to 75" 55 to 83" 61 to 93"
11L-15 6 24 psi (1.7 bar)
(1.30 to 1.91 m) (1 .40 to 2.1 1 m) (1 .55 to 2.36 m)
124-24 8 16 psi (1.1 bar) 10.00-16 52 to 74" 56 to 82" 62 to 92"
(1.32 to 1,88 m) (1.42 to 2.08 m) (1.57 to 2.34 m)

Rear Tires 11L-15 53 to 73" 57 to 81" 63to9r
(1.35 to 1.85 m) (1.45 to 2.06 m) (1,60 to 2.31 m)
12.4-42 6 22 psi (1.5 bar)
11.00-16 53 to 73" 57 to 81" 63 to 91"
13.6-38 6 22 psi (1 .5 bar)
(1.35 to 1.85 m) (1.45 to 2.06 m) (1.60 to 2.31 m)
15.5-38 6 20 psi (1.4 bar) 12.4-24** Not Available 64 to 84"*** Not Available
15.5-38 8 22 psi (1 .5 bar) (1.63 to 2.13 m)
16,9-34 6 16 psi (1.1 bar) 7.50-20* Not Available 60 to 88" Not Available
(1.52 to 2.24 m)
16.9-34 8 16 psi (1.1 bar)
16.9-38 8 16 psi (1,1 bar)
* Hi-Crop Tractors Only
18.4-34 6 16 psi (1.1 bar)
** Power Front- Wheel Drive Tractors Only
18.4-34 8 16 psi (1.1 bar)
***With 12.4-24 R2 tires, minimum tread on 4240
18.4-38 6 16 psi (1.1 bar)
tractor is 68" (1 .73 m)
18.4-38 8 16 psi (1.1 bar)
20.8-34 6 14 psi (1.0 bar)
20.8-34 8 16 psi (1.1 bar)
23.1-30 8 16 psi (1.1 bar)
Fig. 17-Jacking Up Tractor
1. Jack up front end of tractor.
IMPORTANT: Do not place jack under engine oil
pan. On power front-wheel drive, do

tractors with
not place jack under hose guard at front axle.
TM-1181 (Jun-80) Litho in U.S.A. Tractors - 404O and 4240

Adjust Wheel Spacing Continued i
Fig. 20-Lug Bolts

Fig. 18-Front Axle Bolts
Tighten Jug bolts to 100 ft-lbs (135 N-m) (14 kgm)
2. Remove bolt from tie rod.

torque. Check and re tighten as instructed on page
10-05-4.
3. Remove bolts from front axfe. Rear Tread

Limitations
4. Slide axle knee to desired position.
Approximate tread ranges for each tire size are
shown in the chart on the following page.
5. axle bolts. On narrow axles, tighten to 320
Install
ft-lbs(435 N-rn) (44 kgm). On regular and wide axles,

tighten to 370 ft-lbs (500 N*m) (50 kgm). On Hi-Crop
axles, tighten to 445 ft-lbs (600 N-m) (60 kgm).
Fig. 19-Tie Rod Bolts
6. Install bolts in tie rod, making sure tie rod is

R31423
changed same amount as axle. A Heavy Cast Wheel C Heavy Offset Cast Wheel
&-Offset Cast Wheel
7. Adjust other side in same manner. Both sides 21 -Wheel Types
Fig.
should normally be adjusted to same spacing.
Certain tire sizes are available with different wheel
types which permit different tread ranges. Types of
8, Check toe-in each time tread is adjusted.
wheels are illustrated at left.
Tread range for Hi-Crop Tractors is 73 to 97 inches
Reversing Wheel Disk
(1.85 to 2.46 m) for straight wheels or 73 to 102 inches
With 7.5L-15, 7.50-16, 7,50-18, 7.50-20, 9.5L-15, (1.85 to 2.59 m) for offset wheels.
9.50-20, or 10.00-16 fronttires, wheels are reversible. Tread adjustment is usually made with the rack and
With larger tire sizes, wheel dish must be turned out- pinion, but you may need to change rim position on
ward for tire clearance. wheels or reverse wheels on axles to reach certain
tread widths.
Tread is 2 to 5 inches (50
wheel dish turned inward.
to 130 mm) narrower with
A CAUTION: For tractor
operate with single tires having tread width
fess than 60 inches (1.50 m).
stability, never
Tread is measured between centers of tires.
TM-1181 (Jun-80) Utho in U.SA. Tractors - 4040 and 4240

TIRE WHEEL RIM RIM LONG AXLE SPECJAL DUAL AXLE

SIZE TYPE POSITION CLAMP 96 in. (2.44 m) End-to-end 113 in. (2.78 in) End-to-end
15.5-38 Heavy Cast Inner inside Wheel 60 to 82 In. (1.52 to 2.08 m) 66 to 99 in. (1.65 to 2.52 m)
16.9-34 Inner Outside Wheel 65 to 89 in. (1.66 to 2.25 m) 72 to 106 in. (1.82 to 2.69 m)
16.9-38 Outer InsideWheel 67 to 90 in. (1.69 to 2.28 m) 73 to 107 in. (1.85 to 2.72 m)
18-4-34 Outer Outside Wheel 73 to 96 in. (1.86 to 2.45 m) 80 to 114 in. (2.02 to 2.89 m)
18.4-38
15.5-38 Offset Cast Inner Inside Wheel 60 to 76 in. (1.52 to 1.92 m) 61 to 96 In. (1.56 to 2.43 m)
16.9-34 Inner Outside Wheel 60 to 82 in. (1.52 to 2.09 m) 65 to 100 in. (1.66 to 2.53 m)
16.9-38 Outer Inside Wheel 60 to 83 in. (1.53 to 2.12 m) 67 to 101 in. (1,69 to 2.56 m)
18.4^34 Outer Outside Wheel 67 to 90 in. (1.70 to 2.29 m) 73 to 107 in, (1.86 to 2,73 m)
18.4-38
20.8-34 Heavy Cast Inner Inside Wheel 63 to 82 in. (1.60 to 2.08 m) 65 to 99 in. (1.65 to 2.52 m)
inner Outside Wheel -65 to 89 in. (1.66 to 2.25 m) 72 to 106 in. (1 .82 to 2.69 m)
Outer Inside Wheel 67 to 90 in. (1.69 to 2.28 m) 73 to 107 in, (1.85 to 2.72 m)
Outer Outside Wheel 73 to 96 in. (1.86 to 2.45 m) 80 to 114 in. (2.02 to 2.89 m)
20.8-34 Offset Cast Inner Inside Wheel 63 to 76 in. (1.60 to 1.92 m) 61 to 96 in. (1.56 to 2.43 m)
Inner Outside Wheel 63 to 82 in. (1.60 to 2.09 m) 65 to 100 in. (1.66 to 2.53 m)
Outer Inside Wheel 63 to 83 in. (1.60 to 2.12 m) 67 to 101 in. (1.69 to 2.56 m)
23.1-30 Heavy Cast Inner Outside Wheel 66 to 79 in. (1.68 to 2.02 m) 66 to 97 in. (1.68 to 2.46 m)
IMPORTANT: 1. Tires must have at least one inch

(25 mm)clearance with fenders.
Clearance between tires must be
at least 42 inches (1.07 m), with
tires equal distances from center
line.
2. With dual tires, space between

tires must be at least four inches
(100 mm).
3. With single tires, do not exceed

110 inches (2.80 m) for pulling
heavy loads.
4. Pinion might be damaged if hub

R 29589.
is tightened at its very innermost
position. Back away from end of Ftg. 22-Minimum Clearances
rack at least 1/8 inch (3 mm).

Adjust Rack and Pinion Wheel 5. Turn pinion (B) to slide wheel in or out on axle to
desired position. For extreme tread positions, it may be
necessary to reverse wheel on axle or change rim
position on wheel.
IMPORTANT: Tires or weights must have at

leastone inch (25 mm) clearance with fenders. To
prevent damaging pinion when hub is tightened,
do not put wheel in its very innermost position
back it out at least 1/8 inch (3 mm).
6. Back jack screws all the way out against stop. Do

not force.
7. Lubricate threads and tighten special bolts to 300

ft-lbs (410 N-m) (41 kgm). Retighten bolts several
times until all three stay tightened to specified torque.
Jack screws must be free to turn after hub is tightened.
If necessary, loosen jack screws further and retighten
special bolts.
A Rack EWeight Reference Mark IMPORTANT: After driving tractor approximate-

B Pinion F Rim Driving Lugs ly 100 yards (100 m), retighten special bolts to
CSpecial Belts G^-Wheel Driving Lugs
proper torque. Instruct customer to retighten them
DJack Screws
after 3 hours work and again after 10 hours work,
Fig. 23-Rack and Pinion Wheel and to keep them tight.
Adjust rear tread width to customer's needs. Changing Rim Position On Wheel
A tractor is equipped with

CAUTION: Unless
double rear wheels, tread width must be at
least 60 inches (1.52 m) for tractor stability.
1. Jack up tractor. Rotate wheel so that rack is on

top of axle.
2. If needed, clean axle with a steel brush.

Fig. 24-Deep Welt Rim Positions
3. Loosen the three special bolts (C, Fig. 23) ap-
proximately 3/8 inch (10 mm) each.
Deep well rims have only two possible positions on
wheels. Wider side of rim can be turned to inside or
4. Tighten the two jack screws (D) evenly until key
outside.
sleeve loosens.
NOTE: To change rim position and maintain proper
NOTE: tf sleeve is difficult to break loose, also
direction of tire rotation, move each tire to opposite
loosen the three special bolts on inboard side of wheel. side of tractor.
If sleeve stilt will not break loose, strike end of axle
several times with a heavy hammer and evenly re-

tighten jack screws. It helps to soak sleeves with
penetrating oii
TM-1181 (Jun-80) Litho in US.A Tractors - 4040 and 4240

1. Remove snap rings from ends of axles.
2. Following instructions under "Adjusting Rack and

1
Pinion' on page 10-05-8, slide wheels off axles. Install

on opposite axles.
3. Install snap rings on ends of axles.
Fig. 25-Rim Positions for Rims with Double Rings 4. With two jack screws backed all the way out to
Rims have four possible positions
with double rings stops, tighten three special bolts to 300 ft-lbs (400
on wheels. Clamps can be mounted on either side of N-m) (40 kgm) torque. Check and retighten as in-
wheel and can engage either ring on rim. structed on page 10-05-8.
Dual Wheels
Hg. 26-Rim Clamp Bolts
Be sure clamps engage rim driving lugs.
Tighten clamps evenly. Strike each bolt head with a

hammer to seat bolts; then retighten bolts to 170 ft-lbs
(230 N-m) (23 kgm) torque. Check and retighten bolts
R31960-
as instructed on page 10-05-4.
Reversing Wheels on Axles 4-in. (100 mm) Minimum Space D Steei Disk Wheel
B Retaining Bolts E Cast iron Wheel
NOTE: To reverse wheels on axles and maintain C Special Bolts
proper direction of tire rotation, move each wheel to
Fig. 8-Duai Wheels
opposite side of tractor.
IMPORTANT: 1. Space between tires (A) must be

at least four inches (100 mm).
2. Tighten and retighten retaining

bolts.
3. Be sure hub special bolts (C) and

rim clamps are kept tight.
4. When removing a wheel for sin-

gle wheel operation, always re-
move steel disk wheel (D) and
operate tractor on cast iron wheel
R 29599 d y \ v (E).
I
Fig, 27-Reversing Wheels
TM-1181 (Jun-80) Litho in US. A Tractors - 4040 and 4240

Check Rear Wheel Alignment Adjust Front Wheel Toe-In

1. Jack up rear of tractor until one wheel is off
ground.
\''j;K;
A CAUTION: Make sure

NOT engaged.
differential lock is
.. "pffi^S&Ss!^^^
2. Start tractor and place transmission in lowest

gear.
Fig. 30-Checking Toe-In
1. Steer front wheels straight ahead.
2. Measure distance between tires at hub level.
Mark the point at which you measured.
3. Move back about three feet (one meter),

tractor
R34753 hub level behind the axle. Again measure
so mark is at
distance between tires, at same point on tire. Tires
A Run-Out should be 1 /8 to 3/8 in. (3 to 9 mm) closer in front.
F\g. 29-Checking Tire Run-Out Engine Break-In

3. Engage clutch and make sure tire runs straight. Follow procedures for engine breaknn as instructed
on page 220-10-1.
4. If tire does not run straight, loosen rim clamp
bolts.
5. Tighten rim clamp bolts evenly, alternating from

one side of rim to the other.
6. Run tractor again to check alignment.
7. Check alignment of other wheel.
TM-1181 (Jun-80) Lftho in U.S.A. Tractors - 4040 and 4240

.
INSPECTION CHECKS 5. Check transmission/hydraulic system oil level. If
necessary, add oil to bring to upper mark on dipstick.

The second is a list of
part of the predelivery form
factory inspections that must be
by the dealer. verified
6. Check installation of safety shields, handrails and
Use this part of the predelivery form along with the
steps. Be sure mounting hardware is tight.
following illustrated procedures to check and verify
each item on the fist,
7. Check wheel retainer snap rings on axles. Make
sure they are properly seated in groove on axles.
1 Check engine oil level. If necessary, add suffi-
cient oil to bring oil level to full mark on dipstick.

8. Check installation of SOUND-GARD body
mounts. Be sure mounting hardware is tight.
2. Check tension of belts. Tension of both alternator
and compressor belts should be 85 to 95 lbs, (375 to
9. Check specific gravity of batteries. If reading is
425 N).
below 1.215, battery must be recharged. If difference
between cells is more than 0.50 replace battery. t
10. Check instrument panel gauges and lights for

proper operation.
>RteI$& "JS^V
g&vSf
[gat ^>
jj chg7
V01T$ /
R31918 ^
Fig, 33-Voiimeter Gauge
ACover C Primary Element
B Wing Nut D Wing Nut A - Turn key switch to first position. Voltmeter (Fig.
33) hand should rise to green band.
Fig. 31 -Primary Element and Cover
X294Z?
Fig. 34-Transmission Oil and Air Fitter
Gauges
B -While cranking engine, check transmission oil

and Both bulbs should
air filter indicator lights (Fig. 34).
light while key switch is in start position.
Fig. 32-Secondary Element
3. Make sure air cleaner elements are installed

correctly.
4. Check engine coolant level- Proper level is mid-

way between filler neck and top of radiator core.
TM-1181 (Jun~80) Lltho in US, A Tractors - 4040 and 4240

.
INSPECTION CHECKSContinued 17. Make sure brakes function properly with engine
running. Make sure brakes have a solid feel for at least
five applications after engine has been stopped for at
least 15 minutes.
18. Check steering wheel tilt and telescope mech-

anisms.
19. Make sure transmission operates properly in all

Fig. 35-Oil Pressure Gauge gears.
C - Make sure oil pressure gauge hand rises above 20. Check operation of differential lock if equipped.
warning zone within five seconds after engine starts.
While driving tractor, depress differential lock pedal.
Pedal should remain engaged until brakes are used.
1 1 Check operation of fights in all switch positions: Pedal should release when either brake pedal is de-
OFF - To turn lights off.
pressed.
W - To turn on the warning lamps.
H - To turn on the dual-beam head lamps, warning 21. Raise and lower rockshaft several times to
lamps, and red tail lamps. make sure it functions properly.
F - To turn on the dual-beam head lamps and flood
lamps, 22. Check SCV operation.
Attach a remote hydrau-
lic breakaway coupler. See that coupler,
cylinder to a
12. Check start-safety switch operation. Make sure coupler operating levers, and rate of operation valve
engine will start only with transmission in neutral or
function smoothly.
park.
Extend and retract cylinder several times. Make sure

13. Make sure dutch pedal
adjusted correctly.
is
operation lever automatically returns to neutral when
The lowest part of clutch pedal should be 5-1 1 A to cylinder reaches end of its stroke.
5*3/4 in. (133 to 146 mm) above the footrest.
23. Make sure PTO is operating correctly. With

PTO guard removed and engine running, make sure
PTO shaft rotates when PTO clutch lever is engaged
and stops when lever is disengaged.
24. Make sure all seat controls operate properly.
25. Make sure seat belts are installed, if required,

and operational.
26. Inspect all coolant, fuel and oil lines for leaks,
and correct if necessary.
27. Inspect paint and decals for defects. Correct as

Fig. 36-Tachorneter
necessary.
14. Check engine idle speeds on tachometer (Fig.
36), Fast idle should be 2400 rpm and slow idle should
be 800 rpm.
15. Check operation of engine stop knob. Make

sure engine stops when knob is pulled out.
16. Make sure steering operates properly in a full
left and full right turn.

(

DELIVERY SERVICE
A thorough discussion of the operation and service Using the tractor operator's manual as a guide, be
of a new tractor at the time of delivery helps to assure sure the owner understands these points thoroughly:
complete customer satisfaction. Proper delivery should
be an important phase of a dealer's program. A portion 1. Controls and instruments.
of the John Deere Delivery Receipt emphasizes the 2. How to start, and stop the engine.
importance of proper delivery service. 3. The importance of the break-in period,
4. How to use liquid or cast-iron ballast.
Many complaints have arisen simply because the 5. All functions of the hydraulic system.
owner was not shown how to operate and service his 6. Using the power takeoff.
new Enough time should be devoted,
tractor properly. 7. The importance of safety.
at the customer's convenience, to introducing the 8. The importance of lubrication and periodic ser-
owner to his new tractor and explaining to him how to vices.
operate and service it.
Give particular emphasis to sway blocks, rockshaft

IMPORTANT: Install plug in muffler outlet if speed-of-drop, rockshaft selector lever (load and
transporting tractor to customer. This will prevent depth control), transmission oil indicator Jig ht (whether
damage to the turbocharger caused by air passing temperature or pressure and what to do if it comes on),
through the turbocharger and rotating it without voltmeter (how to see whether alternator is charging),
lubrication when the engine is stopped. and SOUND-GARD Body air filters. These areas are
very often misunderstood.
The following procedure is recommended before the
serviceman and owner complete the delivery ac- After explaining and demonstrating the above fea-
knowledgments portion of the delivery receipt. tures, have the owner sign the delivery receipt and give
him the operator's manual.

AFTER-SALE INSPECTION
88SW
The purchaser of a new John Deere tractor is en-
titled to
after the
a free inspection within the warranty period
equipment has been "run in". The terms of
IB ISssS
this after-sale inspection are outlined on the back of assHaa: aCr-sT* -.-
the John Deere Delivery Receipt

IBH^^HM
The purpose of this inspection is to make sure that ny:;:Ht!HHHH3UHH3r::IHH:r
I'^'lf^vf W'$*&sjsjd
the customer is receiving satisfactory performance
from his tractor. At the same time, the inspection
should reveal whether the tractor is being operated,
lubricated, and serviced property.
If the recommended after-sale service inspection is
followed, the dealer can eliminate a needless volume

of service work by preventing minor irregularities from
developing into serious problems later on. This will
promote strong dealer-customer relations and present
fig. 3B-Removing Side Grille Screen
the dealer an opportunity to answer questions that may
have arisen during the first few days of operation.
2. Remove side grille screens. Remove any trash
recommended which has accumulated on radiator and oil cooler-

The following inspection program is
condenser.
within the first 100 hours of tractor operation.
Cooling System
SSSî
R 29212PM ^jl
Fig. 37-Radiator Cap
1. Remove radiator cap and check coolant level.
Level should be at least 1-1/2-inches (38 mm) above

baffle in radiator top tank, tf coolant is low, fill to proper
level and try to determine why coolant was lost
Fig. 39-Cooiing System
3. Check all hoses and connections for leaks. Cor-

rect as necessary.
TM-1181 (Jun~80) Litho in U.SA. Tractors - 4040 and 4240

General Predelivery, Delivery and After-Sale Services 10-05-15
Fuel System
mm
Fig. 40-Fuei Filter Drain Plug
1. Check fuel filter for water or sediment. If any is

A Air Cleaner Element B Dust Unloading Valve
present, remove drain plug and drain it out. Caution
customer about importance of proper fuel storage. Fig. 42-Air Cleaner
4. Inspect air cleaner element (A, Fig. 42) and dust

unloading valve (B). Clean element if needed.
Lubrication
Illlfii sm
rtisr :rr:::;tK::::::
Fig. 41 -Fuel Transfer Pump Hand Primer
2. If fuel filter is drained, bleed air from system.

Loosen hand primer (Fig. 41) and pump until most of
air bubble disappears.
A Dipstick B Filler Cap
3. Check entire fuel system for leaks. Correct as
necessary. Fig. 43-Crankcase Dipstick and Filler Cap
1. With the tractor on level ground and the engine

stopped for 10 minutes or more, loosen the dipstick
and remove it. Observe the engine oil level on the
dipstick, with the dipstick seated evenly. If the oil level
is down to the lower marks on the dipstick, add suffi-
cient John Deere TORQ-GARD SUPREME Engine

Oil or its equivalent of the proper viscosity to bring the
level to the upper marks.

10-05-16 Predelivery, Delivery, and After-Sale Services Genera!
2. Check level of electrolyte in each cell of each

battery. Level should be to bottom of filler neck. If water
is needed, use clean, mineral-free water. (
water must be added to batteries more often than
If
every 200 hours, alternator may be overcharging.

Refer to Group 10 of Section 240.
3. Check tension of fan belts and air conditioning

compressor belt. Adjust if necessary.
IMPORTANT: Do not tension or release belts

when hot.
A Dipstick B Filler Cap Adjust by using a belt tension gauge. Belt tensions
are as follows.
Fig, 44-TransmissiQn-Hydraufic System Dipstick Tension New Belt
Single belt 130-140 ibs. (578-622 N)
2. With the tractor on level ground, check the Dual belt 95-104 lbs. (423-467 N)
transmission-hydraulic system oil level with the dip-
stick. If the oil level is down to the "ADD" mark at the Tension After Run In*
bottom of the "SAFE" range on the dipstick, remove All belts 85-94 Ibs. (378-423 N)
the cap and add John Deere HY-GARD Trans-
filler
mission and Hydraulic Oil or its equivalent to bring the îmmediately after run in (approximately 10 min.)
oil level up to the top of the "SAFE" range. check tension, ft tension is within specification, no
adjustment is necessary. If tension is not within speci-
Electrical System fication, wait ten minutes; loosen belts and tension to
specifications. Tension front belt only.
AAdjusting Cap Screw C-l/4"{6mni) Flex

Ftg. 45-Battery Compartment BMounting Bolt
Ftg, 46-Adjusting Compressor Beit Tension

1. Check specific gravity of batteries with a hy-
drometer. Specific gravity, corrected to 80F (27C) is
1.260 for charged battery. To correct for tern-

a fully
4. Compressor belt should deflect one-fourth inch
perature of electrolyte, add 0.004 for every 10F above (6 mm) when a 15-pound (65 N) force is applied
80F (0.007 for every 10C above 27C). Subtract at midway between pulleys.
the same rate if electrolyte is below 80F (27C).
If batteries are not near full charge, try to determine

the reason. Refer to Group 10 of Section 240.
(

Electrical System Continued GENERAL

5. Check operation of all lights. If you find any 1, Tighten the following bolts to the torques speci-
problem, refer to Group 20 of Section 240. fied.
6. Check operation of starter, gauges and indicator ft-lbs N m kgm

lamps.
SOUND-GARD Body or
ENGINE Four-post ROLL-GARD Mounting
bolts 150 200 20
1. Check engine speeds as instructed on page 12. Front axle-to-knee bolts 445 600 60
2. Check engine vaive clearance as instructed in
Special bolts on rear hubs 300 410 41
Group 10 of Section 20. Intake vafve clearance should Steel wheel-to-hub bolts 240 325 33
be 0.016 to 0.022 in. (0,4 to 0.6 mm). Exhaust valve Rim clamp-to-whee! bolts 170 230 23
clearance should be 0.026 to 0.032 in. (0.7 to 0.8 mm). Rockshaft lift arm retainers 300 410 41
2. Check all other accessible nuts and cap screws.
3. Check engine, fuel system, cooling system, and

hydraulic system for leaks. Correct as necessary.
4. Check air conditioner sight glass as instructed in

Group 05 of Section 290.

Predelivery, Delivery, and After-Sale Services General
10-05-18 _^____

General Tune-Up 10-10-1
Group 10
TUNE-UP
PRELIMINARY ENGINE TESTING ENGINE TUNE-UP
Before tuning up a tractor, determine whether a
tune-up will restore operating efficiency. When there is
doubt, the following preliminary tests will help to de-
termine if the engine can be tuned-up. Choose from
the following procedures only those necessary to re-
store the unit.
1. been stopped for several hours,

After engine has
carefully loosen crankcase drain plug and watch for
any water to seep out. A few drops could be due to
condensation, but any more than this would indicate
problems which require engine repairs rather than just
a tune -up. Refer to Section 220.
With engine stopped, inspect engine coolant for

2.
an film. With engine running, inspect coolant for air
oil
bubbles. Either condition would indicate problems

which require engine repairs rather than just a tune~up.
Refer to Section 220.
Perform a dynamometer test as instructed in

3.
A-Air Cleaner Element B Dust Unloading Valve
Group 10 of Section 220, and record horsepower. Fig. 1-Air Cleaner
Repeat dynamometer test after tune-up, so horse-
power output before and after tune-up can be com-
pared.
At 2200 engine rpm, output should be 90 horse-

power (67 kW) for 4040 Tractors and 110 horsepower
(82 kW) for 4240 Tractors.
4. Perform compression test as instructed in Group

10 of Section 220. If test is performed as outlined,
compression should be 370 to 400 psr (25.5 to 27.6
bar) (26 to 28 kg/cm 2).
Air Intake System

Patting Element Air-Cleaning Element
1. Inspect air cleaner primary element (A, Fig. 1). If
dirty, clean by patting element with your hand or use Fig, 2-Qeaning FHter Element
AR62377 Dry Element Cleaning Gun.
IMPORTANT: Do not blow air from outside of
NOTE: Both primary and secondary elements element to inside. Be sure metal screen does not
should be replaced at least once a year. During a touch paper element, as it would quickly rub holes.
tune-up is a good time to perform this service. Inspect element carefully before reinstalling. Do
not clean secondary element.

10-10-2 Tune-Up General
Air Intake System Continued (c) Disconnect wiring connector (D, Fig. 4) from
switch (C). Unscrew switch from connection on
air intake pipe. (
(d) a 1/8-inch F-1 /4-inch M connector on

install
vacuum gauge. Install a 1/4-inch F "T" connec-
tor. Install a 1/4-inch M-1 /8-inch F connector on
*T' connector and connect indicator switch.
(e) Connect vacuum gauge to one side of "T"

and indicator switch to other side. Connect wiring
to switch.
NOTE: The vacuum gauge is calibrated in inches of

Fig, 3~Air intake Connections water A water manometer may also be used.
2. Check all connections in air intake system for (f) Operate engine at full load and note gauge
possible leaks. Tighten any loose clamps. Be sure reading. With clean filter elements, at 2200 en-
rubber dust unloading vaive is in good condition. gine rpm and full load, read vacuum gauge.
3- Check for restrictions in air intake system by 4040 8 in. (20 mbar)
measuring vacuum. 4240 9-5 in, (24 mbar)
(a) Run engine and bring to operating tempera-

Maximum permitted vacuum is 25 in. of water (62
ture.
mbar).
(b) Remove side shields, grille screens, air stack If vacuum is exoessive, try to find and correct
(g)
extension, muffler, and hood. the cause.
4. While checking air intake system for restrictions,

check operation of restriction indicator switch.
With engine running as in part (f) of step 3, use a

piece of cardboard to partially cover air cleaner intake.
Increase the restriction until air deaner indicator light
comes on, and note vacuum reading.
Restriction indicator switch should close at 24 to 26

inches of water (60 to 65 mbar). If it does not, replace
it.
AWater Vacuum Gauge CSwitch

BPipe Fittings DWiring Connector
Fig. 4-Testing Air intake System Restriction
TM-1181 (Sep-77) Utho in USA. Tractors - 4040 and 4240

Exhaust System Cooling System

Inspect exhaust system for any leaks or restrictions. 1. Clean side grille screens if dirty.
Correct as necessary.
Crankcase Ventilation System ESs^*:J^:.^^j=:-^"::;:::::"";::r"'
Fig. 5-Crankcase Vent Tube ARadiator C Oil Cooler*

BCap Screw Condenser
Inspect crankcase ventilation system for restrictions.

Fig. 6-Radiator and Oil Cooler-Condenser
Lack of ventilation causes sludge to form in engine
crankcase. This can lead to clogging of oil passages, To
2. Clean radiator and oil cooler-condenser.
filters, and screens, resulting in serious engine dam-
clean portion of radiator behind oil cooler-condenser
age.
unit, remove the two screws at top of unit. Slide unit to
one side to expose half the radiator. After cleaning that

Clean crankcase vent tube in solvent if it is restrict-
half, slide the unit to the other side. Replace cap
ed.
screws when finished.
TM-1181 (Sep-77) Litho in USA. Tractors - 4040 and 4240 ;

Cooling System Continued (i) Recheck coolant level after starting engine-
Coolant should be 1-1/2 inches (40 mm) above
3. Drain and flush cooling system.
baffle in radiator top tank.
Cooling system capacity is 38 U.S. quarts (36 I)

for4640 Tractors and 40 U.S. quarts (38 I) for
4840 Tractors. Add 2 quarts (2 I) for Sound-Gard
Body heater.
4. Remove and check thermostats as instructed in
Group 25 of Section 20. Thermostats should open at
160 to 180F (71 to 82C).
5- Check radiator and pressure cap for leaks.
(a) Visually check cooling system for leaks or

damage.
Fig. 7-Cooting System Drain Cocks
(a) Drain cooling system by opening drain cocks

on radiator and engine block.
(b) Turn Sound-Gard Body heater on and leave

it on until finished.
(c) Close drain cocks and fill cooling system with

clean water.
(d) Run engine until it reaches operating tem-
perature to stir up possible rust or sediment.
(e) Stop engine and drain coolant before rust or

sediment settles.
(f) Close drain cocks and fill cooling system with

a solution of John Deere Cooling System Cleaner
and water. Follow the instructions with the AOverflow Valve D5/1 6- Inch Cap Screw
cleaner. B Hose E High Pressure Cap
C Low Pressure Cap F BT-11-52 Radiator Tester
(g) After cleaning, flush the system with clean
Fig. 8-Testing Cooling System
water.
(b) At overflow valve (A, Fig. 8), disconnect hose
(h) Fill cooling system with clean, soft water and (B) which comes from low pressure cap (C).
antifreeze. Use a permanent-type, ethylene gly-
which contains a rust inhibitor but
col antifreeze (c) Plug end of hose by inserting a 5/1 6-inch cap
does not contain a stop-leak additive. screw (D) and clamping it securely.
(d) Remove high pressure cap (E), and attach

BT-11-52 Radiator Tester (F) to filler neck.
(e) Pump pressure up to 18 psi (1.25 bar} (1.25

kg/cm2 ). System should hold the pressure. M it
does not, try to find and correct the problem.

Fig. 1 1-Fuei Transfer Pump Hand Primer
2, If fuel filter is drained, bleed air from system.

Loosen hand primer (Fig. 11) and pump until most of
air bubble disappears.
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/cm 2 ), and high
pressure cap should maintain 14 to 17 psi (0.9 to
1.2 bar) (0.9 to 1.2 kg/cm 2). If either cap is
defective, replace it.
Diesel Fuel System
Fig. 12-Fuei Tank Drain Piug
3. Loosen or remove fuel tank drain plug, and drain

any water or sediment from tank.
g!Ci:^^:W:::nrtvl:;:;lr : ;:?ip-^r ~ j-T

4. Check entire fuel system for leaks. Correct as
B&f\ .^"~ r . necessary.
5. Check injection pump timing as instructed in
Group 05 of this section.
6. Check engine idle speeds as instructed in Group

05 of this section. Slow idle speed should be 780 to
Fig. 10-Fuet Fitter Drain Plug
820 rpm, and fast idle speed should be 2325 to 2425
rpm.
1. Check fuel filter for water or sediment. If any is
present, remove drain plug and drain it out. Caution
customer about importance of proper fuel storage.
NOTE: Fuel fitters must be replaced periodically to

prevent excessive restriction. During a tune-up is a
good time to perform this service.
TM-1181 (Feb-78) Litho in U.SA. Tractors - 4040 and 4240

Electrical System Tension New Belt

Single belt 130-140 lbs. (578-622 N)
Dual belt 95-104 lbs. (423-467 N)
Tension After Run In*
All belts 85-95 lbs. (378-423 N)
Îmmediately after run in (approximately 10 min.)

check tension, if tension is within specificiation, no
adjustment is necessary, if tension is not within speci-
fication, wait ten minutes; toosen belts and tension to
specifications. Tension front belt only.
Fig. 13-Baitery Compartment
1. Clean batteries, cables, and compartments with

a damp cloth. corrosion is present, remove and
If rt
wash the terminals with a solution of ammonia or

baking soda in water. Then flush area with clean water.
2. Coat battery terminals and connectors with pe-

troleum jelly mixed with baking soda to retard corro-
sion. AAdjusting Cap Screw C 1/4" (6 mm) Rex
B Mounting Bolt
3. Test batteries as instructed in Group 5 of Section
Fig. 14-Adjusting Compressor Belt Tension
240. batteries are not near full charge, try to find out
If
why.
7. Check operation of all fights, if you find any
problem, refer to Group 20 of Section 240.
4. Check level of electrolyte in each cell of each
battery. Level should be to bottom of filler neck. If water
8. Check operation of neutral-start switch. Starter
is needed, use clean, mineral-free water.
should not operate unless transmission is in neutral or
park.
If water must be added to batteries more often than
every 200 hours, alternator may be overcharging.

9. Follow engine starting instructions beginning on
Refer to Group 10 of Section 240.
page 12 in Group 05 of this Section. Check operation
of starter, gauges, and indicator lights.
5. If appear to be either undercharged or
batteries
overcharged, check alternator and charging circuit.
10. Check air conditioner sight glass as instructed
Follow diagnosis and testing procedures outlined in
in Group 05 of Section 290.
6. Check tension of fan belts and air conditioning

compressor belt. Adjust if necessary.
IMPORT ANT: Do not tension or release belts

when hot.
Adjust by using a belt tension gauge. Belt tensions

are as follows.
TM-1181 (Feb-78) Lrtho in U.S.A. Tractors - 4040 and 4240

Final Engine Test Front Tires
Repeat dynamometer test as instructed in Group 10 Tire Ply Maximum

of Section 220. Compare performance with previous Size Rating Pressure
test, and record for future reference.
7.5L-15 6 44 ps (3.0 bar) (3.0 kg/cm 2 )
At 2200 engine rpm, output should be 90 horse- 7.50-16 6 44 ps (3.0 bar) (3.0 kg/cm 2 )
power (67 kW) for 4040 Tractors and 110 horsepower 7.50-18 6 44 ps (3.0 bar) (3.0 kg/cm 2 )
(82 kW) for 4240 Tractors. 7.50-20 6 44 ps (3.0 bar) (3.0 kg/cm 2 )
9.5L-15 6 36 ps (2.5 bar) (2.5 kg/cm 2 )
OPERATION 10.0-16 6 32 ps (2.2 bar) (2.2 kg/cm 2 )
11.0-16 8 40 ps (2.7 bar) (2.7 kg/cm 2 )
Perform all checks as instructed under "OPERA-
11L-15 6 32 ps (2.2 bar) (2.2 kg/cm 2 )
TION" beginning on page 1 3 in Group 5 of this section.
12.4-24 6 24 ps (1.6 bar) (1.6 kg/cm 2 )
12.4-24 8 32 ps (2.2 bar) (2.2 kg/cm 2 )
1. Driving tests.
2. Brake accumulator.
Packing Front Wheel Bearings
3. Power take-off.
4. Implement hitch components. .
5. SOUND-GARD Body and operator's station.
If you find or suspect any problem with any compo-

nent, refer to the appropriate area in this manual.
GENERAL
W(f\ -<>
Checking Tire Inflation Pressure
Check inflation pressure of all tires before delivering D Bearings

tractor. Adjust pressure to the maximums listed below.
BOil Seal Cup EAdjusting Nut
C Hub FHub Cap
The customer can then easily reduce pressure slightly
if necessary, depending on how tractor is to be used. Fig. 15-Front Wheel Bearings
Rear Tires 1. Disassemble and clean front wheel bearings.
Tire Ply Maximum

2. Inspect bearings carefully and replace them if
Size Rating Pressure
they are worn. If three deep grooves are worn in oil
12.4-42 6 22 psi (1.5 bar) (1.5 kg/cm 2 ) seal cup, replace cup and seal.
13.6-38 6 22 psi (1.5 bar) (1.5 kg/cm 2 )

15.5-38 6 20 psi (1.4 bar) (1.4 kg/cm 2 ) 3. Pack bearings with wheel bearing grease. Pack
15.5-38 8 26 psi (1.8 bar) (1.8 kg/cm 2) seal lips withJohn Deere AT30408 High Temperature
15.5-38 10 32 psi (2.2 bar) (2.2 kg/cm 2 ) Grease (1 lb. [0.45 kg] can) or its equivalent. TY6281 is
16.9-34 22 kg/cm 2 ) the same John Deere High Temperature Grease in a
8 psi (1.5 bar) (1.5
16.9-38 8 24 psi (1.6 bar) (1.6 kg/cm 2) 14 oz. (0.39 kg) cartridge. Lubricant must be an ex-
18.4-34 6 16 psi (1.1 bar) (1.1 kg/cm 2 ) treme-pressure grease with non-scap base and NGLI
18.4-34 8 20 psi (1.4 bar) (1.4 kg/cm 2 ) No. 2 consistency, and must meet John Deere JDM
18.4-38 6 16 psi (1.1 bar) (1.1 kg/cm 2 ) J13 E4 specifications.
18.4-38 8 20 psi (1.4 bar) (1.4 kg/cm 2)
20.8-34 6 14 psi (0.9 bar) (0.9 kg/cm 2 ) 4. Install wheel and tighten adjusting nut until a
20.8-34 8 18 psi (1.2 bar) (1.2 kg/cm 2) slight drag when wheel is rotated.
is felt
23.1-30 8 16 psi (1.1 bar) (1.1 kg/cm 2 )

5. Back nut off just enough to insert cotter pin in first
hole.

Checking Toe-In Miscellaneous

1. Tighten the following bolts to the torques spec-
ified.
ft-lbs N-m kgm

Four-post ROLL-GARD mounting
bolts 150 200 20
Front axle-to-knee bolts 445 600 60
Special bolts on rear hubs . . . 300 410 41
Steel wheel-to-hub bolts 240 325 33
Rim clamp-to-wheel bolts 170 230 23
Rockshaft lift arm retainers . . . 300 410 41
R 27145H
Fig. 16-1/8 to 3/8 in. (3 to 9 mm) Toe-in

2. Check all other accessible nuts and cap screws.
If you find any that are loose, tighten according to the
chart below.
1. To check toe-in, steer front wheels straight
ahead.
3. Check engine, fuel system, cooling system, and
Measure distance between tires at hub
2. level. hydraulic system for leaks. Correct as necessary.
Mark the point at which you measured.
Move tractor back about three feet (1 m), so mark

3.
is hub level behind the axle. Again measure distance
at
between tires, at same point on tires. Tires should be
1/8 to 3/8 in. (3 to 9 mm) closer in front
4. If toe-in adjustment is needed, remove bolts from

tie rod tubes and loosen clamps on inner ends of tie
rods. Turn tie rod tubes in or out until toe-in is correct.

Replace bolts and tighten clamps.
Tie rods should be adjusted to equal length, so

tractor will turn equally sharp in either direction.
TORQUE CHART
Three Six
Bolt Diameter Plain Head* Radial Dashes* Radial Dashes*
ft-lbs N-m kgm ft-lbs N-m kgm ft-lbs N-m kgm
1/4 in. (6.35 mm) 6 8 0.8 10 14 1.4 14 19 1.9

5/16 in. (7.93 mm) 13 18 1.8 20 27 2.7 30 41 4.1
3/8 in. (9.53 mm) 23 31 3.1 35 47 4.7 50 70 7.0
7/16 in. (11.11 mm) 35 47 4.7 55 75 7.5 80 110 11
1/2 in. (12.70 mm) 55 75 7.5 85 115 12 120 160 16
9/16 in. (14.29 mm) 75 100 10 130 175 18 175 240 24
5/8 in. (15.88 mm) 105 140 14 170 230 23 240 325 33
3/4 in. (19.05 mm) 185 250 25 300 410 41 425 575 58
7/8 in. (22.23 mm) 160 220 22** 445 600 60 685 930 93
1 in. (25.40 mm) 250 340 34** 670 900 90 1030 1400 140
*The types of bolts and cap screws are identified by 6-Dash Head: tempered steel extra high-strength
head markings as follows: bolts and cap screws.
Plain Head: regular machine bolts and cap screws. ** Machine bolts and cap screws 7/8-inch and larger
3-Dash Head: tempered steel high-strength bolts are sometimes formed hot rather than cold, which
and cap screws. accounts for the lower torque.

General Lubrication 10-15-1
Group 15
LUBRICATION
Effective use of lubricating oils and greases is per- Other Oils
haps the most important step toward low upkeep cost, John Deere
Air Torq-Gard Single Vis- Multi- Vis-
long tractor life, and satisfactory service. Use only
Temperature Supreme Oil cosity Ott cosity Oil
lubricants specified in this section. Apply them at in-
tervals and according to the instructions in the lubrica- SAE 30 SAE 30 Not recom-
Above
tion and periodic service section.
32F (0C) mended
ENGINE LUBRICATING OILS -10 to SAE 1GW-20 SAE 10W 10W-30

32*F**
(-23 to 0C)
Below SAE 5W-2G SAE 5W SAE 5W-20

~10F (-23C}
**lf air temperature below 10F (-12C), use an
is
X3377 engine heater, SAE 5W-20 oils may also be used to

insure optimum lubrication of engine and turbocharger
We recommend John Deere TORQ-GARD SU- TRANSMISSION-HYDRAULIC OILS

PREME engine oil for use in the engine crankcase. only John Deere HY-GARD Transmission and
Use
TORQ-GARD oil is compounded specifically for use in Hydraulic Oil or its equivalent in the transmission-hy-
John Deere engines and provide superior lubrication
draulic system. Other types of oil will not give satisfac-
under all NEVER PUT ADDITIVES IN THE
conditions.
and may result in eventual damage. This
tory service
CRANKCASE, TORQ-GARD oil was formulated to may
special oil, available from your John Deere dealer,
provide all the protection your engine needs. Additives
be used in ail weather conditions.
could reduce this protection rather than help it.
If TORQ-GARD SUPREME is NOT USED, use an GREASES

engine oil that conforms to one of the following speci-
Use John Deere AT30408 High Temperature
fications.
Grease (1 lb. [0,45 kg] can) or its equivalent. TY6281 is
the same John Deere High Temperature Grease in a
Single Viscosity Oils
14 oz. (0.39 kg) cartridge. Lubricant must be an ex-
API Service CD/SD treme-pressure grease with non-soap base and NGLI
MIL-L-21G4C No, 2 consistency, and must meet John Deere JDM
J13 E4 specifications. Wheel bearing grease is rec-
Multi- Viscosity Oils ommended for front wheel bearings. Application of
grease as instructed in the lubrication section will pro-
API Service CC/SE, CC/SD T
or SD
vide proper lubrication and will prevent bearing con-
M1L-L-46152
tamination.
Depending on the expected atmospheric tempera-

ture at start for the fill period, use oil of viscosity as
GEAR LUBRICANTS
shown in the following chart. Use John Deere Gear Lubricant or an equivalent
SCL Multipurpose-Type gear oi! meeting API designa-
Some increase in oil consumption may be expected tion GL-4 in the Hi-Crop final drive housing.
when SAE 5W-2G or SAE SWoils are used. Check oil
level more frequently. STORING LUBRICANTS

Your tractor can operate at top efficiency only if
clean lubricants are used. Use clean containers to

handle all lubricants. Store them in an area protected
from dust, moisture, and other contamination.

10-15-2 Lubrication General
GENERAL INFORMATION
Carefully written and illustrated instructions are in- For your convenience when servicing the tractor, the
cluded in the tractor operator's manual. Remind your following chart shows capacities and types of lubri-
customer to follow the recommendations in these in- cants for the various components-
structions.
Type of Lubricant Interval of Service

Component Capacity
Engine Crankcase 17 U.S, quarts (16 L) See "Engine Lubricating Oils' 10 Hours Check level
(includes filter) on page 1 100 Hours Change oil
200 Hours Replace filter
200 Hours Clean breather

filter
Transmission and See page 00-2 John Deere HY-GARD Transmission 200 Hours Check level
Hydraulic System and Hydraulic Oil 200 Hours Replace on

filter
Perma-Clutch tractors
600 Hours Replace filter
on Power tractors
Shift
1200 Hours Change oil
1200 Hours Clean main

pump screen
Hi-Crop Final 2 U.S, quarts Above 32*F (0C), use John Deere 200 Hours Check level
Drive Housings (2L) SAE 90 Gear Lubricant or 1200 Hours Change Oil
its equivalent; below 32F (0C),
use John Deere SAE 80

Gear Lubricant or its
equivalent
Front Wheel
Bearings Wheel Bearing Grease 1200 Hours Repack bearings
Grease Fittings John Deere High Tempera- See pages 6 through 8

ture Grease
ENGINE CRANKCASE With the tractor on level ground and the engine
stopped for 10 minutes or more, remove the dipstick.
Checking Oil Level Observe the engine oil level on the dipstick, with the
dipstick seated evenly. If the oil level is down to the
lower marks on the dipstick, add sufficient John Deere
TORQ-GARD SUPREME Engine Oil or its equivalent
of the proper viscosity to bring the level to the upper
marks.
SERVICE INTERVAL: At predelivery and after every

10 hours.
Fig. 1-Crankcase Dipstick and Filler Cap
TM-1181 (Jun-80) Lltho in USA. Tractors - 4040 and 4240

Changing Oil and Filter While draining the crankcase oil, change the crank-
case oil filter (C). Remove the filter element by turning
it counterclockwise. Clean the filter mounting pad. In-
stall new sealing ring. Apply a thin film of oil to the
sealing ring and screw the new element in place by

hand until it is tight.
IMPORTANT: The element does not have a by-

pass valve. Replace only with a genuine John
Deere filter element.
SERVICE INTERVAL: Every 200 hours.
TRANSMISSION AND HYDRAULIC

SYSTEM
Checking Oil Level
A Crankcase Drain Plug C Filter Element

B Fitter Drain Plug
Fig. 2-Crankcase Drain Plug
With the engine warm, remove the crankcase drain

plug (A, Fig. 2) and drain the oil from the crankcase.
Also remove the o\\ filter drain plug (B) and drain the
filter.
Install the drain plugs and add new John Deere

TORQ-GARD Engine Oil or its equivalent of the proper
viscosity (page 1), Run the engine at slow idle speed, Fig. 3-Transmission-Hydrautic System Dipstick
Check for leaks around the
crankcase drain plug.
Retighten if necessary. The oil level on the dipstick 10 With the tractor on level ground, run the engine for a
minutes after stopping should be at the upper marks. minute to fill the filter. Stop the engine and check the
The capacity is 17 U.S. quarts (16 L). transmission-hydraulic system oil level with the dip-
stick. If the oil level is down to the "ADD" mark at the
Keep a record of all oil and filter changes on the bottom of the "SAFE" range on the dipstick, remove
stickers that come with the filters. the filler cap and add John Deere HY-GARD Trans-
mission and Hydraulic Oil or its equivalent to bring the
SERVICE INTERVAL: Every 100 hours. oil level up to the top of the "SAFE" range.
SERVICE INTERVAL: At predelivery and every 200

hours.

1 0-1 5-4 Lubrication General
Changing Filter Elements Reinstall plugs and fill system with John Deere
HY-GARD Transmission and Hydraulic Oil or its
equivalent. Capacities are listed below. Check oil level
after filling and again after operating.
Transmission-hydraulic system drain and fill

Power Shift Transmission .11.0 U.S. gal. (41.6 L)
QUAD-RANGE or Synchro-
Range Transmission 13.0 U.S. gal. (49.2 L)
Power Front Wheel Drive . . 4.0 U.S. gal. (15.1 L)
Transmission-hydraulic system (dry, production fill)

Power Shift Transmission 15.9 U.S. gal. (60.3 L)
.
QUAD-RANGE Synchro- or
Range Transmission 15.9 U.S. gal. (60.3 L)
Power Front-wheel Drive ... 5.0 U.S. gal. (18.9 L)
Fig. 4-Transmission-Hydcauiic Filter Covers

(Power Shift Shown)
With engine stopped, remove transmission-hydrau-

lic system oil filter cover. On tractors with Power Shift
transmission, remove both covers.
Replace filter element or elements. Replace cover

gasket. Replace cover and tighten to 45 ft-lbs (60 N-m)
(6 kgm).
SERVICE INTERVAL: After the first 100 hours. Then

every 200 hours on all QUAD-RANGE. Every 600
hours on Power Shift.
Fig. 6-Power Front-Wheef Drive Drain Piug

Changing Oil
On Power Front-Wheel Drive tractors, position the
drain piug on the wheel at the bottom, clean the area

around the plug, protect the tire, and drain each wheel
housing. Position the drain hole near the top and put 2
quarts (2 L) of John Deere HY-GARD Transmission
and Hydraulic Oil or its equivalent in each front wheel.
Install the drain plugs. With transmission oil level at the
7
top of the "SAFE '

range, add 2 extra gallons (8 L) to
transmission. Operate the front drive for 2 or 3 hours
and ADD oil to the transmission to bring it to the proper
level. The front wheels hold approximately 2-1/4 gal-
lons (9 L) each.
ATransmission Case Drain Plug SERVICE INTERVAL: Every 1200 hours.
BClutch Housing Drain Plug

Fig. 5-Transmission-Hydrauiic System Drain Plugs
With the engine warm, remove the transmission

case drain plug (A, Fig. 5}. On QUAD-RANGE, also
remove clutch housing drain plug (B).

General Lubrication 10-1 5-5
Cleaning Breather Filter and Main Pump HI-CROP FINAL DRIVE HOUSINGS
Screen
> Checking Oil Level
A Dipstick BFiller Cap

Fig. 7-Tran$mission-Hydraufic System Filler Cap
Remove transmission-hydraulic system filler cap.

Wash breather filter in solvent, and blow it dry with
compressed air.
SERVICE INTERVAL: Every 200 hours..
AOil Level Plug C Drain Plug

B Filler Plug
Fig. 9-Hi-Crop Final Drive Housing
Remove oil from each final drive

level plug (A, Fig. 9)
housing and check oii add gear lubricant at
level. If low,
fifler plug (B), Use John Deere Gear Lubricant or its
equivalent. Use SAE 90 at temperatures above 32F

D
(0 C) and SAE 80 at temperatures below 32T (0C).
Changing Oil
Remove dram plug (C Fig. 9) from each final drive

t
housing and drain oii. Replace drain plugs and remove

Fig. 8-Main Hydraulic Pump Screen
filler plugs. Add 2 LIS, quarts (2 I) of John Deere Gear
Lubricant or its equivalent to each housing. Use SAE

Remove plug (Fig. 8) from bottom of main hydraulic
pump, and remove screen from hole. Wash screen in 90 at temperatures above 32F (0C) and SAE 80 at
solvent, and blow it dry with compressed air. Reinstall
temperatures below 32F (0C).
screen and plug.

FRONT WHEEL BEARINGS GREASE FITTINGS

Cleaning and Packing Bearings Lubricating Front Axle
If tractor has a wide front axle, apply several shots of
John Deere High Temperature Grease or its equivalent

to tie rods, the pivot pins, and the steering spindles (10
On Hi-Crop tractors with radius rods, also
fittings).
apply several shots of grease to the radius rod pivot

grease fitting.
-<E>
A--OH Seal D Bearings

BOH Seal Cup E Adjusting Nut
C Hub F Hub Cap
Fig. 10-Front Wheel Bearings
1. Jack up front axle.
Fig. 11 -Wide Front Axte Grease Fittings

2. Remove hub cap. Remove cotter pin and adjust-
ing nut
3. Disassemble parts. Clean parts in solvent and

blow them dry with compressed air.
4. Inspect parts damage. Replace

carefully for
bearings if seal and oil seal

they are worn. Replace oil
cup if three deep grooves are worn in cup.
5. Pack bearings with wheel bearing grease. Pack

seal with John Deere AT30408 High Temperature
lips Fig. 12-Radius Rod Pivot Grease Fitting
Grease (1 lb. [0.45 kg] can) or its equivalent. TY6281 is

the same John Deere High Temperature Grease in a SERVICE INTERVAL: At predelivery and every 10
14 oz. (0.39 kg) cartridge. Lubricant must be an ex- hours.
treme-pressure grease with non-soap base and NGLi
No. 2 consistency, and must meet John Deere JDM
J13 E4 specifications.
6. Reassemble parts. Tighten adjusting nut until a

slight drag is felt when wheel is turned. Back nut off just
enough to insert cotter pin in first hole.
7. Reinstall hub cap.

Lubricating Wide-Swing Drawbar Lubricating Front Wheels
Fig. 15-Front Wheel Grease Fitting
When the tractor is being operated in extremely wet

Fig. 13-Wide-Swing Drawbar Grease Fittings and muddy conditions, grease each front wheel (ex-
cept Power Front-Wheel Drive) daily or every 10 hours.
If the tractor has a wide-swing drawbar, apply sev- To do so, remove the pipe plugs, install fittings, and
eral shots of John Deere High Temperature Grease or apply several shots of John Deere High Temperature
its equivalent to the drawbar rollers. Grease or its equivalent CONTINUE lubricating the
frontwheels at this interval until the bearings can be
SERVICE INTERVAL: At predelivery and every 10 cleaned and packed with wheel bearing grease.
hours.
SERVICE INTERVAL: Only tractor if is operated in
Lubricating Hi-Crop Rear Axles extremely wet and muddy conditions, lubricate every
10 hours until bearings can be cleaned and packed as
instructed on page 6.
Lubricating 3-Point Hitch
Fig. 16-3-Point Hitch Grease Fittings
Grease the 3-point hitch by applying 3 or 4 shots of

3 2718D.H
John Deere High Temperature Grease or its equivalent
Fig. 14-Hi-Crop Rear Axle Grease Fitting at each fitting.
Hi-Crop tractors, apply several shots of John

On SERVICE INTERVAL: At predelivery and every 200
Deere High Temperature Grease or its equivalent to hours.
the grease fittings on the ends of the rear axles.

\
hours.

Lubricating Load Control Shaft Bushings Lubricating Rear Axle Bearings
Fig. 18-Rear Axle Grease Plug
Grease the rear axle bearings by removing the pipe

plug on each end of the axle housing, installing a
grease fitting, and applying John Deere High Temper-
ature Grease or its equivalent at each fitting until
Fig. 17-Load Control Shaft Bushing grease appears at the axle seals, (If rear wheel weights
Grease Fitting obscure rear axle seal, apply a maximum of 25 shots of
grease.)
Apply two shots of John Deere High Temperature
Grease or its equivalent to each load control shaft SERVICE INTERVAL: At predelivery and every 600
bushing (one on each side of tractor). hours.

hours.
TM-1181 (Jun-80) Litho in USA, Tractors - 4040 and 4240

General Separation 10-20-1
Group 20
SEPARATION
REMOVING SOUND-GARD BODY WITHOUT CONTROL SUPPORT
Fig. 1-Rerpoving Sound-Gard Body Without Control Support
NOTE: Either the Brown Body Lift (shown) or a fork lift with Fork Lift Adapters (see special toots) may be used to
remove Sound-Gard Body.
NOTE: On tractor with a Power Shift transmission,

the Sound-Gard Body can be removed with the controi
support to facilitate service of the rear clutch pack,
planetary, and PTO gear train. The control support
need not be removed with the Sound-Gard Body when
servicing components of Quad- Range transmission.
Removal
1. (Not Illustrated). Disconnect battery ground
cable.
2. (Not Illustrated). On tractors equipped with a

heater, drain the cooling system.
Fig. 2-Removing Muffler, Screens and Cowling
3. Remove muffler.
4. Remove left- and right-hand grille screens.
TM-1181 (Feb-79) Litho in U.S.A. Tractors - 4040 and 4240

.
10-20-2 Separation General
RemovalContinued 15. Disconnect left-hand wiring lead (Fig. 4). (Con-

nector is located under control support,)
5. Remove left- and right-hand side shields (see
Fig. 2).
16. Remove Sound-Gard Body-to-control support
6. (Not Illustrated). Disconnect hood latches. bracket cap screws.
Remove hood (see Fig.
A
7. 2).
CAUTION: Refrigerant-12 by itself is harm-
8. Remove left- and right-hand cowling (see Fig. 2). less and non-poisonous; however, special
precautions should be taken when servicing any
9. (Not Illustrated). Remove floor mat.
refrigerant air conditioning system or handling re-
frigerant fines.
a. Do not expose eyes or skin to liquid refrigerant.

Always wear safety goggles when opening refrigerant
lines. Liquid Refrigerant-12 has a boiling temperature
of approximately -21F (-29C) at sea level; there-
fore, serious injury could result if liquid refrigerant
contacts the eye or skin. If Refrigerant-12 strikes the
eye, call a doctor IMMEDIATELY and:
Do not rub the eye. Splash cold water on the eye to

gradually raise the temperature of the contacted area.
If the liquid refrigerant comes in contact with the

skin, treat the injury as though it were frozen or frost-
bitten,
b. Do
not discharge refrigerant into an area where
Fig. 3-Removing Battery Box Covers and Cap Screws there exposed flame. Heavy concentrations of re-
is
frigerant-12 contacting an open flame will produce a

10. Remove left- and right-hand cab floor filler
poisonous gas.
panels.
1 1 Remove left- and right-hand battery box covers. a Do not weld or steam clean on an air conditioning
system. Excessive pressure could be built-up within
12. (Not Illustrated). Remove batteries and battery the system.
boxes.
Remove d. Before loosening a refrigerant fitting, cover the

13. left- and right-hand riser panels.
connection with a cloth.
cap screws. IMPORTANT: Keep ends of couplers clean to
prevent possible contamination of system*
17. Disconnect refrigerant couplers on tractors with

air conditioning. Disconnect couplers by holding
coupler body (A, Fig. 4) stationary with a wrench and
unscrewing coupler (B) with another wrench.
18. (Not Illustrated). Remove clamp on high pres-

sure refrigerant line located near refrigerant couplers.
A Coupler Body
B Coupler
Fig, 4-Disconnecting Couplers and Wiring

General Separation 1 0-20-3
24. (Not Illustrated). Remove heater hose-to-body

clamps (located inside of right-hand fender well).
NOTE: Identify supply and return hoses for proper

installation (Fig. 6).
25. Disconnect heater hoses.
Fig. 5-Disconnecting Linkage
19. Remove control support-to-Sound-Gard Body

cap screws (left- and right-hand sides).
Fig. 7-Measuring Placement of Hydraulic
Control Inner Support
20. Disconnect speed control rod from inner arm.
21. Remove shifter rods from shifter arms (Quad- 26. Measure distance between hydraulic control
Range). On tractors with a power shift transmission, inner support and Sound-Gard Body to insure that
remove transmission control cable clamps, and re-
support is reinstalled in its original position (Fig. 7).
move control cables from control valve arms.
22. Remove neutral-start switch wiring.
23. Remove speed range selector (ever from arm.
NOTE: On tractors with a Quad-Range transmis-

sion and Power Front-Wheel Drive, disconnect e/ecfir/-
cal connector located under shifter controls. On trac-
tors with a Power Shift transmission and Power
Front-Wheel Drive, disconnect wiring from switches on
transmission.
Fig. 8-Disconnecting Control Linkage
27. Disconnect rockshaft operating rod from control

arm on rockshaft.
28. Disconnect load selective control valve rod from

control arm on rockshaft.
29. Disconnect selective control valve rods from

ASupply Hose BReturn Hose operating arms on selective control valve.
Fig. 6-Discormecting Healer Hoses 30. Remove two cap screws securing support
bracket to rockshaft.
TM-1181 (Feb-79) Litho in USA. Tractors - 4040 and 4240

Removal Continued
Fig. 9-$ecuring Control Rods
31. Wire selective control valve rods and rockshaft Fig. 11 -Sound-Gard Body Removed from Tractor
control rods to remote cylinder transport bracket.

37. Remove Sound-Gard Body and place on sup-
32. (Not Illustrated). Disconnect both lift finks from port stand (Fig. 11).
rockshaft lift arms.

Installation
33- (Not Illustrated). Remove both draft links from
Reverse the removal steps given on the preceding
draft link support.
pages and note the special installation instructions
which follow.
1. Tighten Sound-Gard Body mounting cap screws

to 150 ft-lbs (203 Nm).
NOTE: Roll-Gard mounting cap screws are also

tightened to the above torque.
Brush refrigerant oil on tube ends immediately

2.
before assembly. Tighten pressure line coupling to 35 -

40 lbs- (48 - 54 Nm).. Tighten return line to 45 - 50 lbs.
(61 - 68 Nm).
3. Check for leaks around couplers (p. 290-05-12)

after assembly.
NOTE: Make sure that the selective control valve

Fig. 10-Removing Hoses control support is in the same position as before re-
moval.
34. Remove seat pressure hose (if equipped).
35. Remove seat return hose.
36. (Not Illustrated), Remove left and right cab-to-

rear axle mounts.
TM-1181 (Feb-79) Litho in U.S.A. Tractors * 4040 and 4240

REMOVING SOUND-GARD BODY WITH CONTROL SUPPORT
Fig. 12-Removing Sound-Gard Body With Control Support
Removal 4. Remove left and right-hand grill screens.
1. (Not Illustrated). Disconnect battery ground 5. Remove left and right-hand side shields.
cable.
6. (Not Illustrated). Disconnect hood latches.
2. (Not Illustrated). On tractors equipped with a
7. Remove hood.
heater, drain the cooling system.
8. Remove left and right-hand cowling.
9. (Not Illustrated). Remove floor mat.
Fig, 13-Removing Muffler, Screens and Cowling

Fig. 14-Removing Battery Box Covers and Riser Panels
3. Remove muffler.

Removal Continued 14. Remove clamp on high pressure refrigerant

line.
10. Remove left- and right-hand battery box cover
(see Fig. 13).
15. Disconnect left-hand wiring lead (Under control
11. (Not Illustrated). Remove batteries and battery support).
boxes.
16. Disconnect left-hand brake oil line.
12. Remove left- and right-hand riser panels (see
Fig. 14).
A CAUTION: Follow
found on page 10-20-2 when
the air conditioning system.
all safety precautions
working with
capscrews (left- and right-hand sides).
IMPORTANT: Keep ends of couplers clean to

prevent possible contamination of system.
Ftg, 15-Di$charging Accumulator
A CAUTION: Before disconnecting brake

pressure lines, be sure that the brake ac-
cumulator is discharged. The accumulator can be
18.
Fig. 17-Disconnecting Linkage
Disconnect speed control rod from inner arm.
discharged by opening the right-hand brake bleed

screw (Fig. 15), and holding the pedal down for a
19. Remove shifter rods from shifter arms (Quad-
few minutes.
Range). On tractors with a Power Shift transmission,
remove transmission control cable clamps, and re-
move control cables from control valve arms.
20. Disconnect sound-gard body wiring.
21. Remove the sound-gard body mounting cap-

screws (left- and right-hand sides).
22. Remove neutral-start switch wiring.
23. Remove speed range selector lever from arm.

ACoupler Body BCoupler
NOTE: On tractor with a Quad-Range transmission
Fig. 16-Disconnecting Couplers and Wiring
and power front-wheel drive, disconnect electrical
connector located under shifter controls. On tractors
13. Disconnect couplers on tractors with air condi-
with a Power shift transmission and Power Front-
tioning by holding coupler body (A, Fig. 16), stationary Wheel drive, disconnect wiring from switches on
with a wrench, and unscrewing coupler (B) with an- transmission.
other wrench. If can be heard escaping as
refrigerant
coupler is loosened, retighten coupler and loosen
again.

24. Disconnect right-hand brake oil line. 35. (Not Illustrated.) Disconnect clutch pedal rod
25. Disconnect differential lock oil line. from clutch control arm on clutch housing.
36. (Not illustrated). Disconnect PTO operating rod

from operating valve under footrest.
Fig. 18-Disconnecting Heater Hoses
26. (Not Illustrated.) Remove heater hose -to- body

clamps (located inside of right-hand fender well).
NOTE: identify supply and return hoses for proper
installation. (Fig. 18).
Fig. 20-Removing Starting Circuit Relay
27. Disconnect heater hoses.
37. Remove starting circuit relay from control sup-

port.
38. Remove cab electrical load wire from relay.
NOTE: On tractors with a Power Front-Wheel drive,

disconnect wiring from connector near starting circuit
relay,
39. (Not Illustrated.) Disconnect light dimmer switch

wiring from dimmer switch.
Fig. 19-Disconnecting Cables and Wiring
28. (Not Illustrated.) Thoroughly clean area around

steering valve.
29. Disconnect steering metering pump -to- steer- }ft 27495N
ing valve lines from steering valve.
Fig. 21 -Measuring Placement of Hydraulic
30. Disconnect fuel shut-off cable from injection Control inner Support
pump.
31. Disconnect tachometer drive cable. 40. Measure distance between hydraulic control
32. Remove speed control cable clamp (located inner support and SOUND-GARD Body to insure that
support is reinstalled in its original position (Fig. 21).

under control support).
33. Disconnect speed control linkage at turnbuckle.
34. Remove main wiring harness connector from
control support.
NOTE: To remove connector, remove capscrew lo-
cated in center of connector.
TM-1181 (Jun-80) Litho in U.SA. Tractors - 4040 and 4240

Removal Continued
Fig. 24-Removing Hoses
48. Remove seat pressure hose (if equipped).
Fig. 22-Disconnecting Control Linkage

49. Remove seat return hose (if equipped).
41. Disconnect load selective control rod from con-
trol arm on rockshaft. 50. (Not Illustrated.) Remove left and right cab-to-
42. Disconnect selective control vafve rods from rear axle mounts.
operating arms on selective control vatve.
43. Disconnect rockshaft operating rod from control 51. Remove SOUND-GARD Body with control
arm on rockshaft, support.

44. Remove two capscrews securing support
bracket to rockshaft.
. R 27488N
Fig. 25-SOUND-GARD Body with Control Support
Installation
Fig. 23-Securing Control Rods Reverse the removal steps given on the preceding
45. Wire selective control valve and rockshaft con-
which follow.
trol rods to remote cylinder transport bracket.
46. (Not Illustrated.) Disconnect both lift links from

rockshaft lift arms.
47. (Not Illustrated .) Remove both draft links from
draft link support.
TM-1181 (Jun-80) Utho in USA. Tractors - 4040 and 4240

2. Tighten SOUND-GARD Body mounting cap

screws to 150 ft-lbs (203 N-m).
NOTE: ROLL-GARD mounting cap screws are also

tightened to the above torque.
3. (Not Illustrated.) Brush refrigerant oil on tube

ends immediately before assembly.
4. (Not Illustrated.) Check for leaks around couplers

(p. 290-05-12) after assembly.
5. (Not illustrated.) After installation is complete,

perform the following steps in bleeding the brakes:
BLEEDING THE BRAKES

a. Start the engine.
A Nut E Mount JSpacer
B Washer F Front Bracket
K Cap Screw b. Loosen brake bleed screw lock nuts on both
CControl Support G Sleeve LShim 0.035 in.
sides of transmission case.
Bracket H Mount (0,91 mm)
0 Washers I Washer MShim 0.021 in.
(0.53 mm) c. Turn bleed screws out two turns.
Fig. 25a-Front Mount

d. Tighten lock nuts.
^r^T
>, J e. Depress brake pedals for two minutes.
f. While pedals are being held down, retighten the

bleed screws.
g. Tighten the lock nuts.
R34488
A Special Screw E Mount -Shim 0.035 in.
B Washer FWasher (0.91 mm)

C Mount G Spacer -Shim 0.021 in.
D Mounting Range H Spacer (0.53 mm)
Fig. 25b-Rear Mount
1. Assemble SOUND-GARD Body mounts as

shown in Figs. 25a and 25b. Make
sure identification
marks on special washers (D, Fig. 25a) face upward.
Shims (J and J, Fig. 25b, and L and M, Fig. 25a) may be
used to change SOUND-GARD Body ride. Adding thin
shims (J, Fig. 25b and M, Fig, 25a) will make a more
stiff ride. Adding thick shims (I, Fig. 25b and L, Fig.
25a) will make a softer ride. There should not be more

than four thin or three thick shims on any mount.

SEPARATING ENGINE FROM CLUTCH HOUSING
Fig, 26-Separating Engine From Clutch Housing
Removal
Ftg. 27-Dtscharging Accumulator
/L CAUTION: Before separating tractor, be

" sure that the brake accumulator is dis-
J?a M
charged. The accumulator can be discharged by IMPORTANT: On tractors with a PER MA-
opening the right-hand brake bleed screw (Fig. 27), CLUTCH, remove hexagonal transmission
the
and holding the brake pedal down for a few min- pump drive shaft from rear of transmission case*
utes. 1. Remove center link attaching bracket.
2. Remove plug.
3. Carefully withdraw transmission pump drive
shaft.
4. (Not illustrated.) Put tractor in the "Park" posi-
tion.

5. (Not Illustrated.) Disconnect battery ground 8. Remove left- and right-hand grill screens.
cable. 9. Remove left- and right-hand side shields.
) 10. Remove hood latches.
6. (Not Illustrated.) On tractors equipped with a 11. Remove hood.
heater, drain the cooling system. 12. Remove left- and right-hand battery box covers.
13. Remove batteries and battery boxes.
14. Remove main harness connector from control
support.
NOTE: To remove connector, remove capscrew lo-
cated in center of connector. Remove upper half from
lower half.
15. Disconnect hydraulic oil cooler return pipe.
16. (Not illustrated) Disconnect heater return hose
(if equipped) from top of water pump housing.
17. Disconnect hydraulic pump seal drain line at
transmission.
18. Disconnect hydraulic pump pressure pipe.
19. (Not illustrated) Disconnect start safety switch
wiring from transmission.
20. Disconnect speed control rod at turnbuckle.
21. Remove tachometer drive cable from housing.
Fig. 29-Removing Muffler, Screens and Shields
7. Remove muffler.
>
Fig. 30-Right Side Removal Procedures

Removal Continued
A Coupler Body BCoupler

Fig. 3ULeft Side Removal Procedures
22. Disconnect fuel shut-off cable. 30. Disconnect refrigerant couplers on tractors with
air conditioning by holding coupler body (A, Frg. 31)
23. Thoroughly clean area around steering pipes at stationary with awrench and unscrewing coupler (B)
control support, and disconnect. with another wrench. If refrigerant can be heard
escaping as coupler is loosened, retighten coupfer and
24. Remove starting circuit relay from control sup- loosen again.
port.
25. Remove cab electrical load wire from relay,
26. (Not illustrated.) Disconnect clutch pressure

sending wire from connector near starting circuit relay.
27. Disconnect heater supply hose (if equipped).
28. Disconnect hydraulic pump return line.
29. (Not Illustrated.) On tractors with power front-

wheel drive, disconnect the drain pipe. Fig. 32-Removing Air Bfeed Line
A CAUTION: Follow all safety precautions

found on page 10-20-2 when working with
the air conditioning system.
31. Remove reservoir air bleed line from valve.
i
TM-1181 (Jun-80) Litho in US.A t Tractors - 4040 and 4240

General
Separation 10-20-1 3
Installation
> Revise the removal steps on the preceding pages

and note the special installation instructions which
follow.
1. (Not Illustrated). On tractors with a Quad-Range

transmission, apply a light coat of Permatex No. 3 to
the block bolting flange where block and oil pan make
contact.
2. (Not Illustrated). On tractors with a Quad-Range

transmission, be sure that the oil pump
drive shaft
bushing is in position before reassembling tractor.
NOTE: some cases during separation,

in the clutch
drive shaft may move toward the engine.
3. Tighten engine -to- clutch housing capscrews to

300 ft-lbs (406 Nm) (40.6 kgm).
Fig. 33-Attaching Splitting Stands

4. Tighten oil pan-to-clutch housing cap screws to
85 ft-lbs (115 Nm) (11.5 kgm).

32. Attach JDG-2M rear splitting stand,
33. Attach JDG-12-1 splitting stand to side frames. 5. If cooling system was drained, refill with JDT 781
non-evaporating antifreeze to 1-1/2 inches over
34. (Not Illustrated). Place a drain pan under the
deairatton baffles.
engine-to-clutch housing parting surface on tractors
with a Quad-Range transmission to catch oil from
6. (Not illustrated). After instaflation is complete
clutch housing as separation is made.
bleed the brakes following the procedure on page
35. (Not Illustrated). Remove oil pan -to- clutch 10-20-26.
housing capscrews.
7. (Not Illustrated). Tighten hydraulic hose clamps
36. (Not Illustrated). Remove clutch housing-to-en-
to 35 in-lbs (3.9 Nm) (39 kgm). Retighten after tractor
gine cap screws.
sits for one hour,
Fig. 34-Engine Separated From dutch Housing
37. Separate engine from clutch housing (Fig. 34).
TM-1181 (Feb-79) Litho in U.S.A.

Tractors - 4040 and 4240
A
1 0-20-1 4 Separation General
REMOVING FRONT END

(
Fig. 35-Removing Front End
Removal 6. Remove hood.
1. (Not Illustrated). Disconnect battery ground

7. Remove left- and right-hand battery box covers.
cable.
2. (Not Illustrated). Drain cooling system. 8. (Not Illustrated)- Disconnect battery cables.
9. Remove batteries and battery boxes.
Fig. 36-Removing Muffler, Screens, and Shields
3- Remove left- and right-hand side shields.
4. Remove left- and right-hand grill screens.
5. Remove muffler.
TM-1181 (Feb-79) Litho in US. Tractors - 4040 and 4240

5
Genera/ Separation 1 0-20-1
Hg. 37-Right Side Removal Steps
11. (Not Illustrated). Remove tool box and bracket. 18. (Not Illustrated). Close fuel shut-off valve.
12. Disconnect hydraulic oil cooler return pipe. 19. Disconnect fuel tank -to- injection pump line at
injection pump.
13- Remove plastic ties securing oil cooler return
line to reservoir air bleed line. 20. Remove pressure pipe clamp -to- side frame
capscrew.
14. Thoroughly clean area around steering valve
and disconnect steering valve -to- steering motor pipes 21. Disconnect hydraulic pump return line.
from steering vaJve.
22. Remove pump seal drain line from top of clutch
15. Disconnect horn wiring (if equipped), housing.
16.
17.
Disconnect wiring
Disconnect
at fuel sender.
air conditioning wire (if equipped).

A
the air
CAUTION: Follow all safety precautions
found on page 10-20-2 when working with
conditioning system.
IMPORTANT: Keep ends of couplers clean to

prevent possible contamination of system.

Removal Continued
Fig. 38-Left Side Removal Steps
23. (Not illustrated). Disconnect refrigerant couplers

on tractors with air conditioning.
NOTE: Disconnect couplers by holding the coupler

body stationary with a wrench and unscrewing coupler
with another wrench. If refrigerant can be heard
escaping as coupler is loosened, retighten coupler and
loosen again.
24. Remove upper radiator hose from radiator.
25. Disconnect hydraulic pump return line.

Fig. 39-Removing Fuel Line
26. (Not illustrated). Remove wiring from thermal 31 , Remove fuel line from fuel tank.
fuse on compressor (if equipped).
27. (Not illustrated). Remove refrigerant line clamp

at radiator hose.
28. (Not illustrated). Remove air conditioning com-

pressor with refrigerant lines attached and secure to
front axle.
29. Disconnect lower radiator hose from water

Fig. 40-Removing Air Bleed Line
pump.
32. Remove air bleed line from valve.
30. Disconnect air intake hose from manifold.

Rg. 41 -Hydraulic Pump Drive Coupling

(Engine Removed for Illustration Purposes)
33. Remove hydraulic pump drive coupling. Fig. 43-Positioning Floor Jack and Stands
(Side frames removed for illustration purposes.)
34. Remove hydraulic pump support bracket -to-

engine capscrews. 36. Position a floor jack under clutch housing -to-
engine parting surface.
37. Install floor stands as shown in Fig, 43.
38. Remove side frame -to- engine capscrews.
Ftg. 42-Attaching Splitting Stand

R 27453N "ft-- "./v?- ..
_.,..,
35. Attach JDG-12-1 Splitting Stand with Attach- Fig. 44-Front End Removed
ments to tractor (Fig, 42).
39. Roll front end away from engine.
TM-1181 (Feb-79) Utho in U.SA. Tractors - 4040 and 4240

Installation 6, Adjust compressor drive belt, using a belt tension
gauge, to 130-140 lbs. (578-622 N) on a new belt or

85-94 lbs. (378-423 N) after run in.
which follow.
IMPORTANT: Do not tension or release belt
1. Tighten side frame -to- engine capscrews: when it is hot.
5/8 in 275 ft-lbs (373 Nm) (37.3 kgm).
3/4 in 425 ft-lbs (578 Nm) (57.8 kgm). Immediately after run in (approximately 10 min.)
check tension. If tension is within specification, no
2. Tighten hydraulic pump support -to- engine cap-
adjustment necessary. If tension is not within speci-
is
screws to 85 ft-lbs (115 Nm) (11.5 kgm).
fication, wait ten minutes; loosen belt and tension to
3. Tighten hydraulic pump drive shaft -to- pump specification,
shaft clamping screws to 35 ft-lbs (47 Nm) (4.7 kgm).
7. If coolant was lost, add JDT 781 non-evaporating
Brush #525 Refrigerant Oil on all refrigerant line
4.
anti-freeze to radiator and fill to 1-1/2 inches over
Oring packings and tube ends immediately before
de-airation baffles.
assembly and before connections are made. Tighten
pressure fine coupling to 35 - 40 lbs. (AS - 54 Nm).
Tighten return line to 45 - 50 lbs. (61 - 68 Nm).
5. (Not Illustrated). Tighten hydraulic hose clamps

to 35 in-lbs (3.9 Nm) (39 kgm). Retighten after letting
tractor sit for one hour.
REMOVING ENGINE
cf]Q
D a OC3 k3
R 29699N
Fig. 45~Removing Engine

{

.
Removal
1. Remove front end as previously instructed.
Ftg. 46- Right Side Removal Steps
2. Remove leak-off iine-to-bracket line clamp.
3. Remove leak-off line from injection nozzle, ,
4. Remove fuel shut-off cable from injection pump.
5. Remove tachometer drive cable from tachometer

housing.
6. Remove wire from oil pressure sending unit,
7. Disconnect speed control cable at turnbuckle.
8. Remove water manifold-to-water pump pipe.
9. (Not Illustrated) Remove heater hose from water Fig. 47-Left Side Removal Steps
pump (if equipped).
1 1 Remove steering lines from control support.
10. (Not Illustrated) Disconnect ether aid wiring
from ether aid (if equipped). 12. Remove wiring from temperature sender.
13. (Not Ulustrated) Disconnect heater supply hose

(if equipped).
I 14. Disconnect wiring from starter solenoid.

Removal Continued 18. Remove oil pan -to- clutch housing capscrews.
19. Remove clutch housing -to- engine capscrews.
20. Carefully remove engine from clutch housing,

and place in support stand.
IMPORTANT: If engine is to be turned upside

down for repair and cylinder head is not to be
removed, remove drain plug from base of oil filter
housing and drain out oiL This will prevent oil from
draining into the cylinder head, causing oil blow-
out when restarting engine.
Installation

which follow.
1. (Not Illustrated). Apply a light coat of Permatex
Fig. 48-Attaching Engine Lift Sling No. 3 to the block bolting flange where block and oil
pan make contact.
15. Attach JDE-63 Engine Lift Brackets to cylinder
head. 2. (Not illustrated). On tractors with a Quad-Range
transmission, be sure that the transmission oil pump
16. Attach JDG-23 Engine Lift Sling to brackets. drive shaft bushing is in position before reassembling
tractor.
17. Attach a chain hoist with a one ton capacity or
greater to lift sfrng. 3. Tighten clutch housing to engine capscrews to
300 ft-Jbs (406 N-m) (40.6 kgm).
4. Tighten oil pan -to- clutch housing capscrews to

85 ft-lbs (115 N*m) (11.5 kgm).
5. Tighten tachometer drive cable nut to tacho-

meter drive gear housing finger tight plus 1/2 turn with
wrench.

REMOVING CLUTCH HOUSING FROM POWERSHIFT TRANSMISSION
Fig. 50-Removing dutch Housing From Power Shift Transmission Case
Removal
NOTE: If access to the rear clutch pack, planetary

pack or PTO gear train is desired, remove the Sound-
Gard body with control support, and separate the en-
gine from the clutch housing as previously instructed. If
access to only the front dutch pack is desired, only
separate the engine from the clutch housing.
1. (Not Illustrated), Separate the engine from the

clutch housing as previously instructed.
2. (Not Illustrated). Drain the transmission.
Fig. 51 -Clutch Pack and Transmission Pump
3. Remove dutch pack -to- housing capscrews.
4. Remove clutch pack and transmission pump as-

sembly.

Removal Continued
Fig. 54-Removing Hoses
10. Remove seat return hose.

Fig. 52-Right Side Removal Steps
11. Remove reservoir vent tube hose.

5. Remove pressure oil manifold -to- clutch housing
capscrews. 12. Remove oil cooler return hose.
6. Remove pressure oil manifold -to- attenuator 13. Remove hood support bracket.
hose from attenuator.
7. Remove Sound-Gard Body mounting bracket

-to- clutch housing capscrews.
8. Remove transmission oil pump intake elbow.
Fig. 55-Capscrews
14. Remove two hidden clutch housing -to- trans-

mission capscrews.
Fig. 53-Left Side Removal Steps
9. Remove oil filter to regulator housing pipe.
TM-1181 (Feb-79) Litho in US, A Tractors - 4040 and 4240

Installation
Reverse the removal steps on the preceding pages,

follow.
1- (Not Illustrated). Insure that"O" rings between

clutch housing and transmission are in position before
assembly.
2. (Not Illustrated). Tighten the clutch housing -to-

transmission capscrews.
5/8 inch 170 ft-lbs (230 Nm) (23 kgm)
3/4 inch 300 ft-lbs (406 Nm) (40.6 kgm)
3. (Not Illustrated). Tighten oil filter inlet pipe elbow

capscrews to 45 ft-lbs (61 Nm) (6.1 kgm).
Fig. 56~Attaching Chain Hoist
15. Attach JDG-19 Lift Eyes to clutch housing.
16. Attach a chain hoist and chain with a 400 lb.
(181 kg) capacity or greater to clutch housing.
17. Remove clutch housing -to- transmission case

capscrews.
IMPORTANT: When separating clutch housing

from transmission case, do not lose small rubber
"O" rings.
18. (Not Illustrated). Separate clutch housing from

transmission case.

1 0-20*24 Separation General
SEPARATING CLUTCH HOUSING FROM QUAD-RANGE TRANSMISSION
Fig. 57-Separating Clutch Housing from Quad-Range Transmission Case
Removal 3- Remove center fink attaching bracket.
1. Remove Sound-Gard Body without control sup- 4. Remove plug.

port.
2. Drain the transmission. shaft.
IMPORTANT: Remove hexagonal transmission

pump drive shaft before beginning separation. In-
stall drive shaft last
Fig. 59-Attaching Stands
6. Attach JDG-12-1 Front splitting stand.

Fig. 58-Removing Transmission Pump Drive Shaft

7. Attach JDG-2M Rear splitting stand. 16. Disconnect differential lock pressure line.
17. Disconnect start-safety switch wiring from
transmission case.
18. Remove transmission case -to- clutch housing
capscrews.
19. Remove clutch housing -to- transmission case
capscrews.
20. Remove transmission case cover.
Fig. 60-Left Side Removal Procedures
8. Remove clutch valve pressure oil pipe.
9. Remove oil filter relief by-pass pipe.
10. Disconnect pressure switch wiring.
11. Remove left-hand brake line clamps.

Rg. 62-Cap Screws
12. Disconnect left-hand brake line.

21. Remove the three transmission case-to-clutch
housing cap screws, located inside of transmission
case.
22. Separate dutch housing from transmission
case.
Fig. 61 -Right Side Removal Steps
13. Disconnect rockshaft pressure pipe,
14. Remove brake and differential lock pipe clamps. Fig. 63-Ctutch Housing Separated From Transmission Case
15. Disconnect right-hand brake line.
TM-11S1 (Feb-79) Utho in U.S.A. Tractors - 4040 and 4240

1 0-20-26 Separation Generaf
Installation Bleeding The Brakes

Reverse the removal steps on the preceding pages a. Start the engine.
follow. b. Loosen brake bleed screw lock nuts on both
sides of transmission case.
1. (Not Insure that "O" rings between
Illustrated).
clutch housing and transmission are in position before c. Turn bleed screws out two turns.
assembly,
d. Tighten lock nuts.
2. (Not Illustrated). Tighten the clutch housing -to-
transmission case capscrews. e. Depress brake pedals for two minutes.
5/8 inch 170 ft-lbs (230 Nm) (23 kgm)
3/4 inch 300 ft-lbs (406 Nm) (40.6 kgm) f. While pedals are being held down, retighten the
bleed screws.
3. (Not Illustrated). After installation is complete,
perform the following steps in bleeding the brakes. g. Tighten the lock nuts.
REMOVING REAR AXLE HOUSING
ft 27416N
Fig. 63-Removing Rear Axte Housing
It is not necessary to completely remove the 1. (Not Illustrated) Drain the transmission.
Sound-Gard Body or Roll-Gard to remove rear axle
housing from tractor. However, it is necessary to re- 2. (Not Illustrated) Raise tractor and remove rear
move the Sound-Gard or Roll-Gard rear mounting cap wheel.
screws from the axle housing that is to be removed.
3. (Not Illustrated) Place a support stand under
drawbar support.

General Separation 1 0-20-27
Removal Continued Installation
Reverse the removal steps on the preceding pages,

follow.
Fig. 65-instaiiing Axle Housing

1. When installing axle housing, make sure dowel
pins in housing line up with holes in transmission case.
Fig. 64-Removing Axie Housing 2. (Not Illustrated.) Tighten axle housing-to-trans-

mission case cap screws to 170 ft-lbs (230 N-m) (23
4. Remove SOUND-GARD or ROLL-GARD mount- kgm).
ing cap screw, and remove spacer from axle housing.
5. Remove the differential lock pressure pipe when

removing the right-hand housing.
6. Attach D-05007ST stand with D-05149ST at-

tachments to housing.
7. Remove axle housing-to-transmission case cap

screws.
8. Carefully remove axle housing.

1 0-20-28 Separation General

1
Engine Repair Specifications and Special Tools 20-00-1
Section 20
ENGINE REPAIR
Specifications 20-00-2 Connecting Rods 20-10-4
Special Tools 20-00-4 Removal 20-1 0-4
Inspection and Repair 20-10-4
GROUP 05 - CYLINDER HEAD, VALVES Connecting Rod Bearings 20-10-5
AND CAMSHAFT Cylinder Liners
Preliminary Vaive Checks 20-05-1 Removal, Inspection, and Repair 20-10-5
Checking Vafve Clearance 20-05-1 Deglazing Cylinder Liners 20-10-7
Checking Vafve Lift 20-05-2 Block 20-10-7
Cylinder Head and Valves 20-05-3 Inspection and Repair 20-10-7
Access 20-05-3 Installation 20-10-8
Rocker Arm Assembly 20-05-3 Liners 20-10-8
Removal 20-05-3 Pistons and Connecting Rods 20-10-8
inspection and Repair 20-05-3 Head Gasket Installation 20-10-10
Assembly and Installation 20-05-4
Valves, Valve Springs, Valve Rotators, GROUP 15 - CRANKSHAFT, MAIN BEARINGS
and Wear Caps 20-05-4 AND FLYWHEEL
Removal 20-05-4 Diagnosing Malfunctions 20-15-1
Inspection and Repair . . 20-05-4 Access 20-1 5-1
Vaive Springs 20-05-4 Inspection and Repair 20-15-1
Valves, Rotators and Wear Caps . . . 20-05-4 Damper Pulley 20-15-1
Valve Guides 20-05-5 Front Wear Sleeve 20-15-2
Valve Seats 20-05-6 Crankshaft Gear 20-15-2
Cylinder Head 20-05-8 Flywheel 20-15-2
Assembly 20-05-8 Clutch Shaft Pilot Bearing (Power Shift) 20-15-3
Installation 20-05-8 Clutch Shaft Pilot Bushing and Adapter
Camshaft 20-05-9 (Quad-Range) 20-15-3
Checking Camshaft End Play 20-05-9 Rear Crankshaft Oil Seal, Housing and
Removal 20-05-9 Wear Sleeve 20-15-4
Inspection and Repair 20-05-10 Main Bearings 20-15-4
Camshaft Gear 20-05-10 Thrust Bearings 20-15-5
Thrust Plate 20-05-10 Crankshaft Journals 20-15-6
Bushings and Journals 20-05-10 Installation 20-15-6
Lobes 20-05-1 Main Bearings and Crankshaft 20-15-6
Assembly 20-05-1 Rear Wear Sleeve 20-15-7
Installation 20-05-1 Rear Oil Seal and Housing 20-15-7
Crankshaft Gear, Front Wear Sleeve
GROUP 10 - CYLINDER BLOCK LINERS,T
and Oil Seal -

20-15-8
PISTONS AND RODS
Diagnosing Malfunctions 20-10-1
Pistons 20-10-1
GROUP 20 - LUBRICATION SYSTEM
Access 20-10-1
Removal, Inspection and Repair 20-20-1
Removal 20-10-2
Oil Filter Housing 20-20-1
Inspection and Repair 20-10-2
Oil Cooler 20-20-1
Piston Rings and Ring Grooves 20-10-2
Oil Pumps 20-20-2
Piston Head, Ring Lands and
Tachometer Drive 20-20-5
Piston Skirt 20-10-3
Piston Pins 20-10-4
Oil Cooler By-Pass Valve 20-20-6
Oil Pumps 20-20-6
Tachometer Drive 20-20-9
TM-1181 (Apr-81) Litho in USA. Tractors - 4040 and 4240

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 Water Manifold and Thermostats 20-25-6
Overflow Valve 20-25-2 Inspection and Repair 20-25-6
Fan Belts 20-25-2 Installation 20-25-6
Group 00
SPECIFICATIONS
Item New Part Specification Wear Tolerance
Cylinder Head, Valves, and Camshaft

Valve clearance
Intake valve 0,018 in. (0.46 mm)
Exhaust valve 0.02S in. (0.71 mm)
Waive Ifft at specified clearance
Intake valve 0.424 to 0.454 in. (10.77 to 11.53 mm)
Exhaust valve 0.414 to 0.444 in. (10.52 to 1 1.28 mm)
Valve springs - compressed
Vatve closed 1.81 in. at 54 to 62 lbs. {45.9 mm at 240.2 to 275.8 N)
Valve open 1.36 in. at 133 to 153 lbs. (35.5 mm at 591.6 to 680.5 IM)
Valve face angle 45
Valve face O.D.
Intake valve 1.897 to 1.907 (48.2 to 48.4 mm)
Exhaust valve 1710 to 1.720 (43.4 to 437 mm)
Valve guide LD 0,3745 to 0,3755 in. (9.51 to 9.54 mm)
Valve stem O.D 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 0,1 mm) 0.0060 to 0.0080 in.
(0.15 to 0.20 mm)

Valve seat width 0.0830 to 0.0930 in. (2.11 to 2.37 mm)
Valve seat runout with respect to guide 0.0020 in. (0.05 mm) Max.
Valve seat angle 45
Valve recessed in head
Intake 0.034 to 0.057 in. (0.86 to 1 mm)
.45
Exhaust 0.047 to 0.070 in. (1 .19 to 1 mm)
.78
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. (472 to 4.80 mm) 0.1820 in. (4.62 mm)
Camshaft bushing journal O.D 2.3745 to 2.3755 in. (60.31 to 60.34 mm)
Camshaft bushing I.D 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) (27 kgm)
Camshaft gear 85 ft-Ibs (115 N-m) (11.5 kgm)
Timing gear cover 30 ft-Ibs (41 N-m) (4.1 kgm)
Cylinder Block, Liners, Pistons, and Rods

Cylinder liner height above block (4040) 0.000 to 0.004 in. (0.00 to 0.1 mm)
Cylinder liner height above block (4240)
In new cylinder block 0.001 to 0.0O5 in. (0.03 to 0.12 mm)
In used cylinder block 0.000 to 0.0O4 in. (O.OO to 0.10 mm)
TM-1181 (Apr-81) Litho in U.S.A. Tractors - 4040 and 4240

Cylinder Block, Liners, Pistons, and Rods (Continued)

Piston oil control ring side clearance 0.002 to 0.004 in, {0,06 to 0.1 mm) 0,006 in. (0.1 mm)
Piston O.D. (4040)
Top of skirt
(3.03 in. [77 mm] from bottom of piston) 4.2412 to 4.2419 in. (107.73 to 107.74 mm) "Low"
4.2419 to 4.2426 in. (107.74 to 107.76 mm) "High"
Bottom of skirt
4.2466 to 4.2473 in. (107.86 to 107.88 mm) "High"
Piston O.D. (4240)
Top of skirt
(3.03 in. [77 mm] from bottom of piston) 4.5541 to 4.5547 in. (115.67 to 1 15.69 mm) "Low"
4.5547 to 4.5554 in. (115.69 to 115.71 mm) "High"
Bottom of skirt
4.5584 to 4.5591 in. (115.78 to 115.80 mm) "High"
Cylinder liner I.D. (4040) 4.2493 to 4.2500 in. (107.93 to 107.95 mm) "Low"
4.2500 to 4.2507 in. (107.95 to 107.97 mm) "High"
Cylinder liner I.D. (4240) 4.5615 to 4.5625 in. (1 15.86 to 1 15.88 mm) "Low"
4.5625 to 4.5635 in. (115.88 to 115.91 mm) "High-
Cylinder liner taper 0.002 in. (0.05 mm)
Piston-to-liner clearance (4040)
Bottom of skirt 0.0027 to 0.0041 in. (0.07 to 0.10 mm) 0.006 in. (0.15 mm)
Piston pin O.D. (4040) 1.4997 to 1 .5003 in. (38.09 to 38.1 1 mm)
Piston pin bore in piston I.D. (4040) 1.5003 to 1.5009 in. (38.11 to 3S.12 mm)
Rod pin bushing I.D. (4040) 1.5010 to 1.5020 in. (38.12 to 38,14 mm)
Piston-to-liner clearance (4240)
Bottom of skirt 0.0036 to 0,0053 in. (0.09 to 0.13 mm) 0.006 in. (0.15 mm)
Piston pin O.D. (4240) 1 .6247 to 1 .6253 in. (41.27 to 41.28 mm)
Piston pin bore in piston I.D. (4240) 1.6253 to 1.6259 in. (41.26 to 41.30 mm)
Rod pin bushing LD. (4240) 1.6260 to 1.6270 in. (41.30 to 41.33 mm)
Pin-to-bushing clearance
oil 0.0007 to 0,0023 in. (0.02 to 0.06 mm) 0.003 in. (0.08 mm)
Connecting rod bearing assembled I.D 3-0005 to 3.0O25 in. (76.21 to 76.26 mm)
Connecting rod journal O.D 2.9980 to 2.9990 in. (76.15 to 76.17 mm)
Bearing-to-journa! clearance 0.0010 to 0.0040 in. (0.02 to 0.10 mm) 0.006 in. (0.15 mm)
Connecting rod cap end gap 0.010 in. (0.25 mm)
Connecting rod out-of-round 0.001 in. (0.025 mm)
Torques
Connecting rod cap screws 55 ft-lbs (75 N*m) (7.5 kgm) then an additional
1/4 turn (90 degrees). (See p. 20-10-14).
Piston cooling orifices 85 to 115 in-lbs (9.6 to 12.4 N-m) (0.9 to 1.2 kgm)
Crankshaft, Main Bearings and Flywheel

Crankshaft end play 0.0015 to 0.015 in. {0.04 to 0.4 mm)
Clutch shaft pilot bushing adapter I.D 1.0025 to 1.0055 in. (25.46 to 25.54 mm)
Clutch shaft O.D. at bushing 0.9995 to 1 .0005 in. (25.39 to 25.41 mm)
Main bearing journal O.D 3.372 to 3.373 in. (85.65 to 85.67 mm)
Main bearing assembled 3.374 to 3.376 in. (85.70 to 85.76 mm)
Bearing-to-joumal clearance
Crankshaft rear oil
I.D
seal-to-housing run-out
0.001 to 0.004 in. (0.03 to 0.10 mm)
0.0060 in. (0.15 mm)
0.0077 in. (0.19 mm)
Journal taper per inch of journal length 0.0001 in. (0.0025 mm)
Journal out-of-roundness 0.0004 in. (0.01 mm)
Undersized bearing available 0.002, 0.010, 0.020, and 0.030 in.
(0.05, 0.25, 0.51, and 0.76 mm)
Torques
Damper pulley to crankshaft 150 ft-lbs (203 N-m) (20.3 kgm)
Main bearing caps 150 ft-lbs (203 N-m) (20.3 kgm)
Rear crankshaft oil seal housing 20 ft-lbs (27 N-m) (2.7 kgm)
Flywheel-to-crankshaft 85 ft-lbs (115 N-m) (11.5 kgm)

SPECIFICATIONS Continued
Lubrication System
Hem New Part Specification Wear Tolerance
Engine oil pressure 40 to 50 psi (2.75 to 3.75 bar) (2,80 to 3.86 kg/cm s )
Oil pressure regulating valve
spring - compressed 1 ,91 in. at 30 to 33 lbs. (48.5 mm at 133 to 147 N)
bypass valve spring - compressed
Filter 1.38 in. at 18 to 22 lbs. (35.0 mm at 80 to 98 N)
Cooler bypass valve spring - compressed 1.38 in. at 18 to 22 lbs. (35.0 mm at 80 to 98 NJ
Oil Pump
(Camshaft-Driven)
Depth of gear bore in housing 1.7530 to 1.7570 in. (44.53 to 44.63 mm)
Gear thickness 1.7500 to 1.7520 in. (44.45 to 44.50 mm)
O.D. of gears 3.3801 to 3.381 1 in. (85.85 to 85.90 mm)
Housing gear bore I.D 3.3840 to 3.3860 in. (85.95 to 86.00 mm)
Driver gear LD 0.6220 to 0,6230 in. (15.80 to 15.82 mm)
Idler gear bushing I.D 0.6300 to 0.6310 in. (16.00 to 16.03 mm)
Idler shaft O.D 0.6284 to 0.6290 in. (15.96 to 15.98 mm)
Driven shaft O.D 0.6235 to 0.6245 in. (15.88 to 15.86 mm)
Oil Pump (Crankshaft-Driven)
Drive gear-to-crankshaft gear backlash (min.) 0.003 in. (0.08 mm)
Drive shaft endplay (max.) 0.006 in. (0.15 mm)
Drive shaft side movement (max.) 0.0065 in. (0.17 mm)
Pump gear backlash (max.) 0.039in. (1 .0 mm)
Torques
Camshaft-Driven Oil Pump
Cover-to-housing cap screws 21-40 ft-lbs (29-55 N-m) (2.9-5.5 kgm)
Intake-to-cover 12-23 ft-lbs (16-31 N-m) (1 .6-3.1 kgm)
Housing-to-cylinder block cap screws 20-25 ft-lbs (27-34 N-m) (2.7-3.4 kgm)
Crankshaft-Driven Oil Pump
Drive gear-to-drive shaft nut 37-43 ft-lbs (51-57 N-m) (5.1-5.7 kgm)
Cover-to-housing cap screws 27-33 ft-lbs (38-44 N-m) (3.8-4.4 kgm)
Gear shield -to-housing cap screws 17-23 ft-lbs (24-30 N-m) (2.4-3.0 kgm)
Intake screen-to-cover cap screws 17-23 ft-lbs (24-30 N-m) (2.4-3,0 kgm)
Housing-to-cylinder block cap screws 33-39 ft-lbs (45^51 N-m) (4.5-5.1 kgm)
Oil Pan
0.43 in. (11.1 mm) rail thickness
3/8-in. cap screws 35 ft-lbs (47 N-m) (4.7 kgm)
1/2-in. cap screws 85 ft-Jbs (1 1 5 N-m) (1 1 .5 kgm)
*0.81 in. (20.5 mm) rail thickness
3/8-in. cap screws 50 ft-lbs (68 N-m) (6.8 kgm)
1/2-in. cap screws 120 ft-lbs (162 N*m) (16.2 kgm)
Tachometer drive housing-to-
cylinder block cap screws 35 ft-lbs (47 N-m) (4.7 kgm)
tighten at! cap screws to 40 ft-lbs (54 N-m) (5

*lnitiaffy A
kgm) starting at right-rear corner of oitpan and proceeding
counterclockwise. Finish tightening cap screws to torque specified above.

ttem New Part Specification Wear Tolerance
Cooling System
Radiator leakage test 18 psi (1 .24 bar) (1.26 kg/cm2 )

Radiator cap pressure
7 psi (0,46 bar) (0.49 kg/cm 2 ) cap 6.25 to 7.50 psi (0.43 to 0.52 bar) (0.44 to 0.53 kg/cm 2)
15 psi (1.93 bar) (1.05 kg/cm 2 ) cap 14 to 17 psi (0.96 to 1.17 bar) (0.98 to 1.19 kg/cm 2 )
New fan belt tension
Single belt 130 to 140 Jbs. (578 to 622 N)
Dual belt 95 to 104 lbs. (423 to 467 N)
Tension after run in
AH belts 85 to 94 lbs. (378 to 423 N)
Impeller bore I.D 0.6242 to 0.6252 in. (15.85 to 15.88 mm)
Bearing shaft O.D 0.6262 to 0.6267 in. (15.90 to 15.99 mm)
Impeller-to-housing clearance 0.015 to 0.025 in. (0.4 to 0.6 mm) clearance
Hub-to-rear face dimension
4040 3.76 in. (95.5 mm)
4240 4.49 in. (1 14.0 mm)
Thermostats opening temperature 160 to 180T (71 to 82C)
Torques
Pump cover-to-housing cap screws 20 ft-lbs (27 N-m) (2.7 kgm)
Pump-to-cylinder block cap screws 35 ft-lbs (47 N-m) (4.7 kgm)
Fan-to-fan pulley cap screws 35 ft-lbs (47 N*m) (4.7 kgm)
SPECIAL TOOLS
Cylinder Head, Valves and Camshaft
TOL Materials Required
JDT 405 High Temperature Grease
NUMBER USE
r A-ÎD&SI-I Used to rotate the engine flywheel
B y; ^î
:

: Flywheel Turning when timing the engine.
Too!
B-gDE-81-4
Timing Pin
R 26134N
Fig. 1-Engine Rotation Tool Set
Order from: Service Toots, Box 314, Owatonna, Mn

55060
TM-1181 (Apr-81) LJtho in USA. Tractors - 4040 and 4240

SPECIAL TOOLS^-Continued
Cylinder Head, Valves and Camshaft Continued
TOOL NUMBER USE
A D-05058ST Used to check valves for out-of-

Valve Inspection round.
Center
B D-17011BR Valve Used to clean valve guides.

Guide Cleaning
Brush
C D-20002W1 Used to knurl valve guides.
Knurling Tool Set
Fig. 2-Special Tools
AÎDE-41296 Used to remove valve seats.

Seat Puller
BJDE-7 Driver Used with JOE-79 or JDE-66 Replace-
ment Ring to Install valve seats.
C^JDE-79 Used with JDE-7 Driver to install ex-
Replacement Ring haust valve seats.
JDE-66
Used with JDE 7 Driver to install in-
Replacement Ring. take valve seats.
(Not Shown)
D D-17024 End Used to clean valve seat and bore.
Brush
Fig. 3-Spedai Tools
TM-1181 (Apr-61) Lithe in US. A Tractors - 4040 and 4240

TOOL NUMBER USE
D 1 5001 NU Used to hold cam followers away from

Magnetic Holding camshaft
Tool Set
Fig. 4-D-15001NU Magnetic Holding Toot Set
JDE-6 Camshaft Used to remove andinstall camshaft

Bushing Replace- bushings.
ment Set,
,--
i *
^ I. ::;#4;:vv:i;.v;:
'
R 26149$^. T^,^^,--,?. -^,,, i-r"
"
, ..
Fig. 5-JDE-6 Camshaft Bushing Replacement Set
Cylinder Block, Liners, Pistons and Rods

Cylinder Liner Holding Fixture See Making Special Tools, p. 20-00-12
JDE-93 Ring Used to install piston rings on 4240

Expander Tractor.
ft 27473N
Rg. 6-JDE-93 Ring Expander
TM-1181 (Apr-81) Utho in USA. Tractors - 4040 and 4240

A
SPECIAL TOOLS Continued

TOOL NUMBER USE
illli -,
; :
". l
Si- 1
" .. o- A."-:;:- j
;
;
AJDE-47 Ring Used to install piston rings on 4040
:iM%]--]: '.':: ;''.:: ;*s
iji
Expander Tractor.
m jiP^^
;
mmm j 1i;iH!f^'yp3i?yii":/.
''
BJDE-55 Ring To check wear of compression ring

aiiiapi Wr:. -
s
iâ- Groove Wear Gauge grooves on 4240 Tractor.

".
""!^B JDE-62 Ring To check wear of compression ring
:h Groove Wear Gauge grooves on 4040 Tractor.
*IifciillBii; CNo. 27508 Disk
0 No. 27511 Disk To remove and install piston pin
E No. 27513 Disk bushings on 4240 Tractor.
F No. 27489 Driver
JDE-5 (Not To remove and install piston pin

Illustrated) bushings on 4040 Tractor.
Fig. 7-Special Toots
A^-D-0162AA Used to remove cylinder liners.

Liner Puller
B^D-17004BR Used to hone cylinder liners.

Flex-Hone
D-17015 O-Rlrtg Used to clean O-ring bore in cylinder

Bore Cleaning block.
Brush
Fig, 9-D-17015 O-Ring Bore Cleaning Brush
TM-1181 (Apr-81) Litho in U.S. Tractors - 4040 and 4240

TOOL NUMBER USE
JDE-57 Ring Used to compress piston rings on

Compressor 4040 while installing piston.
JDE-96 Ring Used to compress piston rings on

Compressor 4240 while installing piston.
(Not Shown)
R Z7481N' ''
.-.:. ':::-
"
r:
".'"..
.-" - ,-,.. ,.:,
Fig. 10-JDB-57 Ring Compressor
Crankshaft, Main Bearings and Flywheel
Materials Required:
Permatex Form-a-Gasket #3
A D-1206AA Used with No. 630-6 Step Plate

Puller Adapter to remove damper pulley.
BNo. 630-6 Used with 0-1 206AA Puller to remove

Step Plate Adapter damper pulley.
R 27476JT
Rg. 11 -Special Tools
A^D-01219AA Puller Used to remove crankshaft gear.

B D-01222AA
Pulling Legs
C No. 630-9
Adapter (From
D-01212AA Set)
D D-01218 Pulling
Attachment
R 26170H
Rg. 12-Special Tools
TM-1181 (Apr-81) Litho in USA, Tractors - 4040 and 4240

SPECIALTOOLSContinued
Crankshaft, Main Bearings and Flywheel Continued
TOOL NUMBER USE
Ar-JDE-106-2 Tool Used to install crankshaft rear wear

Set sleeve and rear oil seal.
&-No. 27489
Driver
R 2628m
Ar-JDH-7 Driver Used to install crankshaft gear.

B JDE-3 Driver Used to install front wear sleeve.
C No. 27522 Disk

D No. 27537 Disk Used to install front oil seal.
ENo. 27488 Disk
R 263918
Fig. 14-Speciai Tools
A D-01209AA Puller Used with No. 957 Slide Hammer

Puller to remove clutch shaft pilot
bearing on Power Shift tractors.
Used with No, 959-Bearing Puller to
remove clutch shaft pilot bearing on
mmW "
"": "
"V i WQfHlffiXjy&tp*"* Power Shift tractors.
Fig. 15~Special Tools
TM-1181 (Apr-81) Utho in U.S.A. Tractors - 4040 and 4240

: :
Cooling System
Materials Required:
Permatex Form-a-Gasket #2
TOOL NUMBER USE
JD-262A Used to install bearing in water pump

Installation Tool housing.
mSMm^^^^^mSBiti.
\^ -
^ I ?l^ n??IIIS3lll : I = ; ;l =
:
-:T f r
i
= :
:
:inWl|iggglp?ri H =n
= r
l =
:
- ^f IT rlî eIIh:^!^ Illzill*:?:l-ls1i :tT;?;1i1t =1? : =1*
:'-"

'';':':':':
".
:
l%:\: l^^V::'.zr.: \-\}'y :]-l\-:::
:
^^:l%l\:\ :
::\"r \-?V
:
^::'l^:^lu' ^:^V.
: :
-l- -^y:
:
-\: i :::;;:::;;;;;:; ::: \ :,.".*: ;: .:- --îv^y +::<:-::::
'ilfMinjIji^
Rg. 16-J0-262A installation Toot
D-D5103ST Used to check opening temperatures

Thermostat Tester of thermostats.
WAdik^Ml^m'ihh
r 26a oas
Fig. 17-D-Q5103ST Thermostat Tester
TM-1181 (Apr-81) Litho in US. A. Tractors - 4040 and 4240

MAKING SPECIAL TOOLS
T36748N
11 VT (254.0mm) 92.5" (63.5 mm) 175/16*18 Tap
25" (127.0 mm) 101" mm)
(25.4 182.75" (69.85 mm) Radius
3 1.5" (38.1 mm) 11^0.25" (6.35 mm) 19-^4" (101,6 mm)
416" (405.4 mm) 126" (152.4 mm) 204.38" (111.25 mm)
513" (330.2 mm) 130.328" Drill Through 212.3T (60.45 mm)
60.375" (9-52 mm) 145/16" 18 Tap 225/16" x 1" Cap Screw
70.5" (12.7 mm) 152 used 232.5" (63.5 mm) Angle Iron
6 1.2S"(31.8 mm) 16 12" (304.8 mm)
Fig. 18-Cytinder Liner Holding Fixture
Liner Holding Fixture Hold liner for

deglazing.
*Make in dealers service department
TM-1181 (Apr-81) Litho in USA, Tractors - 4040 and 4240

Engine Repair Cylinder Head, Valves and Camshaft 20-05-1
Group 05
CYLINDER HEAD, VALVES, AND CAMSHAFT
PRELIMINARY VALVE CHECKS Camshaft Failures
Scored camshaft lobes due to inadequate lubrica-
During disassembly, inspect the valve train for the
tion
following malfunctions and causes.
Excessive end play due to thrust plate wear
Sticking Valves Broken or warped camshaft due to improper timing
Carbon deposits on valve stem
Checking Valve Clearance
Worn valve guides
Warped valve stems
Cocked or broken valve springs
Worn or distorted valve seats
Insufficient lubrication
Warped, Worn, or Distorted Valve Guides

itf)
Lack of lubrication
Cylinder head distortion
Excessive heat
Unevenly tightened cylinder head cap screws
Head and Cylinder

Distorted Cylinder
Head Gasket Leakage
Improperly tightened cylinder head cap screws
Faulty gasket installation
Excessive oil pressure
Improper cylinder liner height above cylinder block
Worn or Broken Valve Seats

Misaligned valves
Distorted cylinder head
Carbon deposits on seats due to incomplete com- AJDE-S1 Engine Rotation Tool Set
bustion
Valve spring tension too weak Rg. 1-Setting "TDC"
Excessive heat
Improper valve clearance 1. Use JDE-81 Engine Rotation Tool Set (A, Fig. 1)
Improper valve timing to position No. 1 piston at TDC of its compression
stroke.
Burned, Pitted, Worn, or Broken Valves
Worn or distorted valve seats
2. Turn flywheel until rotation tool timing pin en-
Worn valve guides gages timing hole in flywheel and both valves on No. 1
Insufficient cooling
cylinder are in the up position. (Rocker arms loose).
Cocked or broken valve springs
Detonation
Improper engine operation
Improper valve train timing
Faulty valve rotators
Warped or distorted valve stems
"Stretched" valves due to excessive spring tension
Distorted cylinder head
Bent push rods
Carbon build-up on valve seats
Rocker arm failure

20-05-2 Cylinder Head, Valves and Camshaft Engine Repair
Checking Valve Clearance Continued Checking Valve Lift
Valve Clearance Specifications Measuring valve lift can give an indication of wear to
Intake Valves 0.018 in. (0.4 mm) cam lobes, cam followers, and push rods.
Exhaust Valves 0.028 in. (0.7 mm)
1. Set vaJve clearance to specifications as pre-
viously indicated.
FRONT OF ENGINE -
NO. I TDC COMPRESSION STROKE
NO. 6 TDC COMPRESSION STROKE
Fig. 2-Valve Clearance Adjustment
Fig. 4-Checking Valve Lift
2. Place dial indicator on rotator (Fig. 4).
3. Manually turn engine in running direction with

JDE-81 Engine Rotation Tool.
4. After rocker arm contacts valve stem, observe dial

indicator reading as valve is moved to full open.
Valve Lift Specifications
Intake Valves 0.424 to 0,454 in.
(10.77 to 11.53 mm)

Exhaust Valves 0.414 to 0.444 in.
Fig. 3-Checking Valve Clearance (10.52 to 11,28 mm)
3. Adjust valve clearance on No. 1 3, and 5 exhaust

,
CYLINDER HEAD AND VALVES
valves and No. 1, 2, and 4 intake valves (Fig. 3).
Access
4. Rotate flywheel 360 degrees until No. 6 piston is 1. Remove engine as indicated in Section 10,
at "TDC" of its compression stroke, and tool timing pin Group 25, page 19,
engages flywheel hole.
2. Remove intake manifold.
5. Adjust valve clearance on No. 2, 4, and 6 exhaust
valves and No. 3, 5, and 6 intake valves to the specifi- 3. Remove exhaust manifold.
(
cations listed above.

. .
Access Co nti n ued
4. Remove water manifold.
5. Remove fuel injection lines.
6. Remove fuel return lines.
7. Remove injection nozzles.
8. Remove rocker arm cover vent hose.
9. Remove rocker arm cover.
ROCKER ARM ASSEMBLY R 26131N
Removal
AWorn Area
1. Remove rocker arm shaft clamp cap screws.
Fig. 6-Rocker Arm Wear
NOTE: When removing rocker arm shaft compo-

5. Examine spacer springs on shaft between rocker
nents, identify for reassembly into original position.
arms, and be sure they are strong enough to exert a
positive pressure on arms.
NOTE: if the rocker arm has been damaged by a

valve failure, replace it and the push rod when replac-
ing valves.
Assembly and Installation
1 Assemble parts on rocker arm shaft in reverse of

fi UU1 sequence removed.
2. Make sure rocker arm shaft end plugs are firmly
A End Plugs C Adjusting Screws
seated in end of shaft.
B OH Holes
Fig. 5-Rocker Arm Shaft Components

. .....:;...
:
:|!iii;r :.*^ '*"*"'SH
:
!;:
:s:
::r;!;.:^;j;;r:;.î6t:i::;h:*/
; ' :
":^ r :**' ;
ri(iS,
T ''^' :
:\
;;: ;
r* :';;:;;
: :*
2. Remove rocker arm shaft end plugs and slide

components from shaft (Fig. 5).
Inspection and Repair

1 Inspect rocker arm shaft for scratches, scores, or
excessive wear at points of rocker arm contact.
NOTE: Wear could indicate weak valve springs,

bent push rods, or loose rocker arm shaft clamps.
2. Be sure that all oii holes are open and clean (B,
Fig. 7).
Check rocker arm adjusting nut and screw for

ASpring Pin B Locating Hole
3.
damage (C, Fig. 7). Fig. 7-Rocker Arm Shaft Locating Holes
Check for cups or concave wear on ends

4. of 3. Position rocker arm shaft on head, insuring that
rocker arms where they contact valve tips (A, Fig. 6). spring pin (A, Fig. 7) and locating hole (B) in rocker arm
shaft line up.
4. Tighten rocker arm shaft clamp cap screws to 45
to 65 ft-ibs (61 to 88 N-m) (6.1 to 8.8 kgm).

.
VALVES, VALVE SPRINGS, VALVE

ROTATORS, AND WEAR CAPS
Removal
1. Remove rocker arm assembly as previously de-
scribed.
2. Remove head.
NOTE: When removing valves, valve springs, and

valve rotators, identify for reassembly into original po-
sitions,
3. Use a valve spring compressor to remove valves

from head.
RG2SSB
Inspection And Repair

ArNew Rotator
Valve Springs &14.910 0.381 mm {.5S7 .015 in.)
1. Inspect valve springs for alignment, wear, and

C Old Rotator
D12.624 0.381 mm (.497 .015 in.)
damage.
Fig, B-Eariy and Late intake Vaive Rotators
2.Place springs on a flat surface to see that they
are square and parallel
1 Insure that valve rotators will turn freely in one
3. Check vaive spring tension on a spring tester. direction. If defective, replace with new.
NOTE: Free length of springs differ slightly, but

compressed length must be the same. 2. Replace vaive wear caps if pitted or worn.
3. Visually check valve face and stem for wear or

Valve Spring Specifications
damage.
Compression Height
54 to 62 lbs 1.81 in. 4. Perform the following cleaning procedure before
(240.2 to 275.8 N) (45.9 mm) measuring or repairing valves.
133 to 153 lbs 1.36 in.
(591.6 to 680.5 N) (34.5 mm)

Free Length 2.1 2 in.
(53.8 mm)
Valves, Rotators and Wear Caps;
NOTE: Changes in intake valve rotators are effec-

tive for 4040 Tractors (Serial No. 578706-
the )
and the 4240 Tractors (Serial No. 090535- ).
This new valve rotator helps eliminate intake carbon

buildup. The new valve rotator has a larger cone to
effectively retain the O-ring on the intake valve. This
prevents oil from running down the valve stem and past
the valve guide.

.
Inspection and Repair Continued Valve Guides
Cleaning Valves
1 Hold each valve firmly against a wire wheel on a

bench grinder.
2. Make sure all carbon is removed from the valve
head, face and stem.
IMPORTANT: Any carbon left on the stem will
affect alignment in valve refacer ifvalves need to
be refaced.
3. Polish the valve stems with steel wool or fine
emery cloth to remove any scratch marks left by the
wire brush.
L>
: R 26140N
Fig. 11 -Cleaning Valve Guides
1. Use a valve guide cleaning brush (Fig. 11) to
E 2l;202S
clean valve guides before inspection or repair.
NOTE: A few drops of light oil or kerosene wili help

A Intake valve 1.897 to C0.3715 to 0.3725 in.
dean the guide.
to fuiiy
1.907 in. (48.2 to 48.4 mm) (9.43 to 9.46 mm)
Exhaust valve 1.710 to
1.720 m. (43.4 to 43.7 mm)
B45
Ftg. 9-Vaive Specifications
4. Compare
valve stem O.D. (C, Fig. 9) with valve
guide LD. to determine stem-to-guide clearance.
ft
ig^B
AValve Guide BTelescope Gauge
Fig. 12-Checking Valve Guide
2. Measure valve guides for wear (Fig. 12).
Valve Guide Specifications
LD. of guide in a new head . . . 0.3745 to 0.3755 in.
(9.512 to 9.537 mm)

R 26139H
Fig. 10-inspecting Valves
New guide-to-vaive stem
clearance 0.0020 to 0.0040 in.
5, Use D-05058ST Valve Inspection Center (Fig. (0.051 to 0.102 mm)

10) to determine if valves are out of round, bent or
warped.

. .
Valve Guides Continued

NOTE: Worn guides can allow a clearance of 0.006
in, (0. 15 mm) and still be acceptable. Worn guides may
be knurled to return them to specified clearance if

vatve-to-guide clearance is 0.010 in. (0.25 mm) or less.
If clearance exceeds 0.010 in. (0.25 mm), install over-
size valves.
..->;. .'-:
R26126N
AValve Seat Insert

B Valve Seat Angle 45
C Valve Seat Width... 0.0830 to 0.0930 in.
{2.108 to 2.362 mm)

D Valve Seat Runout . No more than 0.0020 in.
(0.051 mm)
Fig. 15-Vatve Seat Specifications
2. Check seats for cracks, pits, or excessive wear.
3. Recondition vafve seat by grinding.
Grinding Valve Seats
A Knurler C Speed Reducer

B Reamer D Lubricant
Ftg. 13-Knuriing Valve Guides
3. Use No. D-2OO02WI Knurling Too! Set to knurl

valve guides (Fig. 13).
NOTE: Use tool set exactly as directed by the
manufacturer.
Valve Seats
R 26143N
1 Do not grind too long. Only a few seconds are

required to recondition the average valve seat. Avoid
the natural tendency to grind off too much.
2. Do not use too much pressure. While grinding,

support the weight of the driver to avoid excess pres-
* 26I4^ :
;:ff 6:/ r
:
: ?"j sure on the stone.
Ftg. 14-Cteaning Valve Seats
3. Keep the work area clean.
1 . Use an electric hand drill with wire cleaning brush
4. Check the seat width and contact pattern be-
(Fig. 14) and remove all carbon.
tween the seat and valve with blueing.

.
Inspection and Repair Continued 1 . Remove valve seats with JDE-41296 Valve Seat
Puller (Fig. 18).
Checking Valve Height
1 . After grinding, install valve.
'/" ;-,4'
Jrpg&$?.
j:- :;.;;.;.: <m\
* '
Ainsert CJDE-7 Driver

B JDE-79 Replacement Ring
Fig, 19-Instalfing Valve Seat Inserts
2. new insert (A, Fig. 19) and Replace-

Chill both
ment Ring -20F (-29C) in dry ice before
(B) to
installing. Use JDE-66 Replacement Ring on intake
Z(Jl44;^.^:;:î;;g^
Fig, 17-Checking Valve Height vaive seats and JDE-79 Replacement Ring on exhaust
valve seats.
2. Use a diai indicator to check valve height (Fig.
17). and Replacement
3. Use JDE-7 Driver (C, Fig. 19)
Valve Recess Specifications: Rings to drive inserts into place.
Intake 0.034 to 0.057 in.
(0.86 to 1.45 mm) (recessed). 4. Grind valve seat.

Exhaust 0.047 to 0.070 in.
(1.19 to 1.78 mm) (recessed). Installing Oversize inserts
NOTE: If measurement does not meet specifica-
tions, install either new valves, inserts, or both, to In some cases, the outside diameter of the valve
obtain proper vaive height. seat bore may become damaged and require machin-
ing. !n this case, oversize inserts are available in 0.010
Replacing Valve Seat inserts in. (0.25 mm) oversize.
1 Remove valve seats with JDE-41 296 Valve Seat

Puller.
Machine seat diameter to 1.9465 to 1.9475 in.

2.
(49.40 to 49.50mm) on intake seats, and to 1.7585 to
1.7595 (44.67 to 44.69 mm) on exhaust seats.
3. Replace inserts as previously indicated.
I
R 26145?^
Fig. 18-Removing Valve Seats

Cylinder Head Installation

1. Thoroughly clean the cylinder head. NOTE: See page 20-10-10 before installing cylinder
head gasket
1. cylinder head gasket dry.
Install
2. Place cylinder head in correct position on block.

3. Dip cap screws and washers in clean engine oil
Fig. 20-Checking Cylinder Head
2. Use a straight edge to check the head for level

R 26147N
(Fig. 20).
Fig. 21-Cylinder Head Cap Screw

3. Warpage should not exceed 0.001 in. (0.02 mm) Tightening Sequence (Start at No. 1)
for every 5 in. (127 mm) of head length.

4. Install cap screws and tighten to the following
specifications using the sequence shown in Fig. 21.
Assembly Cylinder Head Torques
1. Apply AR44402 lubricant to valve stems and Initial 105 ft-lbs (142 N-m) (14.2 kgm)
guides. Second 117 to 143 ft-lbs (158 to 193 Nm)
(15.8 to 19,3 kgm)
2. Install valves in guides from which they were 5. Install push rods in holes from which they were
removed. removed.
6. Install wear caps on valves making certain caps
NOTE: Valves must move freely and seat properly. rotate freely.
3. Install valve springs making certain that cylinder

head end of spring is located correctly in machined
counter bore of the head.
4. Install rotators.
5. Compress valve springs with valve spring com-

pressor.
6. Install retainer locks on valves.
7. Strike the end of each valve three or four times

with a soft mallet to insure proper positioning of the
retainer locks.
ASpring Pin B Locating Hole
Fig. 22-Ftocker Arm Shaft Locating Hole

.
Installation Continued 1. Place a dial indicator on camshaft (Fig. 23).

2. Check camshaft end play.
7. Position rocker arm shaft on head insuring that
spring pin (A, Fig. 22) and locating hole (B) in rocker Camshaft End Play Specifications
arm shaft line up. New engine end play 0.0025 to 0.0085 in.
8. Tighten rocker arm shaft clamp cap screws to 45 (0.06 to 0.22 mm)
to 65ft-lbs (61 to 88 N-m) (6.1 to 8.8 kgm). Allowable end play 0.0150 in.
9.Reverse access steps. (0.38 mm)

10. Run engine at 2100 RPM for 1/2 hour. NOTE: If end play exceeds wear specification
11. Retighten cylinder head cap screws following check thrust washer thickness during disassembly.
cap screw tightening sequence (Fig. 21) to 135 to 165
ft-lbs (183 to 224 N-m) (18.3 to 22.4 kgm). Removal
CAMSHAFT
Checking Camshaft End Play
NOTE: To service the camshaft, the engine nor-
mally need not be removed from the tractor.
1. Separate the tractor front end from engine.
2. Remove rocker arm cover.

3. Remove rocker arm assembly.
4. Remove push rods.
5. Remove damper pulley. (See page 20-15-2)
6. Remove timing gear cover.
Installing Indicator
Rg. 24-fnstafling Magnetic Holding Tool Set
1 Use D-1 5001 NU (ND425) Magnetic Holding Tool

Set to hold cam followers away from camshaft (Fig.
24).
2. Remove four cap screws from thrust plate.
3. Carefullyremove camshaft from cylinder block so
that camshaft lobes do not drag in bores.
Rg. 23-Check'tng Camshaft End Play

CAMSHAFT(Continued)
Inspection and Repair 2. Support camshaft gear in a press (Fig. 26).
Camshaft Gear
IMPORTANT: Prevent camshaft from striking
floor when pressing camshaft from gear.
3. Press camshaft from gear.
Thrust Plate
After removal of camshaft gear, check thrust plate

for proper thickness,
THRUST PLATE SPECIFICATIONS

New Part Thickness 0.1860 to 0.1 S90 in.
(4.72 to 4.80 mm)

A Positioning Mark Acceptable wear thickness 0.1S20 in.
(4.62 mm)
Fig. 25-Position of Camshaft Gear Parts
1. Check camshaft gear for slippage between the Bushings and Journals
two parts of the gear.
Check camshaft bushings and journals for wear or
NOTE: An indexing mark has been placed across
damage.
the parting tine of the two parts of the gear, (A, Fig. 25).
If the mark has separated, the gear should be re-
BUSHING AND JOURNAL SPECIFICATIONS
placed.
Examine crankshaft gear and injection pump
New O.D
Journal 2.3745 to 2.3755 in.
2.
(60.31 to 60.34 mm)
drive gear forworn or broken teeth and damage.
New Bushing I.D 2.3775 to 2.3795
NOTE: if either gear has failed both gears must be
t
(60.39 to 60.44 mm)

replaced with a matched set
Clearance Allowable 0.0060 In. (0.15 mm)
Removing Camshaft Gear

1 . Remove cap screw and special washer.
R 2U52TN
m
ATool Locking Key CCamshaft Bushing
B Tool Mandrel D Engine Block
Fig. 27-lnstaf!ing Camshaft Bushings
1.Use JDE-6 Camshaft Bushing Replacement Set

to remove and install camshaft bushings.
NOTE: The two bushings can be reached from

first
The flywheel must be removed

the front of the engine.
to reach the other two bushings from the rear of the
engine. When new bushings are installed, be sure that
the elongated bushing oii holes are to the top and
aligned with oil holes in the cylinder block.
Fig. 26-Removmg Camshaft Gear

.
Lobes
1. Check camshaft lobes for wear or damage.
2, Check camshaft oil pump drive gear for wear or

damage.
NOTE: If camshaft is replaced due to a damaged oil

pump drive gear, check gear and shaft on oil pump for
damage and replace if necessary. If camshaft is re-
placed, cam followers must also be replaced.
Assembly
Fig. 29-lnstafiing Camshaft Gear
Installation
If cam followers have been removed, reinstall using

the D-15001NU (ND425) Magnetic Holding Tool Set to
hold cam followers away from camshaft bore until
camshaft is installed.
1. Coat camshaft with JDT405 high temperature

grease, or equivalent.
2. Carefully install camshaft in cylinder block so that

camshaft lobes do not drag in bores.
AThrust Plate CWoodruff Key

B Spacer D Kcyway
Fig. 28*Supporting Camshaft in Press
1 Support camshaft under first journal in a hydrau-

lic press, (Fig. 28),
2. Install thrust plate (A) T and spacer (B),
3. Install Woodruff key (C).
% SHI ^liiHS -#' I

4. Align Woodruff key (C) and keyway (D) and place f/BF"
gear on camshaft with timing mark facing away from
camshaft. A Location Mark C Timing Mark
BThrust Plate Cap Screw
5. Press gear on until tight against camshaft
shoulder (Fig. 29). Fig. 30-Gear Timing
I 3, With No. 1 piston on TDC of its compression
stroke, align timing marks (C, Fig. 30) on camshaft and

crankshaft gears.

20*05-12 Cylinder Head, Valves and Camshaft Engine Repair
Installation (Continued)
4. Turn camshaft gear to align thrust plate holes
with cylinder block holes.
5. Tighten thrust plate-to- block cap screws to 20

ft-lbs (27 Nm) (2.7 kgm).
6. Install special washer on camshaft.
7. Tighten camshaft gear-to-camshaft cap screw to

85 ft-lbs (115 Nm) (11.5 kgm).
8. Check camshaft for 0.0025 to 0.0085 in, (0.06 to

0.22 mm) end play.
TM-1181 (Jun-80) Litho in US. A. Tractors - 4040 and 4240

.
Engine Repair Cylinder Block, Liners, Pistons and Rods 20-10-1
Group 10
CYLINDER BLOCK, LINERS, PISTONS AND RODS
DIAGNOSING MALFUNCTIONS Cylinder Liner Wear and Distortion
Scuffed or Scored Pistons Incorrectly installed compression rings
Uneven cooling around liner
Improper piston-liner clearance
Improper piston-liner clearance
Liner bore damage
Detonation
Coolant leakage in crankcase
Misaligned or bent connecting rod
Warped Cylinder Block
Improperly installed piston Insufficient cooling
Low oil level
Improper operation Broken Connecting Rod
Incorrect connecting rod bearing clearance
Inadequate piston-liner clearance
Carbon buildup in ring groove
Improper break-in
Worn connecting rod bushing
Distorted cylinder liner
Worn piston
Piston pin failure
Contaminated oil
Distorted cylinder liner

Piston Pin and Snap Ring Failure
Worn or Broken Compression Rings Misaligned connecting rod
Excessive crankshaft end play
Detonation
Incorrect snaprings
Improper ring installation
Mottled, Grayish or Pitted Compression
Improper combustion
Rings
Improper timing Internal coolant leaks
Abrasives in combustion chamber
Dull Satin Finish and Fine Vertical
Clogged Oil Control Ring Scratches on Rings
Improper oil Dirt and abrasive in air intake system
Excessive blow-by
Contaminated Oil PISTONS
Improper periodic service
Low operating temperature
Access
Under normal conditions the engine need not be
Stuck Rings removed from the tractor to service pistons, rods and
liners. If engine removal is desirable, see Section 10,
Detonation
Group 25.
Improper oil classification
Improper periodic service
Poor operating conditions
1 Remove cylinder head as described in Group 05.
Coolant leakage in crankcase

Excessive cylinder liner taper
2. Remove oil pan.

20-10-2 Cylinder Block, Liners, Pistons and Rods Engine Repair
Removal 5, Thoroughly rinse piston with water and air after

soaking.
1. Use a short cap screw and washer to bolt down
cylinder liner.
Using Glass Bead Blasting Machine
1 . Only an experienced operator should use a glass
bead blasting machine to clean pistons. Follow manu-
facturer's directions.
2. Remove
rings and wash piston in solvent to
remove and grease. Use a stiff - BUT NOT A WIRE
oil
- brush to help loosen some carbon residue. Dry with
compressed air.
3. Use the proper sized bead and correct pressure.

Do bead blast in one area too long; keep
not hold the
the blast moving. The distance the blast nozzle is held
away from the area will depend on the recommended
pressure.
4. Avoid scratching the ring land area. Be sure ring

grooves are thoroughly cleaned. Excessive deposits
can force rings out, causing scuffing and scoring.
Fig. 1-Removing Ridge From Cylinder Liner Piston Rings and Ring Grooves
1. Examine piston rings for damage, wear, and

2. Remove carbon or ridge from liner bore with a
scratched or scored conditions.
ridge reamer (Fig, 1),
IMPORTANT: Keep bearing inserts with their

respective rods and caps, and mark rods, pistons,
and caps to insure correct reassembly.
3. Remove rod cap screws and rod caps.
4. Gently tap piston through top of cylinder.

Cleaning the Pistons
Clean the pistons by using Immersion-Solvent "D-

ParT and Hydra-Jet Rinse Gun or Glass Bead Blasting
machine,
A CAUTION: Follow manufacturer's instruc-

AVOID CONTACT OF CHEM-
tions exactly.
ICAL WFTH YOUR SKIN OR EYES; chemical con-
tains creosols which can be very harmful.
Using "D-ParT Cleaner

1. Follow manufacturer's directions for handling,
A Piston Ring B-^JDE-93 Ring Expander
mixing and use of cleaner
2. Use a solvent to remove oil and grease from Fig. 2-Removing Piston Rings
piston before soaking in cleaner.
3. One or two soakings may be required to loosen 2. Use JDE-47 Ring Expander on the 4040 and
carbon and residue from piston. JDE-93 Ring Expander on the 4240 to remove piston
4. IF NECESSARY, LIGHTLY scrape piston to re- rings (Fig. 2).
move some carbon. DO NOT scrape on piston skirt. Be
VERY CAREFUL when scraping other parts of piston.

Fig. 5-Checking OH Control Ring Groove Clearance
Fig. 3-Checking Ring Groove Wear OIL CONTROL RING GROOVE SPECIFICATIONS
New part clear-
3. Use JDE-55 Ring Groove Wear Gauge (Fig. 3) to ance 0.002 to 0.004 (0.06 to 0.10 mm)
check wear compression ring grooves on 4240
of Allowable clearance 0.006 in. (0.16 mm)
Tractor, or JDE-62 Ring Groove Wear Gauge on 4040
Tractor. 5. Measure piston as directed on page 20-10-10.
Piston Pins
1. Inspect and measure piston pin, pin bore in pis-
ton and connecting rod pin bushing. Excessive wear

can cause scored pistons or broken connecting rods.
PISTON PIN SPECIFICATIONS (4040)

O.D. of piston pin 1.4997 to 1.5003 in.
(38.09 to 38.11 mm)
I.D. of pin bore in piston 1.5003 to 1.5009 in.
(38.11 to 38.12 mm)
I.D. of rod pin bushing 1.5010 to 1.5020 in.
(38.12 to 38.14 mm)
Pin-to-bushing oil clearance 0.0007 to 0.0023 in.
. . .
(0.02 to 0.05 mm)

R 2U20IN Maximum serviceable
clearance 0.003 in. (0.08 mm)
A Piston with Worn DRing Land
Ring Groove E Gauge Shoulder PISTON PIN SPECIFICATIONS (4240)
BKeystone Ring Groove F Piston with Good
O.D. of piston pin 1.6247 to 1.6253
CRing Groove Wear Ring Groove
in.
Gauge (41.27 to 41.28 mm)

I.D. of pin bore in piston 1.6253 to 1.6259 in.
Fig. 4-Using Ring Groove Wear Gauge (41.28 to 41.30 mm)
I.D. of rod pin bushing 1.6260 to 1.6270 in.
NOTE: Gauge shoulders should not contact ring (41.30 to 41 .33 mm)
land (Fig. 4). Pin-to-bushing oil clearance . . . 0.0007 to 0.0023 in.
(0.02 to 0.05 mm)

4. Check oil control ring groove clearanceby in- Maximum serviceable
stalling a new ring in groove and measuring clearance clearance 0.003 in. (0.08 mm)
with a feeler gauge at several points (Fig. 5).

.
CONNECTING RODS
Removal
1 Remove cylinder head as described in Group 05.
2. Remove pistons.
3. Using a snap ring pliers, remove snap rings from
piston pin bore.

1. Be sure rod oil gallery-to-pin bore is clean and
open.
ANo. 27508 Disk CNo. 27489 Driver

BNo. 27513 Disk
Fig. 8-lnstaIling Pin Bushing (4240)
4. Use No. 27508 (A) and No. 27513 (B) Disks with
No. 27489 Driver (C) from No. 27794 Driver Set to
press bushing into connecting rod on 4240 Tractor
Use JDE-5 Pin Bushing
(Fig. 8). Installation and Re-
moval Tool on a 4040 Tractor.
Connecting Rod Bearings

Rod bearings can be checked with "Plastigage" if
CNo. 27489 rod connected to crankshaft, or by measuring as-

is
A No. 27508 Disk Driver
BNo. 27511 Disk sembled I.D. of connecting rod bearings if rod is out of
Fig. 6-Pressing Bushing From Rod (4240)
the engine.
2. Support rod in a press so that pin bushing may be
pressed from rod. (Fig. 6). NOTE: Use "Plastigage" as directed by the manu-
3. Use No. 27508 (A) and No. 2751 1 (B) Disks with
facturer. Remember, the use of "Plastigage" will de-
No. 27489 Driver (C) from No. 27794 Driver Set to termine bearing-journal clearance, but will not indicate
press bushing from connecting rod on a 4240 Tractor which surface is worn, or the condition of either sur-
(Fig. 6). Use JDE-5 Pin Bushing Installation and Re-
face.
moval tool on a 4040 Tractor.

Measuring Assembled I.D. of bearings and O.D. of
journals
1. Remove connecting rod from engine.
2. Measure connecting rod journal O.D. on crank-

shaft at several points around journal.
3. Install connecting rod cap on rod with bearing in

correct position.
4. Tighten rod cap-to-rod using torque-turn method

on p. 20-10-9.
A^-Oil Gallery Holes

5. Using an inside micrometer, measure inside di-
Fig. 7-Positioning Pin Bushing
ameter of bearing.
IMPORTANT: Make sure oil gallery holes (A, Fig.
7) in pin bushing and connecting rod are aligned
when installing piston pin bushing.
TM-1181 (Feb-79) Utho in U.S.A. Tractors - 4040 and 4240

6. Subtract LD. of rod bearings from O.D. of crank-

shaft journal to obtain oil clearance.
7. Compare the measurements with the following

specifications.
ROD BEARING AND JOURNAL SPECIFICATIONS
Measurement New Part Specification
O.D. of bearing journal 2.9980 to 2.9990 in.
(76.15 to 76.17 mm)
LD. of assembled rod

bearing 3.0005 to 3.0025 in.
(76.21 to 76.26 mm)
Oil clearance 0.0010 to 0.0040 in.

(0.02 to 0.10 mm)
0.006 (0.15 mm) MAX.
1 Blind Hole Cap Screw
Connecting Rod and Cap Fig. 9-Mea$uring Connecting Rod Bore
1. Remove cap from rod. Inspect rod and cap for Remove
7. blind hole cap screw (1, Fig. 9).
wear or damage, such as cracks or chips in the area of Using a feeler gauge, measure gap between rod
8.
the torque-and-groove joint. Also inspect in and and cap. If gap is greater than 0.010 in. (0.25 mm),
around cap screw holes in cap. If any defects are replace rod and cap.
found, replace rod and cap.
CYLINDER LINERS
2. Carefully clamp connecting rod in a vise, cap end
of rod pointing up,
Removal
3. install cap without bearing inserts.
4. Tighten cap screws using torque-turn method on

pg 20-10-14.
5. Using an inside micrometer, measure rod at

center of bore (Fig. 9) and record measurements:
A. At right angle to rod/cap joint.
B. 45 degrees to left of measurement "A".
C. 45 degrees to right of measurement "A".
6. Compare measurements A, B and C. If difference
between greatest and least measurements is more

than 0.001 in. (0.025 mm), rod and cap are out-of-
round and must be replaced.
FG1178
ACylinder Liner CLiner Height

6 Diaf indicator DCylinder Block
Fig, 10-Checking Liner Height

Removal Continued
1. Use a dial indicator tomeasure the height of
bolted down liners before removal from block (Fig. 9),
NOTE: Variations in height can give an indication of

finer distortion, or liner-piston problems.
LINER HEIGHT SPECIFICATION
Height Above
Block 0.000 to 0.004 in. (0,00 to 0.10 mm)
ACylinder Liner Flange B Liner Puller
Fig. 12-Removing Cylinder Liner
2. Use D-01062AA Puller to remove liners (Fig, 12).
Inspection
Pistons and cylinder liners are selectively fitted to
maintain piston-to-cylinder liner clearance. Pistons
color-coded green and stamped with an "L" are "low"
sized and matched with "low" cylinder liners stamped
"LV" (Fig. 13).
"High" sized pistons are color-coded black and
stamped with an "H", "High" sized liners are stamped
"HV".
EG1179
ACylinder Liner C Proper Jaw Position

BD-O1062AA Liner Puller
Fig. 11 -Installing Cylinder Liner PuUer
IMPORTANT: When using Cylinder Liner Puller

(B, Fig. 11) to remove jaw of
liners, insure that
puller is correctly positioned before attempting to
remove liner.
RG1184
Fig. 13-Pistons and Liner Size Marking

Engine Repair Cylinder Block, Liners, Pistons and Rods 20-10*7
Inspection Continued
1 . Carefully inspect pistons and liners and replace
as a unit if:
Ar-Piston Ring Face Wear B Ring Land Wear
Fig, 15-Cylin<ter Contamination

Fig. 14-Cytinder Liner Wear
A. Cross hatch pattern inside the liner has been B. Wear on piston ring face (A, Fig. 15) and ring
worn away in the area of piston ring travel around the land (B) is excessive. Wear
these areas indicates
in
entire liner (Fig. 14). that foreign material has entered the cylinder possibly
through air intake system.

Fig. 17-Cytind9r Contamination
Ftg. 16-Piston and Liner Scoring
D. Wear on thrust side of piston (Fig. 17) and in
C. Scoring is present on both piston and liner. Wear piston ring turn-around area of liner is excessive. Wear
of this type could possibly be caused by the engine in these areas could be caused by foreign material
overheating or a mismatched piston and liner set {Fig, entering the cylinder possibly through the engine oiling
16). system.
E. Any transfer of material between piston and liner
has occurred.
F. Piston or liner shows any breakage or other

obvious failure.
TM-1181 (Feb-79) Litho in US.A. Tractors - 4040 and 4240

EG1188
ACracks in Flange Area B Cracks in Ring Travel Area
EG1187 Fig, 19-Cylinder Liner inspection
A Cracks in Head C Cracks at Piston 3. Carefully examine the cylinder liners for signs of
B Damaged Ring Lands Pin Bore fatigue such as fine cracks the fiange area (A, Fig.
in
19) and cracks in the ring travel area (B).

Fig. 18-Piston inspection (Defects Exaggerated)
2. Carefully inspect the piston under magnification

for signs of fatigue. Look cracks in the piston
for fine
head broken ring lands (B) and
(A, Fig. 18), bent or
cracks around the piston pin bore in the skirt (C). If any
defects are found, replace the piston and liner as a
unit.
VCSfflfr
Fig. 20-0yiinder Liner Erosion
4. Inspect the exterior surfaces of the liner for pitting

and erosion. If liner has eroded to one half its original
thickness, replace (Fig. 20).

RG1204N
Fig. 22-Piston Measurements
E25922N
Fig. 21 -Cylinder Liner Measurements 7. Measure piston O.D. (B, Fig. 22) at 0.09 inch
(2.28 mm) from bottom of piston skirt (A) and record
NOTE: Measure parts at room temperature. measurement.
5. Measure cylinder liner as follows and record 8. Compare piston O.D. measurements (Step 7)
measurements: with liner LD. measurement (Step 6).
A. Measure the liner bore parallel to the piston P1STON-TO-UNER SPECIFICATION {4040}
pin at the top end of ring travel (Fig. 21). Bottom of skirt-to-liner 0.0027 to 0.0041 in.
B. Measure bore in same position at bottom end (0.07 to 0.10 mm)
of ring travel. Maximum serviceable clearance. 0.006 in. (0.15 mm)
C. Measure the liner bore at right angles to the
piston pin at the top of ring travel. PISTON-TO-UNER SPECIFICATION (4240)
D. Measure bore in same position at bottom end Bottom of skirt-to-liner 0.0036 to 0.0053 in.
of ring travel. (0.09 to 0.13 mm)

Maximum serviceable clearance. 0.006 in. (0.15 mm)
6. Compare the results of measurements A, B, C
and D to determine liner has worn tapered.
if
UNER TAPER SPECIFICATION

Maximum in ring travel area . . 0.0020 in. (0.05 mm)

. .
Deglazing Cylinder Liners BLOCK

1 Clean block thoroughly with cleaning solvent or
pressure steam cleaning.
2. Make sure ail passages and crevices are cleared
of sludge, rust, and grease.
3. Make sure all coolant passages are cleaned of

line deposits and scale.
4. Clean liner flange counter bore. Remove any

burrs from bore I.D. (B, Fig. 27) with a file.
5. Inspect block carefully for cracks or damage. If a

cracked block is suspected, pressure test the block. A
procedure for pressure testing is outlined in FOS-30
Engines manual.
R 26164^
Fig. 23-Degiazing Cylinder Liners
1 Secure cylinder liner in a holding fixture (Fig. 23).

(See Making Special Tools p. 20-00-10, for assembly
of holding fixture.)
2. Use D-17004BR Flex-Hone to deglaze cylinder
liner.
R 2S156
Fig. 25-Cieaning O-Ring Bore
6. Use D-17015BR O-ring Bore Cleaning Brush

Fig. 24-Proper Honing Pattern (Fig. 25) to clean O-ring bore.
3. Use D-17004BR Flex-Hone according to in-
structions supplied with tool to obtain a 45-degree
Crosshatch pattern (Fig. 24).
NOTE: After honing, thoroughly clean liners. First,
wipe abrasive residue from liner walls with a dry rag.
Swab out liner as many times as necessary with SAE-
WW oil. Continue to clean finer white rag shows
until
no discoloration,
IMPORTANT: Do not use gasoline, kerosene or
commercial solvents to clean liners. Solvents will
not remove ail the abrasive from liner walls.

. .
Fig. 26-Piston Cooling Orifice
7. Check each piston cooling orifice (Fig. 26) for a

plugged or damaged condition.
NOTE: A cooling orifice failure could cause damage

to pistons, piston pins, rod pin bushings and liners. RG12
8. Reinstall orifices and tighten to 85 to 115 in-lbs

(9.6 to 12.4 Nm) (.9 to 1.2 kgm). ACylinder Liner Square Packing

B Liner Flange Bore LD. E Red O-Ring
Installation CCylinder Block F Black O-Ring
Fig. 27'Liner Sealing Ring Installation
Liners
1 Be sure liner bore is clean. 5. Install square packing on cylinder liner (D, Fig.
27).
2. Install liner without Orings and secure with cap

screws and washers. NOTE: The packing is smaller than the liner and
must be stretched when installing. Make certain O-
3. Check liner height in several places and compare rings are not twisted when installed.
measurement obtained with the following specifica-

tions. 6. Install red O-ring in top groove in block (E, Fig.
27).
LINER HEIGHT
4040 7. Install black O-ring in bottom groove in block (F)
In new or
8. Lubricate Orings and bottom of liner with
used cylinder block 0.000 0.004 in.
to
AR54749 lubricant soap.
(0.00 to 0.10 mm)
4240
In new cylinder
block 0.001-0.005 in. (0,03-0.12 mm)
In used cylinder
block 0.000-0.004 in. (0.00-0.10 mm)
4. Remove liner.
TM-1181 (Apr-81) Litho in US. A Tractors - 4040 and 4240

Fig. 28-lnstalting Cylinder Liner

R 31127
NOTE; "LL" or "HH" mark on liner flange must face

A Piston Head 0 Expander Ring Gap
to front of engine.
B Top Compression E Bottom Compression
Ring Gap Ring Gap
C Oil Control Ring Gap F Front of Engine
9. Work liner in place by hand and seat with a wood
block and hammer. Fig. 29-Staggering Piston Rings
Pistons and Connecting Rods 7, Stagger piston rings according to Fig. 29.
1. Lubricate piston pin and bushing with SAE 10W 8. Carefully place JDE-96 Ring Compressor over
oii.
piston.
IMPORTANT: If a new piston and liner assembly

is to be installed, DO NOT remove
piston from
liner. Push piston out of liner bottom only far
enough to install piston pin.
2. Install piston pin in piston and connecting rod.
3. Insert piston pinsnap rings in grooves, making

certain snap rings are expanded in the grooves in the
piston.
4. Install expander ring in bottom ring bore.
NOTE; "Pip" marks on No. 1 and No. 2 rings face A Ring Compressor B Piston
toward head of piston.
Fig. 30-tnstaIiing Piston
Use JDE-47 Ring Expander on the 4040 and

5.
JDE-93 Ring Expander on the 4240 to install piston 9. Carefuliy pface ring compressor (A, Fig. 30) with
rings (Fig. 2 page 20-10-2). piston (B) and rod over liner.
NOTE; New rings are furnished with the correct end IMPORTANT: Be sure crankshaft journals are
gap, therefore, fitting to the iiner is not necessary. notdamaged when pushing piston into cylinder.
6. Coat pistons, liners, and inside of JDE-57 Ring NOTE; Be sure the word "front" on piston and rod
Compressor (for 4040) or JDE-96 Ring Compressor faces toward front of engine.
(for 4240) with SAE 10W oil.
10. With piston centered in installing tool and rings
staggered correctly, push piston into liner.

11. Apply engine oil to bearing inserts and crank- Head Gasket Installation
shaft rod journals.
Use the following procedure to measure height of
each piston above cylinder block to determine the size
12. Install connecting rod caps.
of cylinder head gasket that should be used.
IMPORTANT: Do not re-use connecting rod cap

screws. Always replace old cap screws with new,
once they are removed or torque disturbed.
13. Dip entire cap screw in dean, heavyweight oil
(SAE 30).
14. Install and tighten cap screws evenly to 55 ft-lbs

(75 ISIm) (7.5 kgm).
15. Turn each cap screw an additional 1/4 turn (90

+ 10-0 degrees).
R 31106
Rg, 32-Measuring Piston Height
a) Make sure area on block where indicator base is
to be placed (Fig. 32) is clean and smooth.
b) Position indicator and base as shown in (A, Fig.

32). Indicator point should be near rear edge of piston.
c) Rotate crankshaft while watching indicator dial.
When piston has reached its highest point (TDC)

1
"zero indicator.
d) Carefully lift indicator point, and rotate indicator

and base to the position shown in (B, Fig. 32).
30648
e) Release indicator point and record reading on
A Reference Mark B90 Degree Mark dial.
Fig. 31 -Torque-Turn Method of Tightening

On a 4040 Tractor:
If height of any one piston measures more than
NOTE: To ensure that the full 1/4 turn is accom-
0.0090 in. (0.23 mm) above the cylinder block, use
plished, the following procedure can be used.
R53438 (Grey and Red) cylinder head gasket. If height
of all pistons 0.0090 in. (0.23 mm), use
is less than
a) After tightening cap screws to 55 ft-lbs (75 Nm)
R48291 (Red) cylinder head gasket.
(7.5 kgm), mark the connecting rod cap and socket (A,
Fig. 31).
On a 4240 Tractor:
If height of any one piston measures more than
b) Make a second mark on the socket (B) 90 de-
0.0290 in. (0.74 mm) above the cylinder block, use
grees counterclockwise from the first mark.
R66065 (Black with Blue stripes) head gasket. If height
of all pistons0.0290 in. (0.74
is less than mm) use
Turn 1/4 turn (90 degrees) clockwise until mark
c)
R55182 (Black) cylinder head gasket.
(B) line with reference mark on cap. This ensures
is in
90 degree rotation of the socket instead of the wrench 1 6. Rotate crankshaft several revolutions to be sure
handle. there isno binding of parts.
17. Reverse access steps for reassembly of re-

maining parts.

Engine Repair Crankshaft, Main Bearings and Flywheel 20-15-1
Group 15
CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL
DIAGNOSING MALFUNCTIONS INSPECTION AND REPAIR
Damper Pulley
Scored Main Bearings (Diagnosis applies
to Connecting Rod Bearings, also See NOTE: The damper assembly should be replaced
every 5 years or 4500 hours, whichever occurs first
Group 10, this Section)
Oil starvation
Contaminated oil
Engine parts failure
Excessive heat
Poor periodic service
Galled or "Wiped" Bearings

Fuel in lubricating oil (incomplete combustion)
Coolant in lubrication system (cracked block or liner
seal failure)
Insufficient bearing oil clearance
Parts not lubricated prior to engine operation
Wrong bearing size
Inconsistent Wear Pattern R 31139 > -/ /

Misaligned or bent connecting rod Fig. 2-Checking Damper
Warped or bowed crankshaft 1. Grasp damper, and attempt to turn in both

Distorted cylinder block clockwise and counter-clockwise direction. If rotation is
felt replace damper.

Broken Main Bearing Caps ::-&&y.i:xl: JS?a^?;;;.
îii
Bfc-""
nsHEi;
:
Improper installation 'A*

"rr!Sstt::H Hjjjpi
Dirt between bearing and crankshaft journal
Low oil pressure ir^-a-! .
i&SH
:
'- ;
::--.-ii
Oil pump failure inilllt?ul!ii
Cracked, Chipped or Broken Bearings

Overspeeding
Excessive idling
Lugging
Excessive oil clearance wzm*
Improper installation
Access R 31140
To inspect and repair crankshaft, main bearings and Fig. 3- Dam per Pulley
flywheel, engine must be removed from tractor.

2. Examine rubber on front and rear portion of
damper pulley, making sure that no large sections of
1. Separate engine from clutch housing (p. 10-25-
rubber have come loose that might affect crankshaft
9).
balance.
IMPORTANT: Do not clean or submerge damper
2. Remove engine from front end (p. 10-25-14).
in solvent. Use plain soap and water only.
I

20-15-2 Crankshaft, Main Bearings and Flywheel Engine Repair
Damper Pulley Continued Crankshaft Gear

3, Replace damper if rubber deterioration has oc- 1. Check crankshaft gear and camshaft gear for
curred in excess of 1 /4 in. deep and a total of 90 of the wear or damage.
circumference of the pulley. NOTE: To remove crankshaft gear, camshaft must
first be removed.
IMPORTANT: If engine is to be turned upside
down for repair and cylinder head is not to be
removed, remove drain plug from base of oil filter
and drain out oil. This will prevent oil from draining
into the cylinder head, causing oil blow-out when
restarting engine.
Front Wear Sleeve

1. Remove
Timing gear cover.
2. Check wear sleeve for wear or damage.
front
IMPORTANT: Do not penetrate wear sleeve with
chisel.
.* Z#17V(.
^
Fig. 5-Removing Crankshaft Gear
2. Remove
crankshaft gear using gear pulling at-
tachment and adapter (Fig. 5).
Flywheel
A Front Wear Sleeve B Score Lightly
Fig, 4-Scoring Wear Sleeve Before Removsi
3. To remove wear sleeve, score lightly with a DULL

CHISEL. DO NOT score too deeply.
4. Gently pry wear sleeve from crankshaft.
5. Inspect crankshaft flange for burrs or nicks.
6. Clean up flange with a light fife and fine emery
cloth, if necessary.
AClutch Mounting Holes C Ring Gear
Front Oil Seal B Flywheel 0 Crankshaft Mounting
Holes
1. Check front oil seal for wear or deterioration.
2. Use a small punch and tap around metal edge of Fig, 6-Flywheei Assembly
seal to remove.
1 Check flywheel for cracks or damage, particularly
.
around clutch mounting (A, Fig. 6) and crankshaft

mounting holes (D).

Engine Repair Crankshaft, Main Bearings and Flywheel 20-15*3
2. Examine flywheel ring gear for chipped or broken Clutch Shaft Pilot Bushing and Adapter (Quad-
teeth. Range)
Remove 1. Check clutch bushing in adapter, and end of

3. gear by placing the flywheel on a
ring
clutch shaft for wear.
soJid flat surface, and driving ring gear off with a brass
drift and hammer,
Clutch Shaft and Bushing Specifications
A CAUTION: Oil fumes or oil can ignite

above 380 D F (193C). Use a thermometer
and do not exceed 360F (182C). Do not allow a
Bushing I.D, 1.0025 to
(25.46 to 25.54
1.0055 in.
mm)
Shaft O.D. 0.9995 to 1.0005 in.
flame or heating element to be in direct contact mm)
(25.39 to 25.41
with the oil. Heat the oil in a well-ventilated area.
Plan a safe handling procedure to avoid burns. 2. Use No. 959 Bearing Puller with No. 957 Slide
Hammer Puller to remove clutch bushing.
4. Install new ring gear by heating gear to 300F
(148C) using either heated oil, oven heat, or flame Check hex.
3. drive in the adapter and end of pump
heat. drive shaft for wear or damage. .
-
IMPORTANT: If flame heat is used, be sure gear
is heated uniformly around circumference. DO

NOT OVERHEAT. SEE CAUTION. Overheating may
also destroy original heat treatment of gear.
5. Tap heated gear into place against flywheel

shoulder.
6. Always replace flywheel cap screws once they

are removed or torque disturbed.
NOTE: Be sure gear circumference is against

shoulder
Clutch Shaft Pilot Bearing (Power Shift)
ACap Screw DCross-bJock

BWasher ETransmission Pump
GSnap Ring Drive Adapter
FCrankshaft Flange
Fig, 8-Tran$mi$$bn Pump Drive Assembly Removal
4. To remove adapter place a 3/8 x 5-inch (127

mm) cap screw (A, Fig. 8) and R43696 washer (B) in
adapter bushing bore.
5. Install a H214R snap ring (C) in adapter bushing

bore.
6. Using a cross-block and two cap screws (D) in

the crankshaft flange, pull adapter.
Fig. 7-Removing Clutch Shaft Pilot Bearing
1 . On tractors with a Power Shift transmission, use

D-01209AA Puller to remove clutch shaft pilot bearing
(Fig. 7).

Rear Crankshaft Oil Seal, Housing, and Measuring Assembled l.D. of Bearings and O.D. of
Wear Sleeve Crankshaft Journals
1. Remove rear oil seal housing. 1. With crankshaft out of engine, install main bear-
ing inserts and caps (be sure inserts are installed
2. Check oil seal for damage or leakage. correctly.)
IMPORTANT: Do not penetrate wear sleeve with 2. Tighten main bearing cap screws to 150 ft-lbs
chisel. (203 Nm) (20.3 kgm).
Fig. SScored Wear Sleeve Before Removal
3. To remove wear sleeve, score lightly with a DULL

CHISEL. DO NOT score too deeply (A, Fig. 9). Fig. 10-Measuring Bearing I.D.
4. Gently pry wear sleeve from crankshaft. 3. Measure bearing l.D.
5. Inspect crankshaft for burrs or nicks.
6. Clean flange with a light file and fine emery cloth

if necessary.
Main Bearings
A drop in oil pressure, excessive oil consumption,
engine knock, or excessive crankshaft end play are
indications of main bearing and main thrust bearing
washer failures.
1. Remove main bearing caps and examine main

bearing inserts for excessive wear, scoring, and dam-
age.
NOTE; Main bearing caps are numbered for reas-

sembly on the same numbered main bearing bosses,
identify bearing inserts for comparison with crankshaft
journals. Fig. 11 -Measuring Crankshaft Journal
NOTE: Main bearing oil clearance can be deter-
mined by measuring the assembled I.D. of bearings 4. Measure crankshaft journal O.D. at several
and 0.0, of crankshaft journals, or with the use of points around journal (Fig. 11).
(
"Plastigage'\

.
Engine Repair Crankshaft, Main Bearings and Flywheel 20*15-5
MAIN BEARING AND JOURNAL SPECIFICATIONS 3. Install main bearing caps, tightening cap screws
to 150 ft-lbs(203 Nm) (20 kgm).
Measurement Specifications
O.D, of main bearing 4. Remove the cap and compare the width of
journal 3.3720 to 3.3730 in, "Plastigage" with scale provided on side of package to
(85.649 to 85.674 mm) determine ciearance.
I.D. of main bearing
(assembled) 3.3742 to 3.3762 in. Thrust Bearings
(85.705 to 85.755 mm)
Clearance 0.0012 to 0.0042 in.
0.0077 in. max,
(0.0508 to 0.1067 mm)
(0.1956 mm - max.)
NOTE: If engine had previous major overhaui and

undersized bearing inserts were used, above listed LD.
and O.D. dimensions may not be the same as those
recorded. However, oii ciearance should be within
specifications.
If wear is even but out of specifications, dress jour-

nals and select proper undersize bearing inserts.
Bearing inserts are available in 0.002, 0.010, 0.020
and 0,030 inch (0.05, 0.25, 0.50, and 0.75 mm) un-
dersizes.
R 2^5H
NOTE: if undersized bearings are used, check A Lower Rear Thrust DMain Bearing Fillet
bearing clearance with bearing caps tightened to Bearing Washer Thrust Bearing
specified torque, if undersize bearings are too tight and B Upper Rear Thrust E Main Bearing Cap
ciearance is not within specifications, the journai and Bearing Washer Thrust Bearing
C Lower Front Thrust F Large Tang
bearing will be wiped clean of oil resulting in premature
Bearing Washer G Small Tang
wear on parts.
Rg. 13-Thrust Bearing and Washer
Measuring Clearance with "Plastigage"
1, Examine crankshaft thrust surfaces and thrust
bearing washers for excessive wear or damage.
2. If crankshaft end play was excessive, dress

thrust surfaces of crankshaft, and install new regular
size or oversize thrust bearing washers.
Thrust bearings are available in 0.002, 0.010, 0.020

and 0.030 inch (0.05, 0.25, 0.50 and 0.75 mm) under-
sizes. Oversize thrust washer sets contain one regular
size washer and two 0.007 in. (0.18 mm) oversize
washers. The regular size washer is installed on the
front side of main thrust bearing cap.
Rg. 12-Determining Main Bearing Ciearance
1 Remove main bearing caps.
2. Place a strip of "Plastigage" in the center of the

cap.
TM-1181 (Feb-79) Litho in US. A. Tractors - 4040 and 4240

Crankshaft Journals INSTALLATION
Main Bearings and Crankshaft
R 263S6N
Fig. 14-Critical Areas of Load Stress in a Crankshaft
1. Check crankshaft for cracks or signs of load

stress (Fig. 14).
NOTE: Stress cracks are more likely to occur at the

No.5 and No. 6 journal oil holes than at other oil holes. AMain Bearing Insert CThrust Bearing Washers
BMain Thrust Bearing D>Front of Engine
2. Use crankshaft journal O.D. measurements to
Ftg. 15~Main Beating Installation
determine if journal is out-of-round or has worn ta-
pered.
1. Install main bearing inserts,
Journal taper per inch of 2. Be sure thrust bearing insert is installed in fifth
journal length 0,0001 in. (0.002 mm) bore from front of engine.
Journal out-of-roundness 0.0040 in. (0.102 mm)
3. Make sure the tangs on all bearings fit in re-
3. If journals have worn tapered or out-of-round or

cesses in bore and that oil slots line up with oil pas-
are scored or damaged, the crankshaft should be sages in block.
ground and proper undersize bearing inserts should be NOTE: If new thrust bearing inserts or thrust bear-
installed. ing washers are installed, they must be installed as a
set
IMPORTANT: Crankshaft grinding should be
done ONLY by experienced personnel on equip- 4. Apply a film of oil to bearing surfaces and to
crankshaft journals.
ment capable of maintaining crankshaft size and
finish specifications. 5. Install crankshaft.
6. Install each bearing cap with the recesses and

tabs facing the same side of the engine as those on the
respective upper bearings in the block.
7. Make sure bearing caps are installed on the

bearing bosses from which they were removed.
NOTE: The numbers stamped on the caps should

be on the same side as the numbers on the block.

.
Engine Repair Crankshaft, Main Bearings and Flywheel 20-15-7
8. Tighten main bearing cap screws (except thrust Rear OH Seal and Housing
bearing cap screws) to 50 ft-Jbs (68 Nm) (6.8 kgm).
9. Align upper and lower thrust flanges on main

thrust bearings.
10. Gently tap crankshaft to the rear then to the

front of engine to line up flanges.
11. Tighten all main bearing cap screws to 150

ft-lbs (203 Nm) (20.3 kgm).
Rear Wear Sleeve

1. Apply a light coat of Permatex No. 3 to the
crankshaft flange before installing wear sleeve.
2. Carefully center new wear sleeve in crankshaft ADriver BOil Seal Housing
flange with the O.D. chamfer of the sleeve toward the
rear of the tractor. Fig. 18-tnstaiting OH Seat
3. To install wear sleeve, first start wear sleeve onto

1 Support the oil seal housing as close to the seal
crankshaft flange.
bore as possible (Fig. 18).
2. Start seal by hand with spring side of seal away

from flange side of housing.
3. Press in seal with JDE-106-2 Driver until driver

bottoms on the housing flange.
4. Lubricate seal lip with engine oil.
5. Carefully work seal and housing over wear

sleeve,
6. Snug, but do not tighten housing cap screws.
Fig. 16-installing JDE-106 Guide
4. Install guide from JDE-106 Too! Set (Fig. 16).
III
]': :'!::!. !;l:li!S.
AO.D. ol Oil Seal C Crankshaft Flange
|JJ Housing Flange DOH Seal

B Dial Indicator
Fig. 19-Checking Oil Seal Run-Out
Fig- 17'instalfing Wear Sleeve

1. Attach a dial indicator base to the crankshaft
5. Use JDE-106 Driver to drive sleeve onto flange
flange (Fig. 19).
until driver bottoms on the guide.

Rear Oil Seal and Housing Continued 3. Use JDE-3 Driver to press on wear sieeve.
8. Locate the dial indicator on the O.D. of the oil

4. Install front oil seal in housing, with spring side of
seal housing flange (A, Fig. 19).
seal facing engine.
9. Turn the crankshaft and check housing bore
run-out.
10. Lightly tap the housing to bring into .0060 in.
(0.15 mm) maximum run-out.
11. Tighten cap screws to 20 ft-Ibs (27 Nm) (2.7

kgm).
12. Trim off gasket material extending below bottom

of oil seal housing.
Crankshaft Gear, Front Wear Sleeve and

Oil Seal
m lipiy^ j:*
l-i m f
vS--:~' j; * *r* * "::K*
::
: -
"i.h. ">.'
'AV^HSi'llill
*î Hn
r
:Iii::IHH:i:I;::H:i:Ifi! KHrrHIK^SIrlHiSiSHSSasK;
,r: ATiming Gear Cover BOU Seal C Driver
:
: r :
^3[gSjH Bfffiiiuu^KrL"!:::;: ":*"

M:i HHr
jljLiLH^n^^ Hj^rlitv Fig. 22-instalting Front Oil Seal
HjyijjjijySS k^SH
slj^jSrunssaSlfeE:"" !?~~?S[=jSj"; SpS 5. Support timing gear cover around seal bore.
1*agt;:KKrr:ggKgdaih xisosoi^f

V::::::: : ::*.-;-iit? sqppfe

Idiis-lliliii
If::?::::!!:;:::
:*:::::v: ^ .pî:.y.r ,:t tss5??rr^'" \ '.::**
4| :
-r; i
j9 6. Press seal in with No. 27522 and No. 27537
'M,:
l."s ;:'::"'
Disks from No. 27797 Bushing Driver Set
: : *
i: :;ns: :
*
:&;!?: 1 ~fiffi
. ~.u. . '_L vifrffit^*' g-jHjr

11 "
NOTE: Closed side of seal should be 0.33 in. (8.4
131
Nîi
jSH^^pi mm) from front of cover.
^sr ! ittir^?::::;::;:;:::;:;
*
.... *
* t:
::::::::: 7. Lubricate seal before installing cover on engine.
:"Q
r. ?;: : ::.:r:.. :
.: "" ' *" ::
'
"".. V::.:*::::: :.::t::
:
Rg. 20-tnstaifing Crankshaft Gear
1. Install crankshaft gear using JDH-7 Driver (Fig.

20).
2. Coat LD. of new wear sleeve with Permatex No.

3.
AWear Sleeve BJDE-3 Driver

Fig. 21 -installing Front Wear Sieeve

Engine Repair Lubrication System 20-20-1
Group 20
LUBRICATION SYSTEM
DIAGNOSING MALFUNCTIONS Oil Pressure Regulator Spring Compression
1 .91 in. (46.5 mm) at 30 to 33 ft-lbs (41 to 45 N-m) (4.1
Low Oil Pressure to 4.5 kgm).
Low oil level

4. Remove filter relief valve plug, spring and valve
Clogged cooler or filter
(C).
Excessive oil temperature
5. Check filter relief vafve spring tension.
Oilpressure regulating valve failure
Excessive main bearing clearance
Oil Fitter Relief Vafve Spring Tension
Clogged oil pump screen
1 .38 in. (35 mm} at 18 to 22 ft-lbs (24 to 30 N-m) (2.4 to
Excessive clearance between oil pump gears
3 kgm).
and cover
6. Make sure that the oil filter housing passages are
High Oil Pressure
clean.
Clogged oil lines Oil Cooler
Oil pressure regulating vaJve failure
Oil Sludge and Dilution

improper operation and servicing
Coolant leakage into lubrication system
Incomplete combustion
Excessive oil temperature
REMOVAL, INSPECTION AND REPAIR

Oil Filter Housing
AOil Cooler Spacer CTo Cooler

B Oil Cooler Cover D From Cooler
Fig, 2-Engine Oil Cooler
1. Remove oil cooler (Hg. 2).
A Adjusting Washer C Filter Relief Valve 2. Check for clogged passages and scale buiid-up.
B OftPressure Regulating DOil Filter Housing
Valve
3. Clean with suitable brush, solvent, and com-
Fig. 1-OH Fitter Housing pressed air.
1. Remove oil pressure regulator plug, spring, and 4. Install oil cooler spacer (A) with large side toward
valve (B, Fig. 1} from base of oil filter housing (D). cylinder block.
2. Check valve (B) and valve bore for damage. 5. Install oil cooler, gasket with center web and oil
cooler cover (B) with pipes (C and D).
3. Check oil pressure regulator spring tension.

. .
20-20-2 Lubrication System Engine Repair
Oil Pumps OIL PUMP SPECIFICATIONS

Depth of gear bore in housing . . . 1.753 to 1.757 in.
1. Drain crankcase.
(44.5 to 44.6 mm)
2. Remove oil pan. Gear thickness 1 .750 to 1.752 in.
(44.4 to 44.5 mm)

Camshaft-Driven Oil Pump O.D. of gears 3.3801 to 3.811 1 in.
(85.85 to 96.80 mm)

NOTE: Late production 4240 Tractors are equipped
3.386 to 3,338
LD. of housing gear bore in.
with a crankshaft-driven oil pump. See heading mm)
(86.0 to 86.1
"Crankshaft-Driven" on page 20-20-3.
i.D. of driven gear 0.6220 to 0.6230 in.
1. Remove oil pump assembly from block. (15.80 to 15.82 mm)

LD. of idler gear 0.6330 to 0.6340 in.
(16.08 to 16.10 mm)

LD. of idler gear bushing 0.6300 to 0.6310 in.
(16.00 to 16.03 mm)

O.D. of idler shaft 0.6284 to 0.6290 in.
(15.96 to 15.98 mm)

O.D. of driven shaft 0.6235 to 0.6245 in.
(15.84 to 15.86 mm)
If the drive gear on top of the shaft is excessively
worn or damaged, check the integral oil pump drive

gear on the camshaft for wear or damage. Replace
pump drive gear and camshaft as necessary.
If either the idler gear or driven gear must be re-
placed, replace both gears.
Oil Pump Gears
R 2U553N
A Drive Shaft E Screen

BIdler Shaft F Driven Gear
C Idler Cover G Housing
D Cover
Fig. 3-Oti Pump
2. Remove intake screen (E, Fig. 3) and pump

housing cover (D).
3. Examine gears and housing for wear or damage

Check dam-
AIdler Shaft B Driven Gear
4. sealing edge of housing for signs of
age that could cause leakage. Fig. 4-Driven Gear Removal
NOTE: Worn gears, shafts of housing can reduce To replace pump gears:
pump output and could indicate oii contamination,
studge or bent or warped shafts. 1 Remove idler gear by sliding from idler shaft (A,
Fig. 4).
2. To remove driven gear (B), press shaft from gear.

RG2947
A Dial Indicator B Pump Drive Gear
C Crankshaft Drive Gear
Fig r 6-Checktng Oil Pump Crankshaft Drive
Gear Backlash
2. Mount dial indicator (A, Fig. 6) as shown and
measure backlash between pump drive gear (B) and

Fig. 5-tnstalIing Driven Gear
crankshaft gear(C).
3. Support pump housing as shown in Fig. 5.

Backlash must be at least 0.003 in, (0.08 mm). If
backlash is less than this amount, replace the pump
4. Use a press adapter that has a bore with an I.D.
drive gear.
larger than the pump shaft O.D. (Fig. 5) to install gear.
Removal
NOTE: Adapter bore must be deeper than 1.02 in.
(25.9 mm).
5. Carefully start gear onto shaft.
6. Use a feeler gauge when pressing on gear to

obtain a clearance of 0.001 to 0.007 in, (0.03 to 0.18
mm) between gear and bottom of housing.

Before removing the oil pump, determine if there is
adequate backlash between the oil pump and crank-
shaft drive gears. To measure backlash:
1 . Remove two cap screws on the gear shield (12, Fig.

15) and remove shield.
f
RG3107
A-^Gland Nut DOil Pump Housing
BOutlet Tube E Delivery Screen
CCover F Bypass Valve Housing
Fig. 7-Crankshaft-Driven Oil Pump
1. Remove delivery screen (E, Fig. 7) to obtain

wrench clearance for loosening gland nut (A).

Crankshaft-Driven
Pump Continued
2. Unscrew gland nut (A, Fig. 7) and remove outlet
tube (B). If unable to remove outlet tube from pump
cover (C), loosen bypass valve housing (F) cap
screws. Then pull tube out of valve housing and pump
cover.
3. Remove four oil pump housing-to-cylinder block

cap screws. Remove pump with drive gear attached.
inspection and Repair
IMPORTANT: Do not alter adjustment of set RG2678

screw (20, Fig. 15). If adjustment has been altered, Fig. 8-Checking Drive Shaft End Play
use procedure given on page 20-20-7 (under illus-

tration) to restore adjustment. 5. Check drive shaft side movement at drive gear
end Mount dial indicator with indicator plunger
(Fig. 9).
NOTE: Leave pump drive gear installed on pump resting on one of the hex nut flats. If shaft side move-
when making wear checks given below. ment exceeds 0.0065 in. (0.17 mm), it indicates ex-
cessive wear on drive shaft bushing and/or drive shaft.
Determine if the pump assembly is reusable before
performing any service work. Use the following pro-
cedure:
1. Visually inspect pump assembly for wear or

damage.
NOTE: Individual pump parts are not available for

service except for intake elbow, screen, gasket and
hardware; drive gear, washer, and nut Remaining
parts are serviced as an assembly only,
2. Flush pump assembly internally with clean sol- ^^l&J^r' V'-.;-:-

'jqsÎEl
RG2679
vent to remove oil from pump. Spin pump gears to
Fig. 9-Checking Drive Shaft Side Movement
remove solvent.
6. Check pumping gear backlash (Fig. 10). Mount

Place pump on work bench with pump-to-cylin-
3.
dial indicator with indicator plunger resting against wall
der block surface of mounting flange facing upward
of gear tooth as shown.
(same as when on engine).
Hold idler gear stationary (by reaching through oil
IMPORTANT: Wear given in numbered
limits
discharge hole) and slowly rotate drive gear back and
steps below are based on conditions given in
forth until contact with idler gear is felt. If backlash
Steps 2 and 3 above. To help ensure accurate wear
exceeds 0.039 in. (1 mm), it indicates excessive
measurements, perform the two above steps first.
pumping gear wear and/or idler shaft and gear bushing
wear.
4. Check drive shaft end-play (Fig. 8). Mount dial
indicator with indicator plunger resting against end of
pump drive shaft. Move shaft toward and away from
indicator. If end play exceeds 0.006 (0.015 mm), it
in.
indicates there is excessive wear on pump cover and/

or wear on end of pumping drive gear.

Install drive gear on shaft of pump to be used.

Secure with washer and nut. Tighten nut to 40 3 ft-lb
(54 3 N-m) (5.4 0.3 kgm).
NOTE: If crankshaft oil pump drive gear is worn or

damaged, the crankshaft will have to be replaced
(Group 15).
Tachometer Drive (Engines With Crank-

shaft-Driven Oil Pump)
Removal
Fig. 10-Checking Pumping Gear Backlash
Pumps Within Specifications
Rush out solvent from pump by adding 1 U.S. pint

(0.5 L) of engine oil through oil discharge hole and "
Pump ready on
spinning drive gear.
engine.
is for reinstallation
;!
Pumps Not Meeting Specifications
Fig. 12~Tachometer Drive
Discard pump assembly and replace with a new
one.
Remove four cap screws (Fig. 12) which secures
assembly to engine block. Pull unit out of engine block.
All Pumps
Disassembly
f^^ S^D
f^"^
RG2718
RG2718
Fig, 1 1-Removing Drive Gear
Inspect pump drive gear. If not in good condition,

replace using the following procedure:
HG2749
1Gasket 7Cap
1. Place drive gear in a "soft jawed" vise (Fig. 11). 2 Snap Rings 8Gasket
Unscrew nut and special washer from shaft until nut is 3Idler Shaft 9 Drive Shaft
flush with shaft end. Midler Gear 10 Hex Pipe Plug
5 Drive Gear 11Tachometer Drive
6 Woodruff Key Housing
2. Lightly tap shaft with soft hammer until gear 12 Cap Screw with Washer
comes loose from tapered shaft- Remove nut, washer,
and gear. Fig. 13-Exploded View of Tachometer Drive

Tachometer Drive Continued 3. install off pump-to-bypass housing tube in pump.

Place gland nut with O-ring on tube.
Disassembly Continued
1. Remove both snap rings (2, Fig. 13). Remove 4. Align tube and gland nut with bypass housing
idler shaft (3) and gear (4). and tighten gland nut. Tighten oil cooler bypass hous-
ing-to-cylinder block cap screws.
2. Remove cap (7) and discard gasket (8).
Oil Pumps
3. Remove hex pipe plug (10). Then remove drive
Camshaft-Driven Pump
shaft (9) with Woodruff key (6) and drive gear (5).
1. Apply JDT405 High Temperature Grease to
Inspection driven gears.
1- Remove all gasket material from cylinder block

2. Install pump cover and intake screen. Tighten
and drive housing.
pump cover-to-housing cap screws 21 -40 ft-lbs (29-55
N-m) (2.9-5.5 kgm). Tighten intake-to-cover cap
2. Inspect gears, shafts, and housing for wear or
screws 12-23 ft-lbs (16-31 N-m) (1.6-3,1 kgm).
damage. Replace parts as required.
3. Spin drive gear to check if both gears turn freely.

3.Clean all parts with clean solvent and dry with
compressed air.
4. Instali oil pump using new cap screws. Be sure
pump drive gear and gear on camshaft mesh.
ASSEMBLY AND INSTALLATION
Oil Cooler By-Pass Valve 5. Tighten oil pump-to-block cap screws to 20 to 25
ft-lbs (27 to 24 N-m) (2.7 to 2.4 kgm).
6. install oil pan.
NOTE: Early production engines used oil pans with

0.43 in, (11.1 mm) rail thickness. Late engines have
pans with 0.81 in, (20.5 mm) rail thickness. Use in-
structions below for instaiiing early pans. See instruc-
tions on page 20-20-8 for instaiiing pans with thicker
rail.
a. Before installing oil pan, remove all old gasket

and sealant materials from pan and cylinder block.
Make sure gasket surfaces are clean.
b. Tighten oil pan cap screws to following specifi-

cations.
Fig, 14-Oit Cooler Bypass Valve Housing Installation-
Shown With Camshaft-Driven OH Pump Location (Ft-lbs) (N-m) (kgm)
Oil pan-to-block
1. Instali the long end of the cooler bypass hous- 1 /2-inch cap screws 85 115 11.5
ing-to-block tube into the housing and insert opposite 3/8-inch cap screws 35 47 4.7
end into block (Fig. 14).
7. Fill crankcase with engine oil having correct

NOTE: Make sure O-ring is property seated be- grade and viscosity.
tween cylinder block and tube to prevent pressure oii
leakage. 8. Start engine and check adequate
pressure
for oil
(Section 220). Also check for leaks. pressure is If oii
2. Adjust tube and housing so housing is fiat against inadequate and/or leaks are present stop engine im-
the block mounting pad. Attach housing to block, but mediately and correct before restarting.
do not tighten cap screws. (

RG2949
1Hollow Dowel (2 used) 11 Drive Gear 21 Lock Nut

2 Pump Gears 12Gear Shield 22Gasket
3 Drive Shaft 13Lock Washer (2used) 23Washer (3 used)
4 kiier Shaft 14 Cap Screw (2 used) 24Cap Screw (3 used)
5 Pump Housing 15Pump Housing Cover 25Screen
& Washer used)
(4 1& Washer (5 used) 26Inlet Tube

7 Cap Screw (2 used) 17Cap Screw (3 used) 27Gland Nut
8Cap Screw (2 used) 18Cap Screw (2 used)

9 Special Washer 19O-Ring (3 used)
10Jam Nut 20Set Screw
Fig> 15-Crankshaft Driven Oil Pump
IMPORTANT: Ifset screw (20, Fig. 15) adjust- 4. Continue to hold set screw and tighten lock
ment has been altered, use the following proce- nut (21) to 8 N m (6 ft-lb). Be careful not to
dure to adjust: over-tighten set screw while tightening lock
nut.
1. Assemble drive gear and idler gear (1) into
Tighten pump 6over-to-housing cap screws
5.
pump housing (5).
to 40 N m (30 ft-lb).
2. Install oil pump cover (15) and finger-tighten
6. Check pump for binding.
cover-to-housing cap screws.
3. Hold cover against housing firmly and tighten
set screw to 8 N-m (6 ft-lb).
TM-1181 (Apr-81) Litho in US, A. Tractors - 4040 and 4240

ASSEMBLY AND
INSTALLATION Continued
1. Check pump cover-to-housing cap screws (17
and pump on
18, Rg. 15) for tightness before installing
engine. Torque cap screws to 303 ft-lbs (41 3 N-m)
(4.10.3kgm).
2. Install pump assembly on cylinder block. Tighten

cap screws to363 ft-lbs (483N-m) (4.80.3 kgm).
3. Discard old O-rings (19) and replace with new

ones. Lightly lubricate O-rings with engine oil before
installing in pump cover (15), on inlet tube (26) and
RG2950
gland nut (27).
A^-3/8" x 1-1/2" D 1/2" x 1-3/4"
Cap Screws Cap Screws
4. Insert inlet tube Into pump cover. Be careful not B3/8" x 2" E Location for First
to dislodge O-ring. Start gland nut into bypass valve Cap Screws Screw
housing, but do not tighten until bypass valve housing C3/8" x 5-1/4"
cap screws are tightened (if previously loosened). Cap Screws

Tighten these screws to 55 ft-lbs (75 N-m) (7.5 kgm).
Fig. 16-Oi! Pan Cap Screws
5. Attach intake screen (25) to pump cover (15).

b) Place new gasket on engine and install oil
Tighten screws to 20 ft-lbs (27 N-m) (2.7 kgm).
pan. Insert a 3/8 x 2-in. cap screw in hole at E, Fig. 1 6.
Insert remaining cap screws, proceeding in a coun-
6. Check oil pump/crankshaft drive gear backlash. terclockwise direction.
See page 20-20-3 of this group.
c) screws to 40 ft-lbs (54 N-m)
Intiaily tighten all
7. Install pump drive gear shield (12). Tighten cap (5.4 kgm). Then, tighten all 3/8-in. screws to 50 ft-lbs
screws to 20 ft-lbs (27 N*m) (2 J kgm).
{68 N-m) (7 kgm). Complete installation by tightening
1/2-in. screws to 120 ft-lbs (162 N-m) (16 kgm).
8. Install oil pan - 0.81 in. (20.5 mm) rail thickness.
9. Fill crankcase with engine oil having correct

a) Before installing oil pan, remove all old gasket
grade and viscosity.
and sealant materials from pan and cylinder block.
Make sure gasket surfaces are clean.
10. Start engine and check oil pres-
for adequate
sure (Section 220). Also check for leaks, pressure if oil
is inadequate and/or leaks are present, stop engine
immediately and correct before restarting.
TM-1181 (Apr~81) Litho in US. A Tractors - 4040 and 4240

Engine Repair Lubrication System 20-20*9
Tachometer Drive (Engines With To install tachometer drive:

Crankshaft- Driven Oil Pump)
Coat all four drive housing-to-engrne block cap
To assemble tachometer drive:
screws (12) with joint sealing compound, except for the
first three threads.
1. Lubricate drive shaft (9, Fig. 13) and drive gear
(5) with light coat of engine oil.
Install drive assembly using a new gasket, being
sure tachometer idler gear is meshed with camshaft

2. Install driven shaft with Woodruff key (6) through
gear. Tighten cap screws with washers to 35 ft-lbs (47
housing (11) and drive gear.
N-m) (4.7 kgm).
3. Lubricate idler gear (4) and shaft (3) with a light

Install cap (7) using a new gasket (8).
coat of engine oil. housing and secure with
Install in
snap rings (2), Spin gears to make sure they rotate
freely.
4. Apply a light coat of joint sealing compound to

hex pipe plug (10). Install plug and tighten securely.


Engine Repair Cooling System 20-25*1
Group 25
COOLING SYSTEM
DIAGNOSING MALFUNCTIONS 4. a 5/16 in. cap screw in end of hose and
Insert
tighten hose clamp over cap screw to seal hose.
Engine Overheats
5. Remove the 15 psi (1.03 bar) (1.05 kg/cm 2)
Loose fan belt
radiator cap.
Dirty radiator or grille screen
Low coolant level
6. Attach D-05104ST Pressure Pump to 15 psi
Low oil level
kg/cm ) filler neck.
(1,03 bar) (1.05
Improper operation
Defective head gasket
7. Use pump to apply 18 psi (1.24 bar) (1.26 kg/
Incorrect timing
cm*) compressed air to system.
Faulty thermostats
Faulty radiator pressure cap
8. Check engine, radiator and hoses for coolant
Faulty water pump leaks.
Corroded coolant passages
Radiator Caps
Low Coolant Level
Improper maintenance
Improper operation
Damaged radiator
Water pump seal leakage -. ""5lWM?:,^::-. . Ai^^tmSS^^^'^m
" **
Leakage -:iJiiiiHll^^SBSSS^~ '".:
, :
' dpt?;tj?r"'>-
'''''"_
'>''dl&"-'''~'-"j^Jll "f !';
jjjJgjf j
Faulty radiator cap
I
;hsl!'!:"I->.
f:
l:;
; .-' r !
*
:
!
;*:;:"
:!;;:;;
:'.':'.
llllMJll *^,
RADIATOR
1. Remove hood.
2. Visually check the radiator for leaks or damage.

III
:
:;i-sr: :.:
Fig. 2-Checking Radiator Cap Pressure
1. Remove 7 psi (0.48 bar) (0.49 kg/cm 2 ) cap and

attach to D-05104ST Pressure Pump.
2. Cap should maintain 6.25 to 7.50 psi (0.3 to 0.4

bar) (0.4 to 0.5 kg/cm2 ) pressure.
3. Remove 15 psi (1.93 bar) (1.05 kg/cm 2) cap and

attach to BT-11-52 Tester.
4. Cap should maintain 14 to 17 psi (0.96 to 1.17

bar) (0.98 to 1.19 kg/cm 2 ).
Fig. 1 -Checking Radiator

)
3. Remove the 7 psi (0.5 bar) (0.5 kg/cm a ) cap to
overflow valve hose from overflow valve.
TM-1181 (Feb-79) Lltho in U.S.A. Tractors - 4040 and 4240

20-25-2 Cooling System Engine Repair
Radiator Caps (Continued) FAN BELTS

IMPORTANT: Do not tension or release belts
when hot
Adjust belt tension by prying on front half of
alternator body only.
Use a belt tension gauge to adjust belts to the

foliowing specifications:
Tension New Belt

Single belt 130 to 140 lbs. (578 to 622 N)
Dual belt 95 to 104 lbs. (423 to 467 N)
ASealing Rubber
Tension After Run In*
Fig. 3-7 psi Radiator Cap
All belts 85 to 94 lbs. (378 to 423 N)
5. Check rubber sea! on 7 psi (0.46 bar) (0.49

immediately after run in (approximately 10 min-
kg/cm 2 ) cap for brittleness and cuts.
utes) check tension. If tension is within specification,
no adjustment is necessary, tf tension is not within
Overflow Valve specification, wait 1 minutes; loosen belts and tension
1. Remove overflow valve from radiator. to specifications. Tension front belt only,
2. Remove overflow hose that leads to 15 psi (1 .03 WATER PUMP

2
bar)(1 .05 kg/cm ) radiator cap and leave hose to 7 psi
cap on overflow valve. Water Pump Access
1. Disconnect wiring from alternator.
2. Remove alternator.
3. Remove fan and pulley from water pump hub.
4. Drain the cooling system.
5. Remove inlet and outlet hoses from water pump.
6. Remove water pump.
Pump leakage can be caused by one or more of the

following conditions:
1. Cracked housing.
2. Damaged impeller bore.
3. Cracked, loose or damaged ceramic insert.
4. Loose or defective rubber cup.

Fig. 4-Checking Overflow Valve
5. Failed bearing.
3. Fill D-05103ST Tester with pure antifreeze.
6. Scratched, damaged or worn seal.
4. Place overflow valve in D-051 03ST Tester as NOTE: Leakage at the drain hole in pump housing
shown. usually indicates a leaking seal.
5. Heat valve element to 222F (1 05.5C) and apply

3 psi (0.2 bar) (0.2 kg/cm 2 ) air pressure.
6. Air flow through valve should stop (closed valve)

between 222F (1 05.5C) and 228F (1 08.8C). If valve
is defective, replace with new.
(
TM-1181 (Feb-79) Lithe in USA. Tractors - 4040 and 4240

Engine Repair Cooling System 20-25-3
12^
ss
j>
^w- - ;;.': : :
r^*"i!;^
RG2952
A One-Piece Seal B Three-Piece Seal

RG2960
Pump
ACover Cap Screws
B
Fig, 8-Water Seals
Bg. 6-lVafer Pump Cover
1. Remove the four pump cover-to-housing cap

screws (B, Fig, 6). Carefully separate cover (A) from
housing.
ASeal BCeramic Insert

R26130N Fig. 9-ImpetIerr Se.al, and Housing
ADriver B Impeller
3. On pumps with three-piece seal, remove seal (A T
Hg. 7-Removing Bearing
Fig. 9) from housing. Remove ceramic insert (B) and
jubber cup from impeller. If pump has a one-piece
2. Use a and driver (A, Rg. 7) to
hydraulic press
seal, remove seal from housing.
push bearing and shaft assembly out of impeller (B)
and pump housing.
NOTE: The unitized-type seal (seal with insert and

cup ail in one piece) has a press fit to both the bearing
shaft and pump housing. See Fig. 8 for a comparison
of the three-piece seal and one-piece seal. Usage of
one-piece seal in production began with Engine Serial
No. (143517- ) on 4240 Tractors onfy.

!js^#iEf! m*& fês^^^miSSmm^ 2. Place JD262A Installation Tool (A, Fig. 11) over
bearing shaft (B) and press bearing into housing flush
with housing edge.
3. Install seal.
Three-piece seal - AH 4040 and Early 424QJTra6tors

;:::?:;;::;:::::::: ::: ::::
.::::?;:::::::;:::::::
a) Be sure that seal is cE$3n and dry. install in

bore.
NOTE: To prevent contamination of the ceramic
insert, do not handle the insert with a bate hand, install
the insert in the cup witfa polished side out.
b) Install the rubber cup and ceramic insert into

the impeller.
IMPORTANT: The seal lip and insert face must

be perfectly clean, as both surfaces are lapped to a
fine finish.
Fig. 10-Pushing Bearing from Hub

One-piece seal - 4240 Engine Serial No. (148517-
4. If bearing or hub is to be replaced, press bearing )
from hub (Fig. 10).
Water Pump Specifications

Impeller bore 0.6242 to 0.6252 in.
(15.85 to 15.88 mm)

Bearing shaft CD 0.6262 to 0.6267 in.
(15.91 to 15.92 mm)

Assembly
1 . Coat bearing shaft with a light coat of clean SAE
10W engine oil.
HG2953
ADriver B Seal C Housing

Fig. 12-lnstaifing One-Piece Seat
IMPORTANT: Use the driver (A, Fig. 12) that is

included with the water pump seal kit. Seal has a
press fit on both shaft and pump housing.
a) Place seal onto shaft with driver over seal (B).
b) Drive seal until it bottoms in housing (C).
p '^jî.y.^ffl.^faj; **k
-
n^rîrt^^^SiMwhttolii i inMJiViihi^âiWfiifafr^'iifrW,
R26399N
AJD262A Tool B Bearing Shaft
Fig. 11 -Pressing in Bearing
TM-1181 (Apr-81) Lttho in US. A. Tractors - 4040 and 4240

Engine Repair Cooling System 20-25-5
Place a spacer (1/16 in. or longer x 11/16 in.

7.
O.D.) under bearing shaft (A, Fig. 14). Press on im-
peller until there is 0.015 to 0.025 in. (0.4 to 0.6 mm)
clearance between machined surface of housing and
impeller.
8.Remove from press, and turn shaft and impeller

to be sure that impeller does not drag on housing.
9. Be sure gasket surfaces on both pump cover and

housing are clean. Using a new gasket, install cover on
housing. Tighten cap screws to 20 ft-ibs (27 N-m) (2.7
kgm).
RG146Q
installation
A Hub-to-Rear Face Measurement
1. Be sure gasket surfaces on both engine block
Fig. 13-tnstatIing Hub and pump housing are clean.
4. Support bearing shaft from rear and press on hub 2.Using a new gasket, install water pump on en-
until hub-to-rear face measurement (A, Fig. 13) is as pump-to-engine block cap screws to 35
gine. Tighten
listed below. ft-ibs (48 Nm) (4.8 kgm).
HUB-TO-REAR FACE SPECIFICATION

3. Install pulley and fan on pump hub. Tighten cap
screws to 35 ft-lbs (48 N-m) (4.8 kgm).
4040 3.76 in. (95.5 mm)
4240 4.49 in. (1 14.0 mm)
4. Complete installation of pump by:
5. Apply a light coat of Permatex Form-a-Gasket

a) Installing pump inlet and outlet hoses.
No. 2 to bearing shaft bore in the impeller. Application
should be from the side opposite the insert to prevent
b) Installing alternator and connecting wiring to
getting Permatex on the insert.
alternator.
6. Apply a light coat of SAE 10W engine oil to insert

c) Filling cooJing system with recommended
face (do not grease).
coolant,
5. Check cooling system for leaks before and after

starting the engine.
ABearing Shaft
Fig. 14*Pressing on Impeller

.
WATER MANIFOLD AND 4. Remove thermostats.

THERMOSTATS
5. Check each thermostat in D-05103ST Tester. (
c
Inspection and Repair Thermostat should open at 160 to 180 (71 to 82C).
Installation
1. Apply Permatex Form-a-Gasket No. 2 to water

manifold-to-thermostat cover parting surface.
2. Install thermostats.
3. Install gasket.
4. Install thermostat cover.
5. Install upper radiator hose.
AWater Manifold
/Fig. 15-Water Manifold
1 Visually inspect area around water manifold (A,

Fig. 15) for leaks.
2. Remove upper radiator hose.
3. Remove thermostat cover.

Fuel and Air Repair Specifications and Special Tools 30-00-1
Section 30
FUEL AND AIR REPAIR
Page
GROUP 00 - SPECIFICATIONS AND GROUP 10 - DIESEL FUEL SYSTEM
SPECIAL TOOLS Fuel Tank 10-1
Specifications Fuel Pump 10-3
Air Intake System 00-2 Fuel Filter 10-3
Diesel Fuel System 00-2 Bleeding Fuel System 10-5
Control Linkage 00-3 Fuel Injection Pump 10-5
Special Tools 00-3 Injection Nozzles 10-8
GROUP 05 - AIR INTAKE SYSTEM GROUP 15 - CONTROL LINKAGE

Air Cleaner 05-1 Speed Control Linkage 15-1
Ether Starting Aid 05-3 Foot Throttle Linkage 15-3
Intake Manifold 05-4
>

30-00-2 Specifications and Special Tools Fuel and Air Repair
Group 00
(
SPECIFICATIONS
Air intake System
rTEM SPECIFICATION
AIR CLEANER
Air intake vacuum at 2200 engine rpm (full load) with
clean filter elements
With extension
4040 Tractors 8 in. (20 mbar) water
4240 Tractors 9.5 in. (24 mbar) water
Maximum permitted reading 25 in. (62.3 mbar) water
Restriction required to activate indicator (amp 24-26 in. (60.0-65.0 mbar) water
INTAKE MANIFOLD
Intake manifold-to-cyiinder head cap screws 35 ft-lbs (47 Nm) (4.7 kgm)
ETHER STARTING AID
Spray nozzle orifice 0.020 in. (0.51 mm)
Voltage to energize solenoid 4 volts
Diesel Fuel System
ITEM SPECIFICATION
FUEL TANK
Capacity
4040 Tractors 37 U.S. gaL (140 I)
4240 Tractors 46 U.S. gal. (174 I)
FUEL SUPPLY PUMP

Normal operating pressure at idle speed 3.5-4.5 psi (0.2-0.3 bar) (0,2-0.3 kg/cm 2 )
FUEL INJECTION PUMP

Timing to engine TDC
Fast idle speed ?
2380-2420 rpm
Slow speed
idle 780-820 rpm
Injectionpump-to-engine stud nuts 35 ft-lbs (47 Nm) (4.7 kgm)
Drive gear-to-hub cap screws 35 ft-lbs (47 Nm) (4.7 kgm)

Fuel and Air Repair Specifications and Special Toots 30-00-3
Diesel Fuel System Continued

ITEM SPECIFICATION
FUEL INJECTION NOZZLES

Model KDEL - 21 mm
Nozzle size
4040 Tractor 5 x 0.25
4240 Tractor 4 x 0.28
Nozzle Opening Pressure
4040 Tractor
New ... 3350 psi (231 bar) (235 kg/cm 2)
Used ... 3200 psi (221 bar) (232 kg/cm 2 )
4240 Tractor
New 3800 psi(262 bar) (268 kg/cm2 )
Used 3600 psi(246 bar) (254 kg/cm 2 )
Nozzle retaining nut .44-58 ft-lbs (60-79 Nm) (6.0-7.9 kgm)
Nozzle gland nut .55-65 ft-lbs (75-88 Nm) (7.5-8.8 kgm)
Fuel delivery pipe connectors 20 ft-lbs (27 Nm) (2.7 kgm)
Control Linkage
ITEM SPECIFICATION
SPEED CONTROL LINKAGE

Force to move hand throttle . . 8 lbs. (35 N)
.
Fast idle speed 2380-2420 rpm

Slow idle speed . . 780-820 rpm
.
FOOT THROTTLE LINKAGE

Foot throttle pedal position at fast idle . . . 1/4-in. (6 mm) above floor mat
SPECIAL TOOLS
Injection Pump TOOL USE
AJDE-61-1 Engine Timing injection pump to en-

Rotation Tool* gine
B-^JDE-81-4 Timing Used in conjunction with JOE-

Pin* 81-1 to time injection pump
O-CS-2428 Line Wrench* Loosening & tightening injec-

tion pump and nozzle fuel
pipe connectors
ft 28B64N
Fig. 1-TooIs for injection Pump Service
I *Order from: Service Toots, P. O. Box 314, Owatonna MN 55060
TM-1181 (Oct-78) Lftho in U.SA. Tractors - 4040 and 4240

30-00-4 Specifications and Special Tools Fuel and Air Repair
SPECIAL TOOLSContinued
Injection Nozzles
TOOL USE
JDE-92 Nozzle installing Robert Bosch KDEL

Socket Wrench* Injection nozzles
RS838BN
Fig. 2-Nozzte Socket Wrench
AJDE-99 Nozzle Seat Removing carbon from nozzle

Reamer* gasket seat in cylinder head
BD-17030BR Thread Cleaning threads in cylinder

Cleaning Brush* head for injection nozzle
CJDF-5 Tap (M28xl.5)* Restoring threads in cylinder

<t* head for injection nozzle
R 28244N
Fig.3-Toois For Reconditioning Nozzle

Seat and Threads tn Cylinder Head
*Order from: Service Tools, P. O, Box 314, Owatonna, MN 55060
TM-1181 (Oct-78) Lrtho in U.S.A. Tractors - 4040 and 4240

Fuel and Air Repair Specifications and Special Toots 30-00-5
TOOL USE
JDE-105 Nozzle Cleaning Cleaning Robert Bosch injec-

Kit* tion nozzles
ABrass Wire Brush

BPin Vise
CSac Hole Cleaning
Drill
DCleaning Needles
EInspection MagnHier
E88363N
Fig. 4-JDE-105 Nozzle Cleaning Kit
AD-01109AA Portable Testing operational perfor-

Nozzle Tester' mance
B **Y-900-2 Fuel Line Connecting adapters to tester
-**Y-900-7 and Y-900-15 Connecting injection nozzles to

Straight Adapters fuel line
R 28245N
Fig. 5-NozzIe Testing Equipment
MATERIALS
Anti-Seize Compound Applied to injection nozzle

{Never-Seez, or equivalent) body and gfand nut to pre-
vent nozzle from seizing in
cylinder head
*Order from; Service Tools, P.O. Box 314, Owatonna, Minnesota 55060.
**Part of D-01110AA Universal Accessory Kit
TM-1181 (Oct-78) Litho in U.S.A. Tractors - 4040 and 4240

30-00-6 Specifications and Special Tools Fuel and Air System Repair
TM-1181 (Oct-78) Litho in USA. Tractors - 4040 and 4240

Fuel and Air Repair Air Intake System 30-05-1
Group 05
AIR INTAKE SYSTEM
AAir Cleaner CRestriction Indicator

BIntake Pipe Switch
Fig. 1-Air Intake System (4040 Tractor Illustrated)
AIR CLEANER
Removal
NOTE: Removal of the air cleaner assembly is not

normally required unless necessary to gain access to
an adjacent component, or to make a repair on the air
cleaner body.
Use the following steps to remove the air cleaner

1 and 2):
(Figs.
1. Remove side shields, grille screens, air stack
extension, muffler, and hood (not illustrated).
2. Disconnect wiring from restriction indicator

switch (C, Fig. 1).
3. Loosen the air cleaner-to-air intake pipe (B) hose

clamps, and disconnect hose from pipe.
Fig. 2-Air Cleaner Mounting Bolts
4. Remove the air cleaner mounting bolts (Fig. 2),
and remove air cleaner.

.
30-05-2 Air Intake System Fuel and Air Repair
Inspection and Service
R Z9044N
1 Unloader Valve 4Wing Bolt 7Lock Nut 9 Secondary (Safety)

2Cover 5Seaf Washer Seat Washer Element
3Wing Nut 6 Primary Element 10 Body
Fig. 3-Exploded view of Air Cleaner Assembly
Disassemble the air cleaner assembly (Fig. 3). Re- Installation

move cover (2) and filter elements (6 and 9).
Install the air cleaner assembly as follows:
The air cleaner body (10) should be carefully in-

1 Mount air cleaner in place on tractor.
spected for cracks and holes which would permit dust
to enter. Repair as required.
2. Connect air intake pipe to intake manifold and to
air cleaner.
Inspect the rubber unloader valve (1) for cracks,
clogging, or deterioration. Clean or replace, as re*
quired.
3. Connect restriction indicator switch wiring.
Service the filter elements whenever a tune-up or

4. Recheck all hose clamps for tightness.
overhaul is to be performed on the engine. See the

tractor operator's manual for filter element service in-
IMPORTANT: To prevent possible severe en-
gine damage caused by injestion of dirt, all con-
structions.
nections between the air cleaner outlet and intake
manifold must be tight.
Check the air cleaner outlet hose for signs of de-
terioration. Replace, if required.
5. Install muffler, hood, air stack extension, side
shields, and grille screens.

Fuel and Air Repair Air Intake System 30-05*3
ETHER STARTING AID
R 29045N
1Starting Fluid Can 8Packing Gland 14Adapter Union

2Adapter 9Bracket 15Clamp
3Packing 10Nut and Lock Washer 16Plate
4 Adapter Cap 11Rear Pipe 17Front Pipe
5 Drive Screw 12Clip 18Elbow
6Chain 13Grommet 19Spray Nozzle Holder
7 Packing 20Spray Nozzle
Fig. 4-Ether Starting Aid (Manually Operated)
1 Control Button
3Switch
3Nozzle
4 Spray NozzJe Holder
5 Elbow
8Pipe
7Solenoid
S Starting Fluid Can
R 29046N
Fig. 5-Ether Starting Aid (Electrically Operated)
>

ETHER STARTING AIDContinued

General Information
Two types of ether starting aids are used:
A. Manually-operated type (Fig. 4) used on tractors ,rtt"

<
without a Sound-Gard Body.
B. Electrically-operated type (Fig. 5) used on trac-

tors with a Sound-Gard Body.
?. i;66lN
The main difference between the two types is the

Fig. 6-Nozz!e Location Arrow
method of handling the ether starting fluid container for
ejecting ether into the engine.
Install nozzle holder in manifold, with arrow (Fig. 6)
pointing toward center of manifold.
Removal, Service, and Installation
Use Fig. 4 or 5 as a guide for removing and installing Install elbow fitting in nozzle holder, and connect
the starting aid. pipe to elbow.
Check the nozzle adapter and nozzle for plugging. Continue to refer to Figs. 4 and 5 to complete the
Use compressed air to clean restricted passages. installation. Check all connections to make sure that
Make sure that the bore is not damaged or enlarged. they are tight.
If switch or solenoid is defective, replace with a new Inspect cap on manually operated starting aid to see
one (electric starting aid). that packing seal (3, Fig. 4) is in good condition and in
place.
Check packing (7, Fig. 4) and replace if required.
On electrically operated starting aids> install a can
To install the ether starting aid: on the solenoid. Keep can installed at all times to
prevent dust from being drawn into the engine.
Install nozzle in nozzle holder. Do not use any
sealing compound on nozzle threads.
INTAKE MANIFOLD
General Information Removal
Intake manifold hose and cap screw connections
should be inspected periodically for tightness and kept
tight.
Fig. 7-intake Manifold Removal Procedures
TM-1181 (Sep-77) Lrtho in U.S.A. Tractors - 4040 and 4240

Fuel and Air Repair Air Intake System 30-05-5
Use the following procedure to remove the intake Inspect the machined mating surfaces of cylinder
manifold, referring to Fig. 7: head and intake manifold. Clean, as required, by using
a scraper and/or wire brush, and compressed air.
1. Loosen hose clamps on air intake hose.
Installation
2. Disconnect the ether starting aid pipe from man-
To install the intake manifold, reverse the removal
ifold (just forward of center manifold port).
procedures given above, using new gaskets.
3. Remove the intake manifold-to-cylinder head

Make sure that the air intake hose is in good condi-
cap screws, and lift off manifold.
tion. Tighten hose clamps securely.

Tighten the manifold mounting screws to 35 ft-lbs
Inspect the intake manifold for genera! condition. (47 Nm) (4.7 kgm) torque.
Always repair or replace manifold if it has cracked or is
not sound in every way.


J ,
:
Fuel and Air Repair Diesel Fuel System 30-10-1
Group 10
DIESEL FUEL SYSTEM
FUEL TANK
Removal
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Fig. 2-Fuef Tank Removal Procedures {Right-Hand Side)
5. Disconnect and remove air intake pipe,

Fig. 1-Fuel Tank Removal Procedures (Left-Hand Side)
6. Disconnect air cleaner mounting brackets from

Use the following procedure to remove the fuel tank, fuel tank and remove air cleaner.
referring to Figs. 1 and 2 where applicable:
1. Remove the side shields, grille screens, muffler, 7. Disconnect radiator brace rod and fuel return
air stack extension, and hood (not illustrated).
pipe.
2. Drain the fuel tank. Capacity is 37 U.S. gal. (140 Disconnect fuel gauge sending
8. unit wire and
I) on 4040 Tractor; 46 U.S. gal. (174 I} on 4240 Trac-
wiring connectors.
tors.
3. Disconnect fuel pipe at shut-off valve under tank. 9. Remove the fuel tank-to-front support mounting
stud nuts and cap screws.
4. Disconnect wiring connector from restriction
switch. 10. Liftoff tank.

.
30-10-2 Diesel Fuel System Fuel and Air Repair
INSPECTION AND REPAIR Repair

Cleaning Soldering
NOTE: Before beginning service work on the fuel Inspect and repair the tank as soon as possible after
tank, remove the fuef gauge sending unit from tank ithas been cleaned. When soldering, the soldering iron
(refer to Section 40 for service information on sending should not be red-hot, A red-hot iron can ignrte any
unit). This will prevent damage to unit and also provide explosive mixture remaining in the tank.
an additionai hole for cleaning.
Welding
Flush the tank for 15 minutes with hot water Run in at
the bottom and allow it to overflow at the top.
A CAUTION: Always fill the tank with water
*^ and ventilate it before starting to weld.

Steam the tank for 30 minutes. Force in Jive steam at
Tanks can be welded without danger, if precautions
top of tank and allow to escape through bottom. If live
it
are taken.
steam is not available, flush the tank with boiling water
continuously for 30 minutes and dry thoroughly with

Weld the tank as follows:
compressed air,
To prevent pockets of fuel,

A CAUTION: Cleaning and
tank
smoking, or
is
fire of
very dangerous.
repairing a fuel
Live sparks,
any nature should never be
1
fill the tank full of water.

plug the tank outlets and
2. Leave the filler cap off to allow for expansion of

permitted in the vicinity of the cleaning or repairing
steam. If the tank must be turned, weld a pipe to an old
operation.
cap and bend up the pipe while installing the cap.
Inspecting For Leaks

3. After welding, retest the tank for leaks.
Use one of these two methods to test the tank for
leaks:
7. Wet method
Plug or cap tank fuel outlet, fuel return, and sending
unit hole.Dry entire outer surface of tank thoroughly
with compressor air and a dean, dry rag. Place tank
so that ail surfaces may be easily seen, such as
settingit on top of blocks. Then fill tank with water.
Insertend of air hose in filler neck and apply ap-

proximately 3 psi (0.2 bar) (0.2 kg/cm 2) air pressure
against water. Examine tank surfaces for moist
spots where water may have been forced through.
2. Air Pressure Method

Plug or cap filler neck, fuel outlet, and sending unit
hole. Attach an air hose to the fuel return hole.
Submerge tank in clean water and apply approxi-
mately 3 psi (0.2 bar) (0.2 kg/cm 2 ) air pressure.
Draw a ring around each spot on fuel tank where
bubbles appear. These bubbles indicate leaks in
tank that need repairing.
R 26804N
Fig. 3-Fuet Tank (4240 Tractor Illustrated)

Installation FUEL FILTER

If the tank was repaired, clean the inside as much as
possible before installing on tractor.
General Information
Install fuel gauge float and sending unit in tank,

using a new gasket- (See Section 40 for service infor-
mation on sending unit.)
Reverse the removal procedures given on page

10-1.
When filling the fuel tank, be sure to use the correct

grade of fuel. Refer to the. tractor operator's manual.
Bleed air from system (page 10-6).
Check the vent hole in fuel tank cap to see that it is
not plugged. If hole is plugged, use a small wire and/or

compressed air to open hole.
FUEL PUMP
Removal
R 26612N
A Inlet E First Stage Filtering

BOutlet Media
C Air Vent F Drain
DSecond Stage GSediment Bowl
Filtering Media I
Supply Pump
Pressure
Fig. 5-Fuei Row Through Fitter
A fuel filter (Fig. 5) is used to prevent dirty fuel from

reaching the injection pump and injection nozzles.
A Pipe Connections B Stud Nut The filter element will require occasional replace-
ment to maintain an adequate flow of fuel to the
Fig. 4-Fuef Pump
injection pump. The frequency of this service will vary
according to the cleanliness of available fuel and the
Close the fuel tank shut-off valve, and disconnect
care used in storage.
the pump inlet and outlet pipes (A Fig. 4). t
Remove mounting stud nuts (B), and lift out pump Replacing Filter
from engine block.
To change the filter element (B Fig. 6), close the
}
Repair fuel shut-off valve at bottom of fuel tank.

The fuel pump is not designed to be repaired. If Remove drain plug (D) and drain filter.
pump is defective, install a new one.
Release the fiiter element retaining spring (C) and
pull off element.
Installation
Be sure engine block pad is clean, and install pump, NOTE: The spring may be released by pressing
using a new packing seal. inward on the outside finger tab (A Fig, 7) until the top
T
hook of the spring can be disengaged. Disengage the

Connect the fuel pipes and open the shut-off valve-
top hook by pulling upward on the inside finger tab.
Bleed the fuel system (see page 30-10-5).

Replacing Filter Continued IMPORTANT: Any dirt lodged in the spring pin
groove or at the end of the spring pin by cleaning
efforts will be washed into the injection system and
may result in severe damage to the injection pump
or nozzles.
A Bleed Plug C Retaining Spring

B Filter Element D Drain Plug
Fig. 6-Fuei Fitter
A Finger Tabs CFuel Filter Body

Before installing anew filter element, inspect the BSpring Pin
filter body where element makes contact. These loca-
tions must be completely void of dirt or other con- Fig. 7-Instailing Fitter Element
taminants. If contaminants are found, clean carefully.
1Filter Support
2Cap Screw with Lock
Washer {2 used)
3Bleed Plug
4Packing
5 Fuel Filter Body
6Connector
7 Elbow
8 Pipe Plug (1/8-in.)
9Washer
10Cap Screw with Lock
Washer (2 used)
11Puel Filter Element
12 Retaining Spring
R1956SN
Fig, 8-Exploded View of Fuel Fitter Assembly
TM-1181 (Sep-77) Litho in U.SA. Tractors - 4040 and 4240

Push new element over the spring pin (B, Fig. 7), NOTE: if the engine will not start, it may be neces-
Hook the bottom end of retaining spring first, then hook sary to loosen the fuel pipes at the injection nozzles to
the top end. bleed the air from system. With the hand throttle in
slow idle position and the engine fuel shut-off control
After changing the element, install drain plug in filter knob pushed all the way in, turn the engine with the
body. starter until fuel without air flows from the loose fuel
pipe connections. Tighten the connections.
Open the fuel shut-off valve and bleed the filter.
FUEL INJECTION PUMP

BLEEDING FUEL SYSTEM
Removal
A CAUTION: Escaping under
diesel
pressure can have sufficient force to pen-
etrate the skin, causing serious personal injury.
fuel
the
Clean the
pump
injection pump,
with cleaning solvent or a
pipes, and area around
steam cleaner.
Before disconnecting lines be sure to relieve all
pressure. Before applying pressure to the system, IMPORTANT: Never steam clean or pour cold
be sure all connections are tight and that lines, water on an injection pump while the pump is
running or while it is warm. To do so may cause
pipes and hoses are not damaged. Fuel escaping
from a very small hole can be almost invisible. Use seizure of pump parts.
a piece of cardboard or wood, rather than hands, to

search for suspected leaks. Use the following method to remove the fuel injec-
tion pump:
If injured by escaping fuel, see a doctor at once.
1. Close the fuel shut-off valve at bottom of fuel
Serious infection or reaction can develop if proper
tank.
medical treatment is not administered immediate-
ly-
2. Position engine at TDC, with No. 1 piston on the
Whenever compression stroke.
the fuel system has been opened up for
service (lines disconnected or filters removed), it will be
necessary to bleed the
NOTE: Obtaining TDC (No. 1 piston on compres-
air from system.
sion stroke) is not required for removing the injection
pump. However, it is required when installing back on
the engine. If the engine is to be disassembled or
rotated after the pump has been removed, disregard
this step and proceed to Step 3,
Fig. 9-Hand Primer
Loosen bleed plug on fuel filter (A, Fig, 6), and

operate hand primer (Fig. 9) on fuel pump until most of
the air bubbles are expelled from the filter.
Push hand primer back (toward engine) as far as it
will go. Tighten filter bleed plug.

ACrankcase Vent Hose C Engine Rotation Tool
B Plastic Plugs D Timing Pin
> Fig. 10-instaiiing JDE-81-1 Engine Rotation
Tool and JDE-81-4 Timing Pin

FUEL INJECTION PUMPContinued 4. Remove fuel pump (page 30-10-3)-
Removal Continued 5. Disconnect the speed control rod at injection

pump.
Disconnect the crankcase vent hose (A, Fig- 10) and
lower vent tube from engine. Remove two plastic cover Disconnect injection pump inlet and pump-to-
6.
plugs (B) from flywheel housing next to oil pressure
nozzle fuel pipes.
sending unit.
7. Disconnect shut-off cable from arm.
8. Disconnect fuel return pipe.
Clean area around timing gear cover and remove

9.
Remove the three cap screws (B, Fig. 11) from
cover.
pump drive gear (A).
1 0. bolt nuts. The pump mount-

Remove mounting
on 4240 Tractors is secured with four nuts,
ing flange
whereas the 4040 Tractor uses three.
A Pump Gear BCap Screw
Fig. 1 1 -injection Pump Removal Steps
3, Remove the timing hole cover (Fig. 11). Rotate

the engine until timing mark on governor weight re-
tainer (B, Fig. 12) is in line with timing mark on cam ring
(A).
Fig, 13-Removing injection Pump

(4040 Tractor Illustrated)
Remove pump (Fig. 13). Be sure to cap all injection

pump and fuel pipe openings to prevent entry of con-
taminants.
Repair
For injection pump repair information and specifica-
tions, refer to TM-1064 "Fuel injection Equipment-
Roosa Master".
Installation
Check engine timing to make sure that No. 1 piston

is TDC on the compression stroke. the engine was
at If

A Cam Ring rotated after the injection pump was removed, crank
the engine until No. 1 piston is starting the compres-
Fig. 12-lnjection Pump Timing Marks sion stroke. Install timing pin (Fig. 10) in cylinder block. (

The compression stroke can be determined by re-

moving the rocker arm cover and turning the engine
until both valves are closed on No. 1 cylinder and
increased turning effort is noted. Continue turning the

engine until timing pin engages the timing hole in
flywheel.
Remove injection pump timing hole cover (Fig. 11).

Rotate pump drive shaft and align the timing mark on
governor weight carrier with the timing mark on the
cam ring (Fig. 12).
Check pump mounting flange packing for damage or

wear. Replace if necessary.
Install injection pump on the engine so the top edge

of the pump flange is parallel to the edge of the mating
flange on the cylinder block. Tighten the mounting bolt
K18383N
nuts to 20-ft-lb. (27 Nm) (2.7 kgm) torque.
Fig, 14-tnjectbn Pump-To-Nozzle Pipe Connections
Install the injection pump gear on hub ("dish" in gear
facing outward toward front of tractor), with the elon- Connect the Injection pump-to-nozzle pipes. Refer-
gated holes in gear approximately centered with holes ring to Fig. 14,connect No. 1 outlet first and continue
in hub. Recheck pump timing mark alignment. If cor- around the pump head in a counterclockwise direction,
rect, install the timing gear-to-hub cap screws, and attaching pipes in order of engine firing (1-5-3-6-2-4).
tighten to 35 ft-lb (47 Nm) (4,7 kgm) torque.
Tighten fuel pipe connectors to 20 ft-lbs (27 Nm)
Remove the timing pin from cylinder block. Rotate (2.7 kgm) torque.
the engine 1-1/2 revolutions in direction of rotation,
then install timing pin in cylinder block. Continue to turn Connect the speed control rod, fuel inlet pipe and
the engine until timing pin engages the timing hole in return pipe to the injection pump.
flywheel. Recheck the alignment of injection pump
timing marks. If marks are not in line, loosen the pump Install fuel pump (page 30-10-3), and open the fuel
gear cap screws, and bring marks into alignment. shut-off valve.
Retighten cap screws to 35 ft-lb (47 Nm) (4.7 kgm)
torque. Remove timing pin and rotation tool from engine,
and plug openings. Connect crankcase vent hose to
IMPORTANT: The normal backlash of gears is lower vent tube.
enough to throw the pump timing off by several
degrees, resulting in poor engine performance. Install injection pump timing hole cover, and engine
Therefore, it is very important that the timing of the timing gear cover. Use new gaskets when necessary.
pump be rechecked after it has been installed.
Bleed the fuel system (page 30-1 0-5),
Remove caps from injection pump and fuel pipe
openings. After bleeding the fuel system, the automatic speed
advance should be checked for proper adjustment.
Refer to Section 230, Group 10.

FUEL INJECTION NOZZLES

Removal (
IMPORTANT: Disconnect battery ground cable

before working on nozzles close to the alternator
to prevent accidental short circuits through tools.
Remove air stack, muffler, grille screens, side

shields, and hood.
To remove the KDEL injection nozzle illustrated in

Figs. 15, 16 and
T
17:
Fig. 16-Leak-Off Line Assembly (Early Style)
Thoroughly clean area around the injection pump

1 .
and nozzles (including all pipe and line connections) 6. Remove leak-off line assembly.
using compressed air (not illustrated).
NOTE: "Early" refers to engine serial No. 4040
( -576677) and 4240 ( -0673501 "Late"
refers to engine serial No. 4040 (576678- ) and
4240 (067351- ).
a. On early engines, disconnect spring clamp

(next to nozzle) from leak-off boot at each nozzle.
On late engines, loosen band clamp on leak-off
boot at each nozzle.
b. On early engines, disconnect front spring

clamp from boot at No. 1 nozzle. On late engines,
separate leak-off line at fitting between No. 1
nozzle and fuel tank.
c. Loosen fuel return pipe clamp cap screw at

front of cylinder head. On early engines, pull return
ISiii l^: pipe out of No. 1 leak-off boot.
d. Remove leak-off boots and line as an assem-

Ftg. 1S-KDEL Infection Nozzle Removal Procedures
bly.
2. Remove the ether starting aid bracket assembly

(not illustrated)
a. Disconnect solenoid wiring.
b. Disconnect pipe at solenoid.
c. Disconnect and remove bracket from engine.
3. Disconnect fuel shut-off cable and tachometer

drive cable.
NOTE: To aid in removal of No, 1 injection nozzle,

disconnect the alternator drive belt and pivot alternator
downward.
4. Remove the fuel return pipe (injection pump-to-

Fig. 17-Leak-Off Connectors
leak-off line).
Disconnect and remove fuel delivery pipes as an

5.
assembly. It is not necessary to remove each pipe (

separately.

Fuel and Air Repair Diesel Fuel System 30-10*9
7. Unscrew leak-off connector from each injection

nozzle (use a 11 mm wrench).
8. Remove the injection nozzle from cylinder head.

Use outer part of JDE-92 Socket (see Fig. 30-10-37) to
loosen the gland nut.
NOTE: A deep-well 24 mm or 15/16-in. socket may

also be used to loosen gland nut Gland nut acts as a
jack screw to raise injection nozzle out of cylinder
head.
Reinstall leak-off connectors (7) on injection noz-

zles.
Testing
Test the injection nozzle before disassembling to
determine its condition. Test for: Opening Pressure,
Leakage, Chatter and Spray Pattern.
A CAUTION: The nozzle tip should always be

directed away from the operator. Fuel from
the spray orifices can penetrate clothing and skin,
A Nozzle
B Fuel
Tester
Line
CAdapter
DBeaker
causing serious personal injury. Enclosing the Fig. 18-Testing Nozzle Opening Pressure
nozzle in a transparent cover, as shown, is recom-
mended. Expel air from the nozzle by operating the pump
handle for several strokes. Then raise the pressure
Before applying pressure to the nozzle tester, be
sure that all connections are tight, and that the
slowly and steadily. Observe the gauge pressure at
which the valve opens. Recheck by completely re-
fittings are not damaged. Fuel escaping from a
leasing the pressure, and gradually building pressure
very small hole can be almost invisible. Use a piece
until the valve opens.
of cardboard or wood, rather than hands, to search
for suspected leaks.
A new nozzle or a used nozzle with a new spring (7,
If injured by escaping
see a doctor at once.
fuel, Fig. 19) should open at approximately the following
Serious infection or reaction can develop if proper pressures:
ly*
On 4040 Tractors - 3350 psi (231 bar) (235 kg/cm*)
On 4240 Tractors - 3800 psi (262 bar) (268 kg/cm 2 )
IMPORTANT: Always use clean, filtered fuel
In nozzles which have been in service, the spring and
when testing injection nozzle performance. Testing
spring seat (8) will have taken a normal set. In this
nozzles with dirty fuel will severely damage the
case, a satisfactory opening pressure should be at
precision parts of the nozzle.
least 3200 psi (221 bar) (232 kg/cm a ) on 4040 Trac-
tors; 3600 psi (248 bar) (254 kg/cm 2) on 4240 Tractors.
Opening Pressure Test
To make the opening pressure test, connect the
KDEL injection nozzle to the No. Y-900 Nozzle Tester
(A, Fig. 18), using No. Y-900-2 Fuel Line (B) and
Y-900-7 and Y-900-15 Straight Adapters (C). A Y-
900-1 1 90 Adapter may also be used. Place a glass
beaker (D) under nozzle.
Pump the handle several times to flush out nozzle

fittings, lighten the fittings.

Shims (6) are available for changing the opening IMPORTANT: Do not lap the machined surfaces
pressure adjustment. Each 0.002 in. (0.05 mm) shim of the intermediate plate in an attempt to stop fuel
changes the opening pressure approximately 100 psi leakage at these locations. The dowels (spring
(7 bar) (7 kg/cm 2 ). pins) in plate have to be removed before the sur-
faces can be lapped. Removing these dowels is not
If the opening pressure is not correct, disassemble recommended as removal is likely to damage
the injection nozzle (Fig. 20) and change shims until them, and replacement dowels are not available as
nozzle opens at the proper pressure. The difference in service parts.
opening pressure of nozzles in any one engine should
not exceed 50 psi (3,5 bar) (3.5 kg/cm 2). If leakage is observed, tighten the nozzle retaining
nut to a maximum of 58 ft-lbs (79 Nm) (7.9 kgm)
IMPORTANT: Always use John Deere nozzle torque. Replace the injection nozzle if leakage contin-
adjusting shims, which are specially hardened. ues.
Other shims will not be satisfactory.
Chatter and Spray Pattern Test
Leakage Test
The injection nozzle should chatter very softly, and
To check a leaking nozzle, wipe the nozzle dry.
for onlywhen the hand lever movement is very rapid (4-6
Bring the pressure up slowly to 285 psi (20 bar) (20 downward movements per second). Failure to chatter
kg/cm 2 ) below the opening pressure, and watch for an may be caused by a binding or bent nozzle valve.
accumulation of fuel from the spray orifice, indicating a
bad seat- If the nozzle drips within 10 seconds, replace Until the chattering range is reached, the test oil
the nozzle assembly (10 and 11, Fig. 19). emerges as non-atomized streams. When the lever
movement is accelerated, the sprays should be very
Check for leakage around the nozzle retaining nut broad and finely atomized.
(12) thread connection with nozzle holder (5).
A partially clogged or eroded orifice will usually
Leakage indicates a bad seat either between the cause the spray to deviate from the correct angle. The
nozzle (11) and intermediate plate (9), or between spray will also be streaky rather than finely atomized.
nozzle holder and intermediate plate.
^^^^^^^^^MiiiU^Mî^^î [ I JISsaB^-i-K-iiiliiiltitiH iU^-

i ; I:;? iin -\ i \ I \
: :':":.:-...::::::
MmUlM':'.' i:
;
1Snap Ring (Upper) 5Nozzle Holder 9Intermediate Plate

2Gland Nut O-Ring 6Shim 10Nozzle Valve
3Gland Nut 7Nozzle Valve Spring 11 Nozzle
4 Snap Ring (Lower) 6Spring Seat 12Nozzle Retaining Nut
(
Flg 19-Expkxted View of
r KDEL injection Nozzle

Fuel and Air Repair Diesel Fuel System 30*10-11
FUEL INJECTION NOZZLESContinued

Chatter and Spray Pattern Test NOTE: While the KDEL injection nozzle is a metric
Continued unit only one size metric wrench is required for disas-
Disassemble the nozzle for cleaning or recondition-

sembly (a 11 mm box-end or open-end for use on
leak-off connector).
ing if it fails to chatter or spray properly.
Unscrew the leak-off connector (E, Fig. 20) out of

REPAIR nozzle holder (F).
General Information
Remove the O-ring and upper snap ring (D) from
Since and water are the worst contaminants in
dirt
nozzle holder. Also see 1 and 2 T Fig. 19.
the fuel injection system, the working area, tools, and
cleaning materials must be kept spotlessly clean.
Slip gland nut (C) off nozzle holder.
Whenever possible, work in an isolated, dust-free
area.
Remove lower snap ring (4, Fig. 19),
Cover the work bench with clean paper before be-

Clampthe two flats of nozzle holder (fuel inlet end)
ginning disassembly of injection nozzle.
in a soft-jawed vise and remove the nozzle retaining
nut (B), using 12-point, 3/4 in. (19 mm) wrench.
As parts are disassembled, place them in a pan of
dean diesel fuel and leave them there until needed. Do

Remove the nozzle assembly (A).
not permit these parts to strike each other.
Pull off intermediate plate (9, Fig. 19). Remove

Use a separate pan of clean diesel fuel for washing
spring seat (8), spring (7), and shims (6).
parts just before assembly.
Withdraw nozzle valve from nozzle. If valve is stuck,

Disassembly
it may be necessaryto soak the nozzle assembly in
Bendix cleaner, acetone, or other commercial cleaners
sold especially for freeing stuck valves.
A CAUTION: Use
fluids in
er's instructions.
these nozzle
accordance with the manufactur-
cleaning
and nozzle are individually fitted and hand

TTie valve
lapped. Keep these mated parts together, and do not
permit the lapped surfaces to come in contact with any
hard substance. Do not touch the valve unless hands
are wet with fuel.
Cleaning and Inspection

Nozzle Assembly
Remove anti-corrosive grease from new or recondi-

tioned nozzles by washing them thoroughly in diesel
fuel.
A-Hazzle D O-Ring and Upper

B Nozzle Retaining Snap Ring Remove carbon from used nozzles, and clean by
Nut E Leak-Off Connector washing in diesel fuel. If parts are coated with hard-
CGland Nut FNozzle Holder ened carbon or lacquer, it may be necessary to use a
GWasher brass wire brush.
Fig. 20-Assembfed KDEL-21 mm injection Nozzle
IMPORTANT: Never use a steel brush to clean
nozzles as this will distort the spray orifices.

.
removing carbon or lacquer from the exterior of

After Always replace a nozzle assembly if the valve does
nozzle, inspect the lapped machined surface (B, Fig. not fall freefy to its seat.
21) for nicks or scratches.
Inspect the piston (large) part of nozzle valve to see

that it is not scratched or scored. If any of these
conditions are present, replace the nozzle assembly
(see Figs. 21 and 22).
Inspect condition of seat for nozzle valve and noz-

zle. Contact area of seat (both parts) must not be
scored or pitted. Use the inspection magnifier provided
in the JDE-105 NozzJe Cleaning Kit to aid making the
inspection.
NOTE: A bad nozzle valve seat will cause fuel to

drip from the nozzle. This condition usually will be
noted when making "Leakage Test" described on page
30-10-10.
APin Vise COrifice

BNozzle
D Cleaning Wire
Fig. 22-Cteaning Nozzfe Orifices
Remove any carbon that may be present in the

spray orifices of the nozzle assembly before reassem-
bling on nozzle holder.
To clean carbon from the spray orifices (Fig. 22):
1 Begin with cleaning wire 0.003-0.004 in. (0.07-

0,10 mm) smaller than the nominal orifice size (D).
R 2685 IN
NOTE: Stoning the wire to provide a fiat surface on

/^-Nozzle Valve CFree-FaN Distance
one side help in reaming carbon from a clogged

B Lapped Surface DNozzle will
hole.
Ftg. 21 -Nozzle Assembly Slide Test
2. Clamp the cleaning wire in pin vise (A). Wire
Further inspect the nozzle assembly by performing a should not protrude from vise more than 1/32 in. (0.8
slide test (Fig. 21). Use the following procedure: mm),
1. Dip the nozzle valve (A) in clean diesel fuel. 3. Insert wire into orifice (C), and rotate.
Insert valve in nozzle (D).

4. For final cleaning, use cleaning wire 0.001 in.
2. Hold nozzle vertical, and pull valve out about 1/3 (0.03 mm) smaller than orifice size. Follow steps given
of its engaged length (C). above.
3. Release valve. Valve should slide down to its
seat by its own weight.

Fuel and Air Repair Diesel Fuel System 30-10*13

Cleaning and Inspection Continued intermediate Plate
Nozzle Holder
H6 x 1
HI 9 x 1
R 26871N
ALapped Surfaces B Dowel Pins

H14 x 1 . Si
Fig. 25-lntermediate Plate
Examine the lapped surfaces (A, Fig. 25) for nicks,

scratches, or worn areas which would permit the fuel to
leak past. Replace the intermediate plate if the lapped
surfaces are damaged or worn.
ALapped Surface BNozzle Holder
IMPORTANT: Do not lap the machined surfaces
Fig. 23-KDEL Nozzle Holder of the intermediate plate in an attempt to stop fuel
leakage at these locations. The dowel pins (B) in
Inspect the lapped machined surface (A, Fig. 23) on removed before the surfaces can
plate have to be
bottom end of nozzle holder (B) for nicks or scratches. be lapped.Removing these dowels is not recom-
Replace holder if not in good condition. mended as removal is likely to damage them, and
replacement dowels are not available as service
Inspect threads (sizes are shown in Fig. 23) on
parts*
nozzle holder for general condition. Threads that are
nicked slightly may be "dressed-up". Replace holder if
Spring Seat
threads can not be restored to a serviceable condition.
Check fuel passages in nozzle holder to make sure

that they are open.
Nozzle Retaining Nut

Clean with oompressed air.
&
R28377N
Fig. 26-Spring Seat
Inspect the spring seat (Fig. 26) for splitting, crack-

ing, or excessive wear. Replace seat if any of these
conditions are evident.
E28376N Nozzle Valve Spring
Fig. 24-Nozzie Retaining Nut
Remove carbon deposits on both inner and outer

surfaces of the nozzle retaining nut (Fig. 24).
Inspect the retaining nut for cracks caused by over-

R283?8N
tightening or a damaged lower seating surface. A
seating surface may be restored by rubbing the surface Fig. 27-Nozzle Valve Spring
on emory cloth.
Any nozzle retaining nut which cannot be recondi- Examine spring (Fig. 27} and shims for pitting or
tioned, must be replaced with a new one. excessive wear. Replace, if not in good condition.

Edge-Type Filter Leak-Off Connector
M6 X 1
!;i;i ** jjijjjHj:::::;:::::: :::::::: ;:;j";|;j|"H:Ht:T^
R_2$38 0N
s^;i Mm. 'x"*M Fig. 30-Leak-Off Connector

:::::::::::t:i
Ipfijf and Washer

'
::
:
r
:
-fcl
I Check passage in leak-off connector (Fig. 30) to see
that it is open. Blow through connector passage with

compressed air.
A Fuel Passage B Edge-Type Filter Location

Check threads (M6 x 1) for general condition. Re-
Fig. 28-Geaning Edge-Type Fitter place connector if threads are damaged and can not be
restored to a serviceable condition.
The edge-type filter is pressed into the nozzle holder
(B, Fig, 28), and is not removable for service. Assembly
KDEL injection nozzles used on 6404D engines
by applying compressed air to the
Clean the filter
(4040 Tractor) and 6466 D (4240 Tractor) are identical
nozzle holder fuel passage (A) at nozzle end. Applying
except for the number and diameter of orifices in the tip
compressed air in a direction opposite to fuel flow will
end of nozzle, and opening pressure adjustment.
expel! foreign particles from the nozzle holder,
IMPORTANT: Be sure to install the correct noz-

NOTE: A cross-sectional view of the edge-type
zle assembly on nozzle holder Do not intermix
filter and the fuel passage is shown in Section 230,
different size nozzle assemblies.
Group 10 (See Fig. 12).
Gland Nut
M28 X K5
B28373X
Fig. 29-Oiand Nut
inspect the nozzle holder gland nut (Fig. 29) for

general condition, especially to be sure that it is not
cracked or split.
Also check condition of threads (M28 x 1.5). BOrifice Size

ANumber of Orifices
Threads which are slightly nicked or damaged may be
"dressed-up". Fig. 31 -Nozzle Markings
Replace gland nut if unable to restore to a service-

able condition.

Fuel and Air Repair Diesel Fuel System'/ 30-10-15

Assembly Continued Clamp the nozzle holder in a soft-jawed vise, and
tighten the nozzle retaining nut to 44-58 ft-lbs (60-79
To help determine the right nozzle assembly for
Nm) (6.0-7.9 kgm) torque.
each application, note that markings (Fig. 31) appear
on the lower part of nozzle.
Install lower snap ring (4) on nozzle holder.
For example, the illustration shows the correct size

Coat bore of gland nut (3) liberally with an anti-seize
nozzle for the 6404D engine (marked 5 x 0.25). The
compound (such as Never-Seez) to help prevent gland
number "5" indicates the number of orifices (A), and
nut from seizing on holder body. Slide gland nut on
"0.25" indicates the orifice size (B) in millimeters.
nozzle holder.
Engine Nozzle Size

Install upper snap ring (1) on nozzle holder, and
6404D 5 x 0.25 position O-ring (2) against gland nut.
6466D 4 x 0.28
Install leak-off connector (E, Fig. 20) on nozzle
holder, using a new washer.
IMPORTANT: Immerse parts in clean fuel before
assembly. Do not dry parts with towels or com- NOTE: The leak-off connector and washer should
pressed air, as dust particles might collect and be installed on the nozzle holder, even though they will
stay on pressure faces of nozzle valve and nozzle have to be removed to install the injection nozzle in
holder. cylinder head. This will help prevent misplacement of
connector and washer before installation on engine.
To assemble the injection nozzle:
Installation
Place shims (6, Fig. 19), spring (7), and spring seat Before installing the KDEL injection nozzle, check
(8) innozzle holder while still wet with diesel fuel. engine cylinder head for:
Position the intermediate plate (A, Fig. 32) on nozzle threads nozzle gland
a. Condition of for nut.
holder (D). Note that the dowel pins (C) in plate will
Threads are metric (M28 x 1,5).
permit installation only one way.
b. Condition of machined surface to seat nozzfe.
Cylinder head threads and nozzle seating surface

must be free of rust and carbon deposits.
IMPORTANT: If the injection nozzle gland nut

threads are not clean, a false reading on the torque
wrench may be obtained when the injection nozzle
is installed. This may prevent the injection nozzle
from seating properly in the cylinder head.
To clean threads which have light or moderate

AIntermediate Plate CDowel Pins foreign deposits, connect the D-17029BR Thread
BNozzle and Valve DNozzle Holder Cleaning Brush (Group 00) to an electric drill. Work
brush up and down several times to thoroughly clean
Fig. 32-Assembting Intermediate Plate
threads.
Insert the nozzle valve into the nozzle (B) while

holding parts below the fuel level in pan.
Install the nozzle assembly on holder and secure

with the nozzle retaining nut (12, Fig. 19).

in cylinder head
Inspect the nozzle seating surface
forcarbon deposits. If seat is not clean, use the JDE-
99 Nozzle Seat Reamer (Fig. 34) to remove carbon.
Stop using tool when seat comes clean.
Insert wood dowel in nozzle bore and blow out

debris with compressed air. Remove wood dowel.
Fig. 33-Using JDF-5 Tap To Clean

Threads in Cylinder Head
To clean threads with heavy foreign deposits, or to

reclaim damaged threads, use the JDF-5 Tap (Fig. 33).
Be sure to start tap straight to avoid possible
crossthreading. A light coating of grease on tap will
help to collect foreign deposits on tap and prevent

Fig. 35-Locations To Apply Anti-Seize Compound
them from falling into nozzle bore.
Apply anti-seize compound (such as IMever-Seez) to

After cleaning threads, insert a 1/2-inch (13 mm)
the gland nut threads and nozzle barrel (Fig. 35). Be
tapered hardwood dowel into nozzle bore. Blow out
sure that anti-seize compound was also applied on
debris from nozzle cavity. Remove wood dowel.
inside (bore) of gland nut during assembly. See Para-
graph 3 in right-hand column on previous page.
NOTE: Applying an anti-seize compound at these

locations help prevent possible seizure of the gland
will
nut to the holder body. Future removal of the injection

nozzle will be much easier when an anti-seize com-
pound is used.
Install a new R64840 steel washer (G, Fig. 20) on tip

end of injection nozzle. !f the aluminum washer
(R59104) has been used on the nozzle, discard it and
use a steel one. The steel washer provides superior
nozzle torque retension.
Insert the injection nozzle into cylinder head. Turn

gland nut by hand to make sure that it is threaded
straight in cylinder head.
Remove the leak-off connector and washer. Use

Fig. 34-JDE-99 Nozzle Seat Reamer outer part of the JDE-92 Nozzle Socket and turn gland
nut down to remove most of the looseness.
Rotate nozzle holder so that the hole for the leak-off

connector is facing straight out from the cylinder head
(see Fig. 42).
(
TM-1181 (Sep-77) Lkho in U.S.A. Tractors - 4040 and 4240


installation Continued
'
iJ.V;nfcfeAA7 : ; :
^v^j^;ri ;: lf'i4^^^^=^f^|
AInner Socket O-Window Fig. 37-Tightening KDEL injection Nozzle

BOuter Socket Using JDE-92 Nozzle Socket Wrench
Fig. 36-lnstafiing JDE-92 Nozzle Socket Wrench

Be sure that rubber O-ring (2, Fig. 19) is positioned
against the injection nozzle gland nut.
Position the inner socket (A, Fig. 36) over the nozzle
holder and engage with the two flats at top of nozzle
Install the leak-off connectors and washers on in-
holder.
jection nozzles (7, Fig. 17).
Place outer socket (B) portion of JDE-92 Nozzle

Install leak-off line assembly (6, Fig. 16).
Socket on gland nut, with socket "window" (C) facing
outward.
Install the fuel delivery pipes (5, Fig. 15). Tighten
connectors to 35 ft-lbs (47 Nm) (4.7 kgm) torque.
Insert handle (Fig- 37) through window into the inner
socket. The ball detent in handle will keep it secured to
Install fuel return pipe (4), and ether starting aid
the inner socket.
bracket assembly (2).
NOTE: The handle simulates the position of the

Bleed the fuel system (see page 10-5).
leak-off connector, which must be "square" with the
engine to permit proper installation of leak-off lines.
Start the engine and check for leaks,
Tighten the injection nozzle gland nut to 55-65 ft-lbs

Install hood, muffler, air stack, grille screens, and
(75-88 Nm) (7.5-8.8 kgm) torque, keeping the handle
side shields.
pointing straight out while tightening (Fig. 37). Socket
window is cut deep enough to obtain a new "bite"
without also removing the inner socket.


Fuel and Air Repair Control Linkage 30-15-1
Group 15
CONTROL LINKAGE
(Without Foot Throttle)
R29063N
ALever DVertical Control Rod F TurnbuckJe

BLever Friction Spring Screw ECable or Rear GFront Control Rod
CLever Stop Screw and Jam Nut Control Rod HThrottle Lever
Fig, 1-Speed Control Linkage (Without Foot ThroWe)
General Information trol lever, while the lever stop screw and jam nut (C)
The speed
controls the slow idle speed. The fast idle stop screw
mounted in the
control lever (A, Fig. 1) is
console to the right of the operator. A rod and cable
on the injection pump limits the fast idle speed.
arrangement (D, E, and G) connects the speed control

lever to the pump throttle lever (H).
A iever friction spring screw (B) regulates the

amount of effort required to move the speed con-

30-15-2 Control Linkage Fuel and Air Repair
SPEED CONTROL LINKAGEContinued

Removal On all models:
Disconnect the front control rod (G, Fig, 1) at injec-
tion pump and at turnbuckle (F).
3. Remove the console cover (C, Fig. 2) to gain
access to the vertical control rod and speed control
lever mounting.
ACable CConsole Cover

B Arms DCabfe Clamps
Fig. 2-Cabfe Removal
On tractors with a Sound-Gard Body: AControl Rod -Friction Spring Screw CLever
1. Remove the floor mat, floor panel, and foot rest Fig. 3-Disconnecting Linkage And Removing
panel from inside Sound-Gard Body. Speed Control Lever
2. Remove cable 4. Disconnect the vertical control rod (A, Fig, 3)
a. Disconnect cable (A, Fig. 2) from arm (B). from the speed control lever (C) and outer cross-shaft
b. Remove two cable clamps (D) which support arm,
cable at front and rear.
5. Remove lever cap screw (B), retainer, spring,
On tractors without a Sound-Gard Body: and friction plates with facings. Remove lever.
1. Remove floor panel. 6. Remove the inner and outer arms (B Fig. 2) by
F
driving out the spring pin that secures the arm to shaft.
2. Remove rear control rod used in place of cable Remove bushings and shaft.
(A, Fig. 2),
TM-1181 (Sep-77) Utho in U.S.A. Tractors - 4040 and 4240

Fuel and Air Repair Control Linkage 30-15-3
Inspection and Repair arms). Excessively loose linkage connections will give
Inspect condition of facings on speed control lever poor response to selecting engine speed.
friction plates. If facings are glazed or worn exces-
sively, the speed control lever will not stay where
Worn linkage connections can usually be repaired
placed. Replace as required.
by welding. Use brass welding rod to fill worn holes and
worn control rod ends. Restore repaired areas to the
original size and shape. If unable to repair worn part
Inspect condition of friction spring. Spring must not
satisfactorily, replace with a new one.
be weak or broken.
Inspect condition
Installation
of linkage connections where
control rods (or cables) connect with control levers (or Reverse the removal procedures to install speed
Use Fig. 1 as a guide.
control linkage.
H26923N
AVertical Control Rod DInner Arm H Pedal

B Outer Arm EArm Shaft I Pedal Arm
C Rear Control Rod FShaft Arm J Pedal Support
GSpring
Fig. 4-Foot Throttle Linkage
TM-1181 (Sep-77) Litho in US.A. Tractors - 4040 and 4240

30-15-4 Control Linkage Fuel and Air Repair
FOOT THROTTLE LINKAGEContinued

Removal arm assembly into position and push
Insert outer
shaft through outer bushing and through the outer arm
Remove the floor mat, floor panel, and foot rest
assembly. Secure shaft arm to shaft with spring pin.
panel
Install bushings in pedal support (J). Insert pedal
Disconnect the from
vertical control rod (A, Fig. 4)
through bushings.
outer arm (B). Remove rear control rod (C). Disconnect
the control cable or rod from inner arm (D).
Position pedal arm (I) on pedal shaft. Fasten arm to
pedal shaft with bolt, fiat washer, lock washer, and nut.
To remove the speed arm shaft (E), drive out
control
the spring pin securing inner arm to shaft. Drive out
Install the rear control rod (C). Yoke-end of rod
spring pin securing speed shaft arm (F) to shaft. Re-
connects bottom hole of inner arm, and is retained
to
move arms from shaft, and pull out shaft. Remove
with a steel pin, washer, and cotter pin. Front end of
spring (G) to separate arms. Remove bushings.
rod is secured with a retaining ring.
The foot pedal (H) may be removed from the control

Connect control cable or rod (leading to turnbuckle)
support by loosening round head bolt on pedal arm (I).
inthe upper hole of arm (D). Install cotter pin and
Pull out pedal from pedal support (J). Remove two
washer or retaining rings.
bushings from pedal support-
Place end of vertical control rod (A) in middle hole of

Installation
outer arm and retain with cotter pin.
Insert shaft (E) into platform support, with end of
shaft having hole farthest from the end facing toward Check the foot throttle linkage adjustment before
middle of tractor. Position nylon bushings on shaft so completing the installation. (See Section 230.)
that large shoulder of bushing will be against the inner
and outer arms. Complete the installation by checking all connec-
see that they are secured, and installing floor
tions to
Install inner arm (D) on shaft with large shoulder panels and floor mat.
toward the outside and secure with spring
t
pin. Install
spring (G) on outer arm (B) and shaft arm (F). Make
sure that ends of spring are in their respective notches.

Electrical Repair Specifications and Special Tools 40-00-1
Section 40
ELECTRICAL REPAIR
Page Page
GROUP 00 SPECIFICATIONS AND GROUP 15 STARTING CIRCUIT

SPECIAL TOOLS General Information 40-15-1
General Information 40-00-2 Solenoid 40-15-1
Charging Circuit 40-00-3 Starting Motor Removal ; . 40-15-2
Starting Circuit 40-00-3 Disassembly and Repair 40-15-3
Lighting Circuits 40-00-4 Assembly 40-15-9
Instrument and Accessory Circuits 40-00-4 Installation 40-1 5-9
Power Front-Wheel Drive 40-00-5
Special Tools 40-00-6 GROUP 20 LIGHTING CIRCUITS
Testing Flood Lamp Relays 40-20-1
GROUP 05 HARNESS REPLACEMENT Testing Turn Signal Controller 40-20-2
Genera! Information 40-05-1 Testing Light Switch 40-20-2
Right-Hand Lighting Harness Bulb Replacement 40-20-3
(ROLL-GARD) 40-05-1
Right-Hand Lighting Harness GROUP 25 INSTRUMENT AND
(SOUND-GARD) 40-05-4 ACCESSORY CIRCUITS
SOUND-GARD Body Harness 40-05-4 instrument Cluster 40-25-1
Removing Connector Body 40-05-5 Radio and Tape Player 40-25-4
Right-Hand Wiper Motor 40-25-5
GROUP 10 CHARGING CIRCUIT Left-Hand Wiper Motor 40-25-6
Removal 40-10-1
Disassembly 40-10-1 GROUP 30 POWER FRONT-WHEEL DRIVE
Repair 40-10-2 Power Shift Transmission Switches 40-30-1
Assembly 40-10-6 QUAD-RANGE Transmission Switches . . 40-30-2
Installation 40-10-6 Syncro-Range Transmission Switches . . . 40-30-4

40-00-2 Specifications and Special Tools Electrical Repair
Group 00
SPECIFICATIONS
GENERAL INFORMATION
Batteries
Item Specification
Battery ground Negative

John Deere part no AR 47455
BCI group 5D
Battery volts 6,2 to 6.5
Cold cranking amps at 0T (-18C) 800
Reserve capacity (minutes at 25 amps) 340
Full charge specific gravity 1 .260
Circuit Breakers
A Front FJood Lamps and Upper Rear Flood Lamps

B Horn, Lighter
C Key Switch
D Turn Signals, Warning Lamps, Tail Lamps, Lower Rear
Flood Lamps
E Head Lamps, Dome Lamp
FSOUND-GARD Body Serial Number ( -167013) Radio,
Left- Hand Wiper, Blowers
FSOUND-GARD Body Serial Number (167014- ) Radio,
Wipers
G SOUND-GARD Body Serial Number ( -167013) Right-
Hand Wiper, Blowers
G SOUND-GARD Body Serial Number (16701 4- ) Blower
H SOUND-GARD Body Relay
R 28792N
Fig. 1 -Circuit Breakers
(Tractor With SOUND-GARD Body)
Breaker "A" 30 amps

Breakers number "B", "D", "E", and "F" at load center 20 amps
Breaker "G" at load center
SOUND-GARD Body serial number ( -167013) 20 amps
SOUND-GARD Body serial number (167014- ) 30 amps
Breaker number "C" at load center 10 amps
Power front-wheel drive breaker 10 amps
Electrical remote control breaker 25 amps
Breaker trip time with 50% overload 20 to 50 seconds
Breaker reset time with load removed 60 seconds

CHARGING CIRCUIT
Item Specification
Voltage checks:
"BAT" terminal Battery voltage
Red wire to No. 2 terminal Battery voltage
Brown wire to No. 1 terminal (key switch on)
With wire connected to terminal 2 to 9 volts
With wire disconnected at alternator Battery voltage
Voltage increase at "BAT" terminal (engine running/engine stopped) . . 0.5 volts minimum
AC voltage ripple at No. 1 terminal (engine running) 0.4 volts maximum
Regulated voltage at "BAT* terminal after 15 minutes operation:
Air Temperature 1 in. (25 mm)

Behind Regulator Case Voltage
85F (29C) 13.8 - 14.9 volts

105F (41C) 13.6 - 14.7 volts
125F (52C) 13.4 - 14.6 volts
145F (63C) 13.2 - 14.4 volts
Output test (optional)

72-amp alternator 60 amps minimum
72-amp alternator stator winding connection "Delta"
61-amp alternator stator winding connection "Y"
|
Alternator pulley nut torque 60 fHbs (80 Nm) (8 kgm)
STARTING CIRCUIT
Solenoid pull-in winding current draw at 12.0 volts 140 to 150 amps
Solenoid hold-in winding current draw at 12.0 volts 11 to 13 amps
Starting motor no-load test:
Current draw at 1 2.0 volts 90 to 1 30 amps
Armature speed 4000 to 5000 rpm
End bushing I.D 0.669 to 0.670 in.
(17.00 to 17.03 mm)
Center bushing I.D 1 .182 to 1 .184 in.
(30.03 to 30.08 mm)

Minimum brush length 5/8 in. (1 6 mm)
Minimum brush spring tension 40 oz. (1 1 N)
Torque:
Shift lever housing to main frame 6 ft-lbs (8 Nm) (0.8 kgm)
End frame screws 10 ft-lbs (14 Nm) (1 .4 kgm)
Pole shoe screws and shift lever pivot screw 30 ft-lbs (41 Nm) (4.1 kgm)

1
LIGHTING CIRCUITS
Item Specifications
BULBS (1216 volt)

Dual-beam headlight 4460
Flood lamp; front and lower rear 4466
upper rear 441
Tail lamp (white, double contact) 1 157
Warning lamp (single contact) 1 1 56
Tachometer lamp (miniature bayonet base) 1893
Console lamp 168
Dome lamp (bayonet base) 1003
Cluster lamps (wedge base) 1 94
Transmission oil and air cleaner indicator lamps (wedge base, flashing) 557
Hi-beam, indicator lamp (miniature bayonet base) 1 893
INSTRUMENT AND ACCESSORY CIRCUITS

Voltmeter:
Indicator at left edge of battery voltage green range 1 1 .8 volts
Indicator straight up 13.0 volts
Indicator at right edge of charging voltage green range 1 5.5 volts
NOTE: For fuel, water and oil pressure gauge and sending unit resistance checks, see page 240-06-56,
TM-1181 (Nov-86) LITHO IN USA. Tractors-4040 and 4240

INSTRUMENT AND ACCESSORY CIRCUITS Continued

Item Specification
Aircleaner indicator lamp switch;

Closes above 24 to 26 in. water
(60 to 65 mbar)
Transmission oil pressure switch:
Closes below 90 to 100 psi
(6.2 to 6.9 bar)
(6.2 to 6.9 kg/cm*)
Transmission oil temperature switch (Power Shift):
D
Closes above 215 to 225 F (102 to 107C)
Horn (Robert Bosch, Model 320 023 006):
Current draw at 1 2.0 volts 3.3 amps
Radio and tape player fuses 5 amps
Tape player relay:
Current draw at 1 2.0 volts 0.07 amps
Winding resistance 1 80 ohms
Electric starting aid solenoid:
Current draw at 1 2-0 volts 4 to 5 amps
Winding resistance 1.5 ohms
Wiper motor current draw:
Low speed 2 to 3 amps
High speed 3 to 4 amps
Additional accessories:
Maximum added to accessory circuit breaker 5 amps
Maximum connected to added circuit breaker 20 amps
Minimum power supply wire size to added circuit breaker 10 gauge
Minimum wire size to added accessories 16 gauge
POWER FRONT-WHEEL DRIVE

Solenoids:
Current draw at 12.0 volts Approx. 1 A amps
Winding resistance Approx. 8.5 ohms
Clutch pressure switch 30 to 60 psi
(2.1 to 4.1 bar)
(2.1 to 4.1 kg/cm 2 )

SPECIAL TOOLS
General Information Tool Use
*D-24001MO Battery Tester Test Batteries
a *?&
Fig. 2-D-24001MO Battery Tester
*D-05136ST Voltage Test wiring circuits for opens,

Detector shorts, or ground
& 2S794*
Fig. 3-D-05136ST Voltage Detector
*D-19001TT Volt-Ohm-Amp Test any electrical components

Meter for voltage, resistance, or cur*
rent draw
"Order from:
Service Tools, inc.
P.O. Box 314
Owatonna, MN 55060
a z&?$m (
Fig. 4-D-19001TT Voft-Ohm-Amp Meter

General Information Continued Tool Use
D*05138ST Carrying Case Store D-24001MQ Battery

Tester D-05136ST Voltage
Detector, D-19001TT
Volt-Ohm-Amp and
Meter,
their operator's manuals
Fig. 5-D-05138ST Carrying Case
Charging Circuit
D-19001TT Volt-Ohm-Amp Test charging circuit

Meter
JD-306 Alternator Puiley Remove and install alternator
Nut Remover pulley retaining nut
Fig. 6-JD-306 Alternator PuUey Nut Remover
Starting Circuit
JDE-60 Starter Wrench Remove and install mounting

bort behind starting motor
R 26547N
Fig. 7-JDE-80 Starter Wrench

Lighting Circuits D-05136ST Voltage Test Wiring circuits for

Detector opens, shorts, or grounds
Instrument and Accessory Circuits
JDST-33 Universal Gauge Test fuel gauge, water

Tester temperature gauge, engine oil
pressure gauge, and their
senders.
^sffimi:
Fig. 8-JDST-33 Universal Gauge Tester
Order special tools from Service Tools, Box 314* Owatonna MN 55060.

Electrical Repair Harness Replacement 40-05-1
Group 05
HARNESS REPLACEMENT
GENERAL INFORMATION When replacing the harness that passes through the
When replacing a harness, refer to the illustrations four-post Rolf-Gard right front post, disconnect the
for harness connections. Refer to Figs. 2 and 3 for Molex connector (A, Fig. 1) first (molded connector
clamping and banding instructions and for placement with nine round terminals) between right-hand fighting
of the harness on the tractor. Refer to Section 240, harness and the main lighting harness.
Group 05 for detailed wiring diagrams.
1. Drill out blind rivets (B) fastening head liner to
Fasten wiring harness to the pipe securely with outer edge of roof. Removing head liner makes har-
nylon cable ties so the harness will not have the ness installation easier.
insulation worn off or be subject to any other damage.

If fastened to a pipe which is hot or which
2. Disconnect warning lamps (C), rear flood lamps
may vibrate T
place a split hose around the harness or place a (D), console lamp (E), right-hand tailiight (F) right-hand
grommet around the pipe. headlight (G), and right-hand flood
lamp (H). (Remove
head lamp access cover to disconnect head lamp and
Right-Hand Lighting Harness Installation flood lamp.)
on a Four-Post Roll-Gard
3. Attach a wire to one end of the harness and pull
harness out from the other end, so the wire can be
used to puil a new harness into position.
4. Attach new harness to wire, and pull it into posi-

tion.
5. Make all connections at both ends of harness.

Check all lights to be sure they work.
6. Install clips to fasten harness in position.
NOTE: Six adhesive clips fasten harness to rear

and side members under the roof. A hose is cemented
across the inside upper edge of the Roli-Gard frame
where the harness emerges from the frame.
7. Install headlines using R52118 blind rivets to

fasten headliner to roof.
A Molex Connector E Console Lamp

B Blind Rivets F R.H. Tailiight
C Warning Lamps G R.H. Headlight
D Rear Rood Lamps HR,K Flood Lamp
Fig. 1 -Right-Hand Lighting Harness on Four-Post
Roil-Gard

40-05-2 Harness Replacement Electrical Repair
R2818SF
1Upper Rear Flood Lamps 16Split Hose 31 Front Flood Lamp

2Warning Lamps 17--ConsoleLamp Harness 32 Engine Harness
3Grommet 18Dome Lamp Switch 33Left-Hand Fender Harness
4 Lamp Ground Harness
5Left-Hand Wiper Harness
19Lamp Ground Harness 34Compressor Wiring Lead
20Clip 35Compressor Ground Lead
6Adhesive Clip 21Sound-Gard Body Harness 36Thermal Fuse
7Grommet 22 Lower Rear Flood Lamps 37 Bulkhead Harness
8Clamp 23 Right-Hand Wiper Harness 38Dimmer Switch
9 Left-Hand Wiper Motor 24Right-Hand Wiper Motor 39Clamp
10Radio
25 Tail Lamp 40Ground Lead
11Molding Strip 2&-Clip 41Conduft
12Wiper Switch 27Grommet 42 Front Flood Lamp
13 Air Conditioning Thermostat 28Right-Hand Lighting Harness 43Dual-Beam Head Lamp
14 Blower Swftch 29Head Lamp Ground Harness 44Lighting Relay Harness
15 Dome Lamp 30 Dual-Beam Head Lamp
Fig. 2-Hamess Routing and Attaching Diagram for 4-Post Rolt-Gard or Sound-Gard Body, (
(See Fig. 3 for Instrument and Engine Harness Routing and Attaching)

Electrical Repair Harness Replacement 40-05-3
R28185F
1Instrument Cluster 14 Instrument Harness

2Clamp 15Speed-Hour Meter
3 Cleaner Indicator Sender
Air 16 Lighter
4Clamp 17 Key Switch
5Engine Harness 18 Horn Switch
6Conduit 19Transmission Oil Temperature Switch
7 Fuel Gauge Sender 20Transmission Oil Pressure Switch
8 Horns 21Dimmer Switch
9 Engine Oil Pressure Gauge Sender 22 Bulkhead Harness
10 Water Temperature Gauge Sender 23Starter-to-Relay Harness
11Starter Circuit Relay 24Start-Safety Switch
12Starting Aid Switch 2510" (250 mm) Wiring Lead
13 Light Switch 26Starting Aid
Fig. 3-Engine and instrument Harness Routing and Attaching Diagram
TM-11&1 (Sep-77) Lithe in US. A. Tractors - 4040 and 4240

Right-Hand Lighting Harness Installation Installing Sound-Gard Body Harness

on Sound-Gard Body
jR2lmNi
Afloof Opened C H.H. Wiper Cover?

B Heater- Evaporator Cover
Fig. 5-Access to Sound-Gard Body Harness from Above
1, Open roof (A Fig. 5). Remove heater-evaporator

r
cover (B) and right-hand wiper cover (C).

A Roof C Headlight Access Panel
BMoldings
Fig, 4-Right-Hand Lighting Harness on Sound-Gard Body
1. Open roof (A, Fig. 4). Open side window and

remove trim moldings (B) at rear of right front post and
at bottom of side window.
2. Remove right-hand headlight access panel (C).
3. Disconnect all wires from harness, including
headiight and tailiight.
4. Attach a wire to one end
of the harness and pull
the harness out from the other end, so the wire can be
used to pufl a new harness into position.
5. Attach new harness to wire. Insert Molex con-
nector (molded connector with nine round terminals}
through hole in inner roof. Pull harness down into
position. AControl Panel CTrim Studs
6. Make afi connections to the harness. Check alf
B Speakers DTrim Moldings
electrical components in the Sound-Gard Body to be Fig. 6-Access to Sound-Gard Body Harness from Below
sure they all work.
7. Install split hoses around harness where it
passes through the top of the fender and the inner roof.
Route harness away from any sharp edges,
8. Install grommets on tail light wire. Install trim
molding and headlight access panel. Close roof.
(

Electrical Repair
Harness Replacement 40-05-5
2. Remove control panel (A, Fig. 6). Disconnect and Removing Connector Body From
remove radio speakers (B). Disconnect dome lamp. Terminals
3. Remove trim studs (C) holding front of headlines

using side cutters or needle nose pliers. Headliner is
VERY EASILY damaged.
4. Open windows and remove trim moldings (D)

which support headliner. Have a person on each side
supporting the headliner to prevent damage. Remove
headliner,
5. Disconnect and remove old harness. Switches

are easier to disconnect and connect
^X^0-
if you first remove
them from their mountings. B259728
6. Install new harness and make connections. A Female Terminal B Male Terminal
Check a/I electrical components in the SOUND-GARD
Body to be sure they all work, install grommet where Fig. 7-Removing Connector Body from Terminal
harness passes through inner roof. Place sealant

1. Use a small screwdriver to depress locking tang
around harness and grommet to prevent air leaks.
on terminal. Slide connector body off.
7. Install head liner, control panel, wiper cover, and
heater-evaporator cover. Close the roof.
2. Be sure to bend locking tang back to its original
position before installing connector body.
>
TM-1181 (Jun-80) Litho in U.S. A, Tractors - 4040 and 4240

<
<

Electrical Repair Charging Circuit 40-10-1
Group 10
I
DELCOTRON CHARGING CIRCUIT REPAIR
REMOVAL
NOTE: See Section 240, Group 10 for charging
circuit diagnosis.
16b 3QN
Fig, 2-Removing Alternator Puttey Nut
NOTE: If pulley nut remover

is not available, wrap a
R 26529N discarded, oversize around pulley. Carefully
V-beit
hold pulley in vise, and remove pulley nut If pulley slips
AAlternator EAdjusting Cap Screw on shaft, separate housing as instructed below. Care-
BFan F Mounting Bolt fully hold rotor in vise, and remove pulley nut
CPulley G Shield
D Drive Belts
1. Remove pulley, fan, and collar.
Fig. 1 -Alternator Removal

2. Before separating housing, chalk a mark across
To remove alternator, remove adjusting cap screw one side for reference when reassembling. Front and
(E) and mounting bolt (F). Leave shield (G) with rear housings can fit together any of four ways.
mounting hardware.
Remove four thru bolts (1, Fig. 3), and separate
3.
DISASSEMBLY frontand rear housings. If necessary, pry carefully with

two screwdrivers on opposite sides to force housings
NOTE: Pulley nut needremoved if you are
not be apart.
certain that front bearing good condition. Just
is in
separate housing as described below, and leave rotor 4. Set alternator on rear housing, and slide front
installed in front housing. housing off. Lift rotor out of rear housing.
JD-306 Alternator Pulley Nut Remover is recom- 5. Place a piece of masking tape over rear bearing
mended for removing and installing pulley nut. Install a to keep trash out.
15/16-inch socket on remover. Engage socket on pul-
ley nutand remover in end of shaft. Hold shaft and 6. Remove other components only as necessary.
remove nut
>

40-10*2 Charging Circuit Electrical Repair
REPAIR
23
d 22
[ 21 20
29 23
U&P
R 26301N
1Thru Bolt (4 used) 10 Regulator Ground Screw 18 Slinger Washer 26Capacitor

2OH Seal 11Insulated Screw (2 used) 19Front Housing 27 Diode Trio
3 Rear Bearing 12Stator 20Pulley Nut 28 Rectifier Ground Screw
4Output Terminal 13 Rotor 21Lock Washer 29Lock Washer
5Insulating Washer 14Inner Collar 22Pulley 30Nut (4 used)
6 Rear Housing 15Screw used)
(3 23Fan 31Washer
7 Regulator 16Bearing Retainer 24Outer Collar 32 Insulating Washer
8 Brush Assembly 17 Front Bearing 25 Screw (2 used) 33 Rectifier Bridge
9Lock Washer (4 used)
Fig. 3-Atternator
Front Bearing Bearing may be reused if not damaged, Clean

bearing and fill it 1/4 full with Delco-Remy Lubricant
Remove bearing retainer (16, Fig. 3) by removing
three screws (15). Remove bearing (17) and slinger
No. 1948791 before assembly. Do not overfill.
washer (18).
Reinstall slinger washer and bearing,
install new bearing retainer if felt seal is hardened or

worn. Fill cavity between retainer plate and bearing
with 1948791 Lubricant.
Rear Bearing
Replace rear bearing if defective or if its grease
supply is exhausted. Do not attempt to relubricate.
Support housing near bearing diameter (A 1-1/4

inch socket makes a suitable support) and press
bearing to inside. Press new bearing in until flush.
Install new seal with lip toward rotor. Coat sea! lip
with oil for easier assembly.
Fig. 4-Pressing Front Bearing
NOTE: If necessary to press bearing out of or into

housing, carefully support housing near bearing diam-
eter, as shown in Fig. 4. A 1-3/4 inch socket makes a (
suitable support.

Electrical Repair
Charging Circuit 40-10-3
Rotor
R 26534N
R 26532N
AAmmeter b Battery
OOhmmeter Fig. 7-Checking Rotor for Short Circuit
Fig. 5-Checking Rotor for Grounds
To check rotor for short circuit, connect one slip ring
To check rotor for grounds, use an ohmmeter or test to one terminal of 12-volt test battery. Connect am-
lamp to test for continuity between each slip ring and meter to other slip ring and other terminal of test
rotor shaft. Replace rotor test shows battery.
if continuity.
Current draw should be 4.0 to 4.5 amps at 12 volts.

Excessive current draw indicates a short circuit. Re-
place rotor if current draw exceeds 5 amps.
Rough or out-of-round s!ip rings result

in short brush
life. If are defective, mount rotor on lathe. If
slip rings
rings are scored, turn them just enough to eliminate
roughness. If rings are out-of-round, turn them to
within 0,002 inch (0.05 mm) total indicator reading.
R 26533N ^-<o) Polish slip rings sparingly with number 00 sand-

paper or 400-grit silicon carbide paper.
OOhmmeter
IMPORTANT: Clean rotor and stator with com-
Fig. 6-Checking Rotor for Open Circuit pressed air only. Cleaning solvent would damage
insulation.
To check rotor for open circuit, use an ohmmeter or
test lamp to test for continuity from one slip ring to the
other. Replace rotor if test does not show continuity.

40-10-4 Charging Circuit Electrical Repair
Stator To check stator for grounds, use an ohmmeter or

,:i!Blll :
'
.:
::
i#^ test lamp to test for continuity between each stator lead
,:s::::ct:E::3 .
T:ft"t " :tat::s::::'":::.:t:!Ki:3::"::: :::"::? ,::::::
and stator frame. Replace stator if test shows continu-

"
IshP" ity.
fig. -'V Connected Stator
Stator windings for 61 -amp alternator are "Y"con- R 26537N

nected. Other ends of wires A, B, and C form a
common junction.
O Ohmmeter
Fig. 1 1-Checfting Stator for Open Circuit
To test 61 -amp
stator for open circuit, use an ohm-
meter or lamp to test for continuity between leads
test
A and B, between leads A and C, and between leads B
and C. Replace stator if any test does not show conti-
nuity.
NOTE: A 72-amp stator cannot be tested for an

open circuit without disconnecting terminals from stator
windings.
Fig. 9- uDetta" Connected Stator A short-circuited stator can be very difficult to iden-
tify. If an ohmmeter sensitive to resistances of to 1
Stator windings for 72-amp alternator are "delta" ohm is available, repeat the tests for open circuit.
connected. Each terminal is connected to two wind-
ings, like the three points of a triangle. Resistance between each pair of terminals should
be approximately 0.1 ohms for 72-amp stator or 0.2
Inspect stator for defective insulation. Check for ohms for 61 -amp stator. Ohmmeter needle should
discoloration or a burned smell which would indicate a deflect to zero if leads are touched together. If resis-
short circuit. Replace stator if you find any defect. tance is low, windings are short-circuited and must be
replaced.
A stator will occasionally exhibit an open circuit or

short circuit only when hot, making the defect even
more difficult to diagnose.
you suspect, but cannot confirm, that stator is

If
check all other components. If prob-

defective, double
lem cannot be found elsewhere, replace stator.
IMPORTANT: Clean stator and rotor with com-

R 26536N pressed air only. Cleaning solvent would damage
insulation.

O Ohmmeter
Fig. W~Checking Stator for Grounds

Electrical Repair Charging Circuit 40-10-5
Brush Assembly Diode Trio

To check the diode trio, first remove the stator, then
remove the attaching screw and the diode trio, noting
the insulator positions.
*Z8B02K' *
.:
&''
A Brush Contact from CRegulator Ground __ _ _ _

:
^yB Ji;M ?JJ:"J':Hia '^'i"i';r

: !! : -: :
r-i
Diode Trio Screw

B Brush Contact from Regulator
Fig. 12-Checking Brushes for Grounds Fig. 14-Checking Diode Trio
A grounded brush assembly results in either no Use an ohmmeter or test lamp to test for continuity
output or uncontrolled output, depending on where the between points A and D, Fig. 14. Then reverse leads
ground is located. and test for continuity between same points in opposite
direction. A good diode trio will have continuity in one
Check insulating washers on screws holding both direction only.
brush leads (A and B, Fig. 12). Replace if necessary. If Repeat tests between points B and D and between
circuit is grounded elsewhere, replace regulator. points C and D. Replace diode trio unless tests show
continuity in only one direction in each case.
A grounded brush assembly may also damage the
diode trio. Before assembling alternator, check diode Rectifier Bridge
trio as instructed at right.
Ftg. 15-Rectftier Bridge
Rg. 13-Checking Brushes for Open Circuit has a grounded heat sink (A, Fig.
Rectifier bridge
15) and an insulated heat sink (E).
Use an ohmmeter or test lamp to test for continuity Use an ohmmeter or test lamp to test for continuity
between points A and B Fig. 13. Also check between
t
between points A and B. Then reverse leads to test for
points C and D. Replace brush assembly if either continuity between same two points in opposite direc-
check does not show continuity. tion. A good rectifier bridge will have continuity in one
direction only.
Repeat tests between points A and C, A and D, B
and E, C and E, and D and E. Replace rectifier bridge
unless tests show continuity in only one direction in
each case.
TM-1181 (Feb-78) U'tho in USA. Tractors - 4040 and 4240

.
40-10-6 Charging Circuit Electrical Repair
Regulator INSTALLATION
Regulator cannot be tested satisfactorily. Replace
regulator if indicated by brush assembly tests on page
5 or diagnosis and tests in Section 240.
The only suitable way to test regulator is to install it
on an alternator you know is good and measure output.
ASSEMBLY
Be sure insulating washers for rectifier bridge are
1 .
in Be sure insulating screws for brush as-

position.
sembly are in position.
R 26529N
AAlternator EAdjusting Cap Screw

B Fan F Mounting Bolt
C Pulley GShield
DDrive Belts
Fig. 17-Aiternator Installation
1 Hold alternator (A, Fig. 17) and pulley shield (G)

in position, and install mounting bolt (F) through lower
holes.
2. Loosely install adjusting cap screw (E) through
lock washer, washer, adjusting strap, and pulley shield
into front housing.
Fig. 16-Btocking Brushes in Position with Wire 3. Make sure good condition, and use a
belts are in
reliable belt tension gauge to adjust tension. Tighten
Push brushes back to dear slip rings. Block
2. new belts to 100 pounds (445 N) tension. belts have If
brushes in position by inserting a wire through hole in been run, tighten to 90 pounds (400 N) tension. Adjust
rear housing. Insert wire only far enough to hold tension only when belts are cool.
brushes. NOTE: If necessary to pry against alternator to
tighten belts, pry only against front housing.
3. Remove tape from rear bearing, and carefully slip
rotor into rear housing.
4. Carefully slip front housing over rotor shaft. Align

frontand rear housings in proper relationship. If hous-
ings were not marked during disassembly, position
regulator terminals on same side as threaded hole for
adjusting cap screw,
5. Install four thru bolts. Tighten alternately and

securely.
R 265 39N
6. Remove wire from hole in rear housing.
A Red B Resistance Wire
7. Install collar, fan pulley, washer, and pulley nut.
T
Ftg. 18-Altemator Connections
| Tighten pulley nut to 60 ft-Ibs (80 Nm) (8 kgrn), using
JD-306 Alternator Pulley Nut Remover as shown in 4, Attach wires as shown in Fig. 18. (Terminal be-
Fig. 2. hind Terminal 2 is not used.) Attach battery ground
cable.
IMPORTANT: Never attempt to polarize an al-

ternator.
m-1181 (Feb-78) Litho in U.SA. Tractors - 4040 and 4240

Electrical Repair Starting Circuit 40-15-1
Group 15
STARTING CIRCUIT REPAIR
GENERAL INFORMATION 5. Connect ammeter in series with puli-in winding
as shown in Fig. 1, Use an ammeter capable of mea-
NOTE: See Section 240, Group 15 for starting cir-
suring several hundred amps. Current draw should be
cuit diagnosis,
about 140 to 155 amps at 12 volts.
IMPORTANT: Never operate starting motor

IMPORTANT: Do not energize pull-in windings
longer than 30 seconds. Allow at least two minutes
longer than five seconds. Heat builds up rapidly
for cooling and battery recovery before operating
and could damage windings.
again. Overheating, caused by excessive opera-
tion, will seriously damage starting motor.
SOLENOID
Solenoid can be removed and checked without re-
moving starting motor.
1. Disconnect battery ground cable.
2. Disconnect cable and wires from solenoid termi-

nals. Disconnect strap from field terminal.
3. Remove two cap screws securing solenoid to R 25567N
shift lever housing. Carefully remove solenoid.

AAmmeter D Switch Terminal
4. Manually move shift lever back and forth. If
B12-Volt Battery E Motor Terminal
C Battery Terminal FSolenoid Frame
mechanism appears to bind, solenoid may not be at
Remove and check
fault. starting motor as instructed Fig. 2-Measuring Hold-in Winding Current Draw
on following pages.
6, Connect ammeter in series with hold-in winding
as shown in Fig. 2. Current draw should be approxi-
($) mately 11 to 13 amps at 12 volts.
-* - +
- * 7, current draw for either winding is significantly
-J
If
^,
^pj \
higher or lower than specified, it indicates the following:
High Ammeter Reading

Windings short circuited or grounded
+
Low Ammeter Reading
R 26566N Excessive resistance in circuit, usually due to poor
connection
AAmmeter DSwitch Terminal
B 12-Voft Battery E Motor Terminal No Ammeter Reading
C Battery Terminal F Solenoid Frame
Windings open circuited
Fig. 1-Measuring Pull~ln Winding Current Draw
8, Remove end cap from solenoid. Check for poor

IMPORTANT: Do not energize solenoid wind- damaged wire. Unless problem can be
connection or
ings when plunger is unrestrained. Either reinstall
found in this area, solenoid must be replaced.
\ solenoid on starting motor or restrain plunger to
prevent movement.
TM-1181 (Sep-77) LUho in USA. Tractors - 4040 and 4240

. . N
40-15-2 Starting Circuit Electrical Repair
STARTING MOTOR REMOVAL

Inspection and Removal
1 Inspect starting motor for obvious defects before
removing it. Check for loose mounting bolts or pole
shoe retaining screws. Operate starting motor and
listen for rattling, squealing, or grinding.
3. Disconnect cable and wires from solenoid.
Fig. 5-Turning Armature by Hand
2. Turn armature by prying against pinion with

screwdriver. Check for dragging armature, seized
bushings, or bent shaft.
If you discover any interference, disassemble and
repair starting motor. See instructions on following
pages. Do not conduct no-load test unless armature
turns freely.
No-Load Test
Fig. 3-Using JOE-80 Starter Wrench
4. Remove mounting bolts. Use JDE-80 Starter

Wrench to reach bolt behind starting motor.
Tests Before Disassembly

Observe motor carefully before beginning
starting
disassembly. Problem may be readily apparent, mak-
ing repair much easier.
Checking for Interference
R 26571
AAmmeter DTachometer
B 12- Volt Battery E Motor Terminal
C Motor Frame
Fig, 6-No-Load Test
1 If armature turns freely in step 2, make connec-
shown in Fig. 6 and conduct no-load test. Use an

tions
ammeter capable of measuring several hundred amps.
Current draw should be approximately 90 to 130
R 265 6 *#
amps at 12 volts. Armature speed should be approxi-
Fig. 4-Turning Overrunning Clutch Drive by Hand mately 4000 to 5000 rpm.
2. If speed and current draw are slightly low, con-
1. Turn overrunning clutch drive by hand. It should nect a voltmeter between motor terminal and motor (
turn freely on shaft in overrunning direction only. frame. Observe voltage during test. Voltage may be
reduced because of high current draw on battery.

. A
3. If speed or current draw is significantly different IMPORTANT: Never clean armature, field wind-
than specified, diagnose problem as follows. ings, or overrunning clutch drive in solvent All
parts except overrunning clutch drive may be
Fails to Operate, No Current Draw cleaned with mineral spirits and a brush. Wipe
Open field circuit (all field overrunning clutch drive with a clean cloth.
windings)
Open armature windings
Defective brush contact with commutator NOTE: Starting motor has metric bolts and nuts
Open except for those on switch cover.
solenoid windings
Defective solenoid contacts
Brush Assembly
Fails to Operate, High Current Draw
Grounded field windings or armature windings
Seized bearings
Low Speed, Low Current Draw
High internal resistance

Defective brush contact with commutator
Low Speed, High Current Draw
Excessive friction
Shorted armature
Grounded armature or field windings
High Speed, High Current Draw R 25572ft
Shorted windings
A Grounded Brushes
field
C Brush Spring
B Insulated Brushes
DISASSEMBLY AND REPAIR
Fig. 7-Brush Assembly
Remember two basic rules when working with start-
ing motors;
1. Remove end frame cover, (30, Fig. 15).
1. Diagnose the problem as thoroughly as possible

2. Inspect brushes (A and B, Fig. 7) closely. Make
before beginning disassembly.
sure brushes are not binding in holders. Full width of
each brush should contact commutator
2. Disassemble only as far as necessary to correct
problem.
3. Replace brushes if they are oil soaked or worn to
less than 5/8 inch (16 mm) in length.
Whenever starting motor is disassembled for any
reason, lubricate it as follows.
4. Check each brush spring (C) to be sure it is
holding brush tight against commutator. Replace
1 Resaturate center bearing and oil wick with me-
springs if they are distorted, discolored, or weak.
dium grade engine oii.
5. To remove brushes, remove brush lead screws.

2. Apply a coat Bosch VS
10 832 Ft grease" to
of
Pry brush spring out of way, and pull brush out of
both end bearings, grease reservoirs for both end
holder.
bearings, armature shaft except center bearing area,
brake washer, both ends of shift lever, and shift lever
pivot shaft.
*lf specified grease is not available, substitute Esso
Beacon 325 or Delco-Remy Lubricant No. 1960954.

I
3. Avoid excessive lubrication.
TM-1181 (Jun-80) Litho in U.S. Tractors - 4040 and 4240

Brush Assembly Continued
R 26573N
||jf::;"i.^t"|liJir^ :
?% ;. sS H!iS. k'
:
wg0W&Ljm
A Field Terminal CShunt Winding Ground
B Shunt Winding Terminal Ohmmeter
ABrush B Brush Spring
Fig. 9-Testing Field Windings for Grounds
Fig. 8-8rush Installation
Disconnect shunt winding ground inside main frame.

6. When brushes, cross brush leads 180
installing Be sure thatwire is not touching frame, and use an
as shown in Fig, 8. On insulated brushes, push leads ohmmeter or test iamp to test for continuity between
down tight against brushes to prevent grounding. shunt winding terminai and frame.
Field Windings if either test shows continuity, windings are ground-

ed. Check for worn insulation. Repair or replace wind-
Removal ings.
1. Remove terminal cover and fiefd connector Dis-

connect shunt winding lead.
2. Remove end frame cover.
3. Remove brush lead screws from two insulated

brushes,
4. Remove two cap screws securing end frame to

main frame. Remove end frame,
5. Chalk a reference mark across drive housing, R 26574N
shift lever housing,and main frame for proper reas-

sembly. OOhmmeter
Fig. 10-Testing Shunt Winding for Open Circuit
6. Remove eight special screws securing drive
housing and shift lever housing to main frame. Care-
With shunt winding ground disconnected, use an
fully remove main frame.
ohmmeter or test lamp to test for continuity between
shunt winding ground and shunt winding terminal as
Testing
shown in Fig. 1 0. If test does not show continuity, shunt
Use an ohmmeter or test lamp to test for continuity winding is open circuited. Repair or replace windings.
between field terminal and main frame as shown in Fig.
9. Be sure brush connectors are not touching frame.
TM-1181 (Jun-80) Litho in US. A, Tractors - 4040 and 4240

There is no suitable way to check field windings for

short circuits. Winding resistance is too low to permit
detection of a short circuit. If starting motor appears
weak and no other cause can be found, replace field
windings.
R 26575N
A1/4-Ohm Resistor [> Insulated Brush Lead

B12-Vo!t Battery E Steel Bar
C Fiefd Terminal
Fig. 11 -Testing Field Windings for Open Circuits
Connect a test battery to field terminal and either Fig. 13-Removing Pole Shoe Screws
insulated brush connector, using a resistor to limit
If necessary to remove field windings, use a large
current as shown in Fig. 11.
screwdriver bit and socket wrench on pole shoe,
Use a steel bar to test each winding for magnetism. screws.
If windings do not have magnetism, they are open
Take care to prevent distortion of main frame. Do not
circuited. Repair or replace windings.
squeeze sides in vise or strike with hammer. If you
NOTE: Because 1/4-ohm resistors capable of car- must use an impact screwdriver to loosen screws,
rying several hundred watts are not widely available, a support each pole shoe individually, using a pole shoe
suggested alternative is to connect four 1-ohm resis- spreader or the nose of an anvil.
tors in parallel Each resistor should be rated for at
Handle windings very carefully. They are easily
least 150 watts. A carbon pile can also be used. Limit
damaged, causing shorts, opens, or grounds.
current to 40 to 70 amps.
When installing field windings, tighten pole shoe
screws as tight as reasonably possible. Use a center
SiV punch to lightly stake one edge of each screw.
R 26576N
AAmmeter B 12- Volt Battery
Fig. 12-Testing Shunt Windings for Short Circuit A Brush B Brush Spring
Fig. 14-Holding Brushes Back

Connect an ammeter in series with shunt windings
asshown in Fig. 12. Windings should draw 15 to 20 Reassemble starting motor in reverse order of dis-
amps at 12 volts. A high reading indicates a short assembly. Before installing end frame, push each
circuit. A low reading indicates a poor connection. brush back far enough for brush spring to rest against
Repair or replace windings if defective. side of brush as shown in Fig. 14. After installing end
I frame, let brushes down against commutator.

r 252361*
1Drfve End Bushing 11Shunt Winding Lead 21 Field Winding 31Gasket

2 Drive End Housing 12Armature 22 Pole Shoe (4 used) 32Commutator End Frame
3 Packing 13Bakelite Washer 23 Square Washer Bushing
4Overrunning Clutch 14Oil Seal 24Insulating Bushing Brush used)
33 (4
5 Lever Pivot
Shift 15Center Bearing Bushing 25Square Insulator Brush Spring used)
34 (4
6O-RIng 16Oil Felt 26-Special Bolt Commutator End Frame
35
7 Lever
Shift 17Brake Washer 27Field Coil Connector 36 Field Frame
8Center Bearing Housing 18Pinion Stop 28Terminal Cover
9 Solenoid Winding 19 Snap Ring 29Brush Ground Strap
10Solenoid Switch Cover 20Shunt Winding Ground Screw 30 End Frame Cover
Fig. 15-Starting Motor
<

.
Overrunning Clutch Drive Inspection
Check overrunning clutch drive by hand before dis- Inspect overrunning clutch drive for signs of over-
I caused by keeping switch engaged too long
assembling starting motor. Drive should turn smoothly heating,
in overrunning direction only. Drive should slide after engine starts.
smoothly on armature shaft.

If drive has been damaged, check armature shaft
closely. Replace armature if you find any damage to
Removal
shaft.
If necessary to remove overrunning clutch drive, use
Overrunning clutch drive is not serviceable. Install
the following procedure.
new drive if old one is defective.
1 Remove terminal cover and field connector from IMPORTANT: Do not clean overrunning clutch
solenoid. Disconnect shunt winding lead, and remove drive with solvent. Solvent would dissolve lubri-
solenoid. cant in clutch mechanism. Clean only by wiping
with a clean cloth. Do not lubricate drive.
2. Chalk a reference mark across drive housing,
shift fever housing, and main frame for proper reas- Reassembly
sembly.
1. Place overrunning clutch drive in shift lever
housing, making certain that shift lever is engaged in
3. Remove eight special screws securing drive
slot.
housing and shift lever housing to main frame. Remove
drive housing. 2. Slide shift lever housing and overrunning clutch
drive onto armature shaft.
ft ScSoOK
R 26SSSH A Pinion Stop CWasher (Remove

B Retaining Ring After Using)
APipe Coupling B Pinion Stop Fig. 17-tnstalling Pinion Stop
Ftg. 16-Removing Pinion Stop 3. Slide pinion stop onto shaft, with open side
toward end of shaft. Install retaining ring in groove.

4. Remove pinion stop. Use a pipe coupling or other Force pinion stop over ring, using a washer and two
metal cylinder to drive pinion stop toward pinion. Re- pairs of pliers as shown in Fig. 17. Remove washer.
move retaining ring and slide pinion stop off shaft.
4. Install shift lever housing and drive housing.
5, Carefully slide shift lever housing and overrun-

ning clutch drive off shaft. Do not slide armature out of
brush assembly at other end of shaft.

.
Armature Undercut insulation between commutator bars to

1/32 inch (0.8 mm). Touch up commutator with sand-
To remove armature, starting motor must be almost
paper after using lathe. Clean dust and metal chips
completely disassembled.
from armature when finished.
1 Remove and field connector from

terminal cover
solenoid. Disconnect shunt winding lead, and remove
solenoid.
2. Remove end frame cover,
3. Remove brush lead screws from two insulated

brushes.
4. Remove two cap screws securing end frame to

Fig. 18-Checking Armature for Bent Shaft
main frame. Remove end frame.
Place armature in V-blocks and check for a bent
5. Chalk a reference mark across drive housing, shaft as shown in Fig. 18. Replace armature if shaft is
shift lever housing, and main frame for proper reas- bent.
sembly. If no-load test indicates possibility of grounded,

short circuited, or open circuited windings, check ar-
6. Remove eight special screws securing drive mature for these defects. Windings are large, and
housing and shift lever housing to main frame. Remove defect might be easy to spot.
drive housing.
Grounded Windings
7. Remove pinion stop. Use a pipe coupling or other
metal cylinder to drive pinion stop toward pinion, as Symptoms
Starting motor cranks engine slowly or
all. On no-load test, motor has low armature
not at
shown in Fig. 16. Remove retaining ring and slide
pinion stop off shaft. speed and high current draw or fails to operate and has
high current draw.
8. Remove main frame.
9. Carefully slide armature shaft out of shift lever
housing and overrunning clutch drive.
IMPORTANT: Do not clean armature with sol-

damage insulation on wind-
vent. Solvent could
ings. Use only mineral spirits and a brush.
Give armature a close visual inspection. Look for

signs of dragging against pole shoes. Look for scoring
under bushings or overrunning clutch drive.
R 26561N
Carefully check commutator. Look for roughness,

Fig. 19-Checking Armature for Grounded Windings
burned commutator bars, or any material which might
cause short circuits between bars. Use an ohmmeter or test lamp to test for continuity
between commutator bars and armature shaft. If test
Clean and touch up commutator if necessary with 00 shows continuity, a winding is grounded. If fault cannot
sandpaper. Never use emery cloth. Clean all dust from be corrected, replace armature.
armature when finished.
All armature windings are connected in series, so
you need to check only one commutator bar.

If commutator is out of round, badly burned, or
rough, it can be turned down slightly on a lathe. Re-
move only enough metal to eliminate problem.

(
TM-1181 (Sep-77) Litho in US.A Tractors - 4040 and 4240

Short Circuited Windings ASSEMBLY

Symptoms
Starting motor cranks engine slowly. Assemble starting motor in reverse order of disas-
On no-load test, motor has low armature speed and sembly. Install pinion stop as shown in Fig. 17. Use
high current draw. new seal and packings.
Check armature carefully for windings which are Apply a coat of Bosch VS 10 832 Ft grease to both
bent and touching. Check commutator for anything end bearings, grease reservoirs for both end bearings,
which could conduct electricity between bars. armature shaft except center bearing area, brake
washer, both ends of shift lever, and shift lever pivot
if a growler is available, use it to locate short circuit. shaft. Avoid excessive lubrication.
Follow manufacturer's instructions.
* If specified grease is not available, substitute Esso
Open Circuited Windings Beacon 325 or Detco-Remy Lubricant No. 1960954.

Symptoms Starting motor cranks engine slowly. INSTALLATION
On no-load test, motor has low armature speed and
high current draw.
Open circuits are usually due to overheating caused

by excessive cranking. Check connections of windings
to commutator bars. Also look for burned edges on
commutator bars.
Certain growlers are capable of locating open cir-
cuits. If one is available, use it according to manufac-

turer's instructions.
Open circuited windings can sometimes be repaired.

Use solder and rosin flux. R 252^4211
AWhite B Red C Positive Starter Cable

Bushings
Fig. 20-$tarter Connections
When installing new bushings, press bushings in
from chamfered end of bores. Align botes in end

Install starter. Use JDE-80 starter wrench on nut
bushings with lubrication wicks.
behind starter. Connect wiring harness and positive
battery cable as shown in Fig. 20.
Install a new seal and lubrication wick when replac-
ing center bearing. Saturate wick with medium grade
engine oil.
Only if necessary, ream bushings after installation.
I.D. end bushings should be 0.669 to 0.670 inch

of
(17.00 to 17.03 mm). LD. of center bushing should be
1.182 to 1.184 inches (30.02 to 30,07 mm).
>


.
Electrical Repair Lighting Circuits 40-20-1
Group 20
>
LIGHTING CIRCUIT REPAIR
NOTE: See Section 240, Group 20 for lighting cir- To test a relay, carefully note mounting of terminals
cuit diagnosis. and position as shown in Fig. 2.
TESTING FLOOD LAMP RELAYS 1 Connect ohmmeter leads to terminals B and D.

Switch should be open, giving a resistance of infinity. If
not, replace relay.
2. Connect a 12-volt battery to terminals A and C,

and note ohmmeter reading. Switch should close, giv-
ing a resistance of zero. If not, replace relay.
ADJUSTING HEADLIGHTS
(9$ 0
Fig. 1 -Lighting Relays
0-
Relays are mounted inside control support. For
RB6580N
access, remove cowl rear cover and left-hand cowl.
NOTE: Center relay uses five terminals and is not A Height of Lamp C Lower Light Zone
interchangeable with other two. Do not mix. BCenterline of Tractor 0Upper Light Zone
Fig. 3-Ught Pattern at 25 ft. (8m)
Adjust headlights so they shine slightly down and to

the right
Use Fig. 3 as a guide for adjustment. Have lights on

low beam. Sight across hood ornament and steering
wheel to locate tractor centerline.
R 31172
AGround Power Out

B Power In E Power Out (Center
CControl Circut Relay Only)
Fig. 2-Lighting Relay Terminals

>

40-20-2 Lighting Circuits Electrical Repair
TESTING TURN To test controller, use an ohmmeter or test lamp to

SIGNAL CONTROLLER test for continuity as shown in the following chart.
(
Switch Terminals in Continuity
Posftion with Terminal No. 1
Off 3, 4 (Through flasher for flashing operation;

not through flasher for steady operation)
Left 3, 6 (Through flasher)
2, 4 (Not through flasher)
Right 4, 5 (Through flasher)
2, 3 (Not through flasher).
Overtightening the long turn signal lever attaching

screw may cause the turn signal controller to bind,
making it difficult to move the lever. If this happens,
loosen the screw four or five turns and gently drive the
screw inward to reposition the threaded insert in the
controller.
TESTING LIGHT SWITCH
ATurn Signal Lever CMounting Bracket

BTurn Signal Controller DIndicator Lamp Ground
Fig. 4-Tum Signal Controller
NOTE: If by local reg-

flashing lights are prohibited R171S3N
an AR67398 Turn Signal Controller.
ulations, install
Fig. 5-Light Switch Terminals
Warning lamps will then glow steadily.
Light switch should have continuity between termi-
Terminal usage is indicated in following chart. For
nals listed in the following chart. To test switch, dis-
access to turn signal controller, remove left cowl.
connect wiring and use an ohmmeter or test lamp to
test for continuity.
WIRE
TERMINAL COLOR USE
Switch Position Continuity Between
1 Purple Power in from fight switch for W Bat A to WL
warning lamp operation
2 Blue Power in from circuit breaker H Bat. A to TL, WL
for turn signal operation Bat B to HD
3 Orange To left turn lamp and indicator
lamp Bat A to FLR
4 Orange To right turn lamp and indica- Bat B to HD
& Black tor lamp
5 Not used
6 Not used
<

.
Electrical Repair Lighting Circuits 40-20-3
BULB REPLACEMENT 1 Remove lens by removing four screws.
Flood Lights and Headlights 2. Remove bulb by pressing it slightly inward and
turning counterclockwise.
3. Press new bulb in, turn clockwise, and replace

lens.
Instrument Lights and Indicator Lights

1 . Remove cowl rear cover and left-hand cowl.
Fig. 6-Removing Headlight Bulb
1. Use a screwdriver to pry bulb from rubber bezel.

Work your way around circumference, taking care to
not break bulb.
2. Disconnect wires, and connect new bulb.
Fig. 8-Removing instrument Light Bulb

3. Carefully push bulb into rubber bezel. Make sure
it is properly positioned.
2. Remove bulb socket from back of instrument
cluster by turning counterclockwise. Remove bulb from
Warning Lights and Tail lights
socket by pulling straight out.
3. Press new bulb firmly into socket, install socket in

instrument cluster, and reinstall cowl.
\
Fig. 7-Removing Taitlight Bufb
TM-1181 (Sep-77) Litho in USA, Tractors - 4040 and 4240

40-20-4 Lighting Circuits Electrical Repair
Tach Light, High-Beam Indicator, Dome Light and Console Light

and Turn Indicators
1. Remove cowl rear cover and right-hand cowl.
Fig. 11 -Removing Dome Light Bulb
To remove dome lamp bulb, remove lens by

Fig. 9-Removing High-Beam indicator Bulb
squeezing sides Press bulb
slightly together. slightly
inward and twist counterclockwise to remove.
2. On tach light or high-beam indicator, pull bulb
socket from back of tube. On turn indicators, remove
mounting bolts and raise dash panel.
Rg. 12-Removing Console Light Bulb
To remove console light bulb, lower lamp housing

Fig. 10-Removing Turn Indicator Bulb
from roof by removing two screws. Remove bulb
socket by twisting slightly counterclockwise. Press bulb
3. Press bulb slightly inward and twist counter-
slightly inward and twist counterclockwise to remove.
clockwise to remove.
4. Reverse the procedure to install new bulb. (

Electrical Repair Instruments and Accessory Circuits 40-25-1
Group 25
INSTRUMENT AND ACCESSORY CIRCUIT REPAIR
NOTE: See Section 240, Group 25 for instrument
and accessory circuit diagnosis.
INSTRUMENT CLUSTER
Fig. 2-fnstrument Ouster Removal
Testing
0 0
B 5?tm
1Water Temperature Gauge Terminals

2Fuel Gauge Terminals
3Engine Pressure Gauge Terminals
Oil
4Voltmeter Terminals
Fig. 1 -instrument Cluster Terminals
Access and Removal

For access to back of instrument cluster, remove
left-hand cowl. This provides enough room to change
bulbs or connect wiring.
R 26582N
To have enough room for removal of cluster, you 1Transmission Oil 10Multiple Connector
must tilt dash panel back.
Indicator 11Transmission Oil
2 Air Cleaner Indicator Sender
1. Remove four cap screws securing dash panel. 3Engine Temperature 12 Air Cleaner Sender
Gauge 13Engine Temperature
4Fuel Gauge Sender
2. Tilt dash panel back, and remove cap screw
14Fuel Sender
at
5Engine Oil Pressure
each corner of instrument cluster. Gauge 15Engine Oil Pressure
6Voltmeter Sender
3. Disconnect multiple connector, and remove 7Instrument Lamp 16Light Switch
cluster. 8Instrument Lamp 17Key Switch
9 Diodes
Fig. 3-Schematic Diagram of instrument Ouster

.
40-25-2 instruments and Accessory Circuits Electrical Repair
indicator Lights Gauges

1 Make sure both lamps glow when key switch Is in If all four gauges malfunction, either power in or
start position. A test circuit is provided through terminal ground circuit is probably defective.
C of multiple connector and terminal G of key switch.
Power source is ignition terminal of key switch, through 1. Instrument cluster is protected by 10-amp circuit
terminal F of multiple connector. breaker, if it trips, you will also lose power to starter
and Sound-Gard Body circuits.
lamps do not glow, check for a defective bulb, poor
If
connection, poor ground at key switch, or open diode 2. If breaker is not tripped, remove left cowl and
on printed circuit board. disconnect multiple connector from instrument cluster.
2. Remove wire from sender, and touch it to ground.

With key switch on, lamp should glow when wire is
grounded. If it doesn't, check for poor connection, open
circuit, or defective bulb.
3. Test sending units. Air cleaner indicator sender is

normally open and should close at 24 to 26 inches (500
to 640 mm) of water. Measure with a water manometer
as instructed in Group 105 of Section 30,
Power Shift tractors use a temperature switch as

sender for transmission oil indicator lamp. It is normally R 26583N
open and should close above 220F (105C).

A Not Used
Perma-Clutch tractors use a pressure switch and BTo Transmission Oil Sender
may also have the temperature switch described CTo Terminal G of Key Switch
DTo Air Cleaner Sender
above.
ETo Engine Temperature Sender
FTo IGN Terminal of Key Switch
Pressure switches have been subject to confusion. GTo Ground
Make sure AR61969 switch is used on 4840 Tractors. HTo Fuel Sender
has a black lead and should close at pressures below
It
KTo Engine Oil Pressure Sender
LTo HD Terminal of Light Switch
120 psi (8,3 bar) (8.4 kg/cm a >.
Fig. 4-Muttipte Connector Terminal Usuage
Make sure AR61970 used on 4640 Trac-
switch is
tors. It has a blue lead and should close at pressures 3. Turn key switch on. Use voltage detector, volt-
below 95 psi (6.5 bar) (6.6 kg/cm*). meter, or test lamp to test for battery voltage at terminal
F of multiple connector. If terminal does not have
4. both lamps glow when only one should, one or
If voltage, check poor connection at key switch or
for
both of the diodes are defective. Replace printed circuit circuit breaker or for a defective key switch.
board in instrument cluster.
4. Use voltage detector, ohmmeter, or test lamp to
make sure terminal G of multiple connector provides a
good ground, if not check for a poor connection at
ground screw near circuit breakers or at ground wire at
front right-hand Sound-Gard Body mount.

if a single gauge malfunctions, either that gauge or its TESTING VOLTMETER

sending unit is probably defective,
) IMPORTANT: Never ground terminal F on a gauge
NOTE: For fuel, water, and oil pressure gauge and (shielded terminals on back of in-
sending unit resistance checks, see page strument cluster). To do so would
240-06-56. destroy printed circuit board.
Voltmeter has only two terminals. Indicator should rise

to left edge of solid green band with 1 1 .8 volts applied
to terminal F and terminal G grounded. With 13 volts,
it should point straight up, Wrth 15.5 bolts, it should
reach right edge of solid green band.
Ifa gauge does not read correctly wfth tester con-

nected directly to gauge terminals, replace gauge.
Ifgauge does read correctly, check carefully for a poor

connection or open circuit between gauge and sender.
Problem could be in sender wire terminal, bulkhead
connector, multiple connector at cluster, or printed
circuft board.
R26S$6N
Fig. 7Spring Washers
Gauge terminals must have spring washers to make

contact with printed circuit board, as shown in Fig. 7.
>
TM-1181 (Nov-86) LITHO IN USA. Tractors-4040 and 4240

40*25-4 Instruments and Accessory Circuits Electrical Repair
Assembly Electrical Connections
If cluster Is disassembles, make sure each gauge <

terminal has a spring washer to make contact with
printed circuit board.
install glass with blue coated surface inward.
Install a new gasket. Turn smooth side inward, and

make sureit will seal across both glass and cluster
case.
RADIO AND TAPE PLAYER
ARadio Wiring UTape Player Wiring

BSpeaker Harness ERadio & Tape Player
CTwo-to-Thre* Wire Adapter Harness
Fig. 9Radio and Tape Player Electrical Connections
Dual speakers are installed in all tractors at the factory.
Radio Fuseholder When installing radio or tape player make the following
A
C To Ground
electrical connections,
BTape Player Fuseholder
Fig. 8AM-FM Multiplex Radio and Tape Player Assembly 1. AM-FM radio Connect radio wiring A, Fig. 9)
directly to speaker harness (B).
Radio and tape pfayer have 5 amp fuses (A and B, Fig.
8). 2. AM radio Connect AR73923 two-to-three wire
adapter (C) between radio wiring and speaker harness.
To gain access to radio fuse on radio without tape
remove the
player, six screws. Radio and grille are 3. Tape player Connect radio wiring, tape player
removed as a unit. and speaker harness to radio and tape
wiring (D), relay,
player harness (E). Use AR60557 harness with AM
To gain access to a fuse on a radio and tape player, radio or AR69589 harness with AM-FM radio.
open Sound-Gard Body roof. Remove the two radio
and tape player assembly mounting screws from the
top side of the inner roof. Then remove the six screws
from grille. Lower radio and tape player assembly.
TM-1181 (Nov-86) LITHO IN U.S.A. Tractors-4040 and 4240

4. Connect power in (fused) wire to brown wire in
SOUND-GARD body harness.

To assure a good ground, make a ground wire
5.
withan eyelet on one end and an R32025 male blade
connector on the other. Connect to radio chassis and
to black wire in SOUND-GARD body harness.
Antenna Trimmer
If AM radio reception seems poor, adjust antenna
trimmer capacitor screw. To do so, select a weak
station near 1400 and adjust trimmer screw to obtain
maximum volume.
A Cover B Wire Leads
Fig. 1URighUHand Wiper Motor
3. Disconnect wire feads from wiper motor (B).
Fig. 10-Adjusting Antenna Trimmer Capacitor Screw on

Motorola Radio
On Motorola Radio, screw is located behind tuning
knob. Remove tuning knob and the knob behind it.

Insert a screwdriver in small hole below tuning shaft to
adjust trimmer.
ILLUSTRATIONS
FM portion of an AM-FM radio does not have an
antenna trimmer capacitor. When stereo FM signal is
weak, radio automatically switches to monaural re-
ception.
NOTE: If radio works on FM but not on AM, check
for a poor connection to antenna.
RIGHT-HAND WIPER MOTOR

Removal
1. Remove two cap screws from top of roof and
three screws at front of roof.
A Cap Bolt C Rubber Cap
B Wiper Arm D Cap Screws
Raise roof and remove cover
2. (A, Fig. 11) from
wiper motor cavity. Fig, 12-Wioer Arm Attachment
4. Remove cap bolt and lock washer (A, Fig. 12).
5. Remove wiper arm (B) from wiper motor shaft.

.
40-25-6 Instruments and Accessory Circuits Electrical Repair
RIGHT-HAND WIPER MOTORContinued Brush assembly and armature are no longer avail-
Removal Continued able as service parts. If any part of motor other than
drive gear is defective, replace motor. (

6. Remove
rubber cap and large nut (C) and wash-
ers from shaft
To install a new drive gear (7, Fig. 13):
1. Remove clip and washer (1).

7. Remove two cap screws (D) from wiper pivot
plate, and remove
2. Remove connecting link (2) from drive arm (4).
plate.
3. Remove nut and washer (3), drive arm, and
8. Wiper motor can now be removed from the top spring washer (5).
roof cavity.
4. Remove three screws (1 1) and gear cover (10).
Repair 5. Remove two felt washers (9) from ears on hous-

ing (6).
6. Move park adjusting plate (8) out of way, and

push drive gear out of housing.
7. Coat space between bearings in drive shaft bore

with grease. Place enough grease in cavity to immerse
lower 1/8 inch (3 mm) of drive gear Apply a thin film of
grease to portion of housing which contacts drive gear
and to cam and recessed portion of new gear face.
8. Install new drive gear. Reassemble motor by

reversing steps 1 through 6.
LEFT-HAND WIPER MOTOR

Diagnosis
On certain tractors, SOUND-GARD body doors may
not be adequately grounded. This causes intermittent
operation of dome lamp and left-hand wiper motor.
As a remedy, install a ground wire between door and

1Clip and Washer 10--Gear Cover frame. Later tractors include a ground wire in left-hand
2Connecting Link 11 Screw wiper harness.
3 Nut and Washer 12 Brushes and Holder
Drive Arm
4 13-Housing The wiper drive shaft with drive end is the only
Spring Washer
5
14 Armature replacement part available. If any other part of the
Gear Housing
6 15 Nylon Thrust Washer motor is defective, replace it,
7 Drive Gear 16 Metal Washer
8 Park Adjusting Plate 17 End PJate
9Felt Washer 18Thru Bolt
Removal
Fig. 13-Right-Hand Wiper Motor Repair 1 Remove wiper arm from wiper motor shaft.
2. Remove outside pivot shaft nut and washers.
3. Disconnect wiring leads and capacitors.
4. Remove wiper motor from door frame by remov-

ing the machine screw on the left end of motor mount-
ing bracket.
TM-1181 (Jun-80) Litho in U.S. A. Tractors - 4040 and 4240

LEFT-HAND WIPER MOTOR Continued

Repair
;s,:.-. ,;.;". ;:;:; :;;;;;:;;;
'M03ffl
Fig. 14-Motor Housing Cover Screws
A E-Clip B Attaching Link
1. Remove four screws (Fig, 14) from housing Fig. 1$-Attaching Link E-Ciip
cover. Hold cover in place after removing screws be-
cause brush carrier (C, Fig. 15) is spring loaded 3. Remove attaching link E-clip (A, Fig. 16) from
against cover. pivot shaft bell crank.
4. Disconnect attaching link (B) from pivot shaft befi
crank and swing it to one side.
5. Turn assembly over and remove pivot shaft re-

taining nut.
AOrange Wire C Brush Carrier

B Brown Wire and Spring
[> Bell Crank Pivot Shaft
Fig. 15-Removtng Housing Cover
2.Slowly lift cover from housing as though it were

immsx
hinged on the motor side of the housing (Fig. 15). Fig. 17-Removtng Pivot Shaft from
Remove the spring and brush carrier (C) and, using a Housing
needle nose pliers, disconnect the upper orange wire

(A) and lower brown wire (B). 6. Tap end of shaft lightly with hammer to free it
from housing (Fig. 17) and remove it from inside of

gearbox.

40-25-8 Instruments and Accessory Circuits Electrical Repair
LEFT-HAND WIPER MOTOR Continued 14. Mount wiper motor on tractor and connect ca-
Repair Continued pacitors and wiring leads as illustrated in Fig. 18.
7. Install new pivot shaft from inside of gearbox and 15. Before reinstalling the wiper blade, start wiper
press it into the bore as far as possible by hand. motor and allow it to cycle several times. Use the wiper
motor switch to shut it off. (Do not use the key switch.)
8. Install the removed pivot shaft retaining nut and
tighten it against housing until snap ring on wiper end 16. Install wiper blade so that it does not strike the
of pivot shaft is pulled tight against inside surface of rubber molding on either side of windshield during
gearbox. operation.
9. Reconnect attaching link to pivot shaft bell crank

and secure with new E-ciip.
10. Install orange and brown wires to the terminals

from which they were removed (Fig. 15).
11. Position the spring and new brush carrier (D,

Fig. 15) on the end of the bell crank pivot shaft.
12. Carefully lower the cover into place on the

housing, making sure the spring and brush carrier stay
in proper position against the inside of the cover.
13. Reinstall the four cover screws.
R34548
ALong Black Wire
BGreen Wire
CRed Wire
DShort Black Wire
Fig. 18-lnstaHing W\pef Motor

Electrical Repair Power Front-Wheel Drive 40-30-1
Group 30
POWER FRONT-WHEEL DRIVE REPAIR
POWER SHIFT
TRANSMISSION SWITCHES
ft 26504N
ACircuit Breaker DTransmission Switches Fig. 2-Power Shift Transmission Switches

B Clutch Pressure Switch ESolenoids
C Operating Switch
Disconnect wiring harness from transmission
1 -Power Front-Wheel Drive
each switch for continuity in each gear.
switches. Test
Fig. Electrical System
Switches should be closed only in the gears listed
below.
NOTE: For additional information on Power Front-
Wheel Drive, refer to the following areas:
Section 240, Group 30
Electrical diagnosis
Switch No. 1 (top switch) Closed in all reverse
Hydraulic and mechanical diagnosis Section 250,
speeds.
Group 30 Switch No. 2 Closed in all forward speeds.
Hydraulic and mechanical repair Section 50,

Switch No. 3 Closed in 1 , 2, 3, 4, 5, and 6 speeds.
Group 40
Switch No. 4 (bottom switch} Closed in 1 2, 3 and
,
4 speeds.
Add or remove shim washers to adjust switches.
>

40-30-2 Power Front-Wheel Drive Electrical Repair
QUAD-RANGE 2. Remove the five special screws securing console

TRANSMISSION SWITCHES cover,
(
3. Remove rockshaft selector lever knob (D).
4. Lift up on control fever guide, and remove con-

sole cover.
AConsole Cover CControl Lever Guide

BSpecial Screws DSelector Lever Knob
Fig. 3-Access to Transmission Switches
To check transmission switches, you must remove

control console cover (A, Fig, 3}.
1.Loosen the three special screws (B) securing

A Range Switch C^Hi-Lo Switch
B Speed Switch
control lever guide (C). Screws are reached from out-
side Sound-Gard Body, below right-hand fender Fig. 4-Quad-Range Transmission Switches
BL GR
R288S2H
A Range Switch C^HM_o Switch B Black BR Brown O Orange R Red WWhite

BSpeed Switch DDiode BLBlue GR Green PU Purple TTan YYellow (
Fig. 5-lntemat Connections for Quad-Range Transmission Switches

Testing Range Switch Switch Adjustment

Disconnect the range switch wiring harness. Use an
> ohmmeter or test Jamp to test for continuity between
the following wires at the connector terminal.
A rangeWhite and green.

B rangeWhite and red.
Orange to black (A
diode prevents flow
from black to orange).
C range White and red.

Blue to orange (diode).
Blue to black (diode).
Orange to black (diode).
D range No continuity.
Testing Speed Switch

Disconnect the speed switch harness at both mul-
tiple connectors and the hi-lo switch. Use an ohmmeter
or test lamp to test for continuity between the following
wires.
Speed 3 or 4Green and blue.

Tan to blue (A diode prevents flow
from blue to tan). A Range Switch CControl Rods
Orange to blue (diode). BSpeed Switch
Fig. 6-Rotary Switch Adjustment
Speed 1 or 2Green and blue.
Tan and blue.
If a rotary switch fails the preceding tests, check
Orange to blue (diode).
switch adjustment as foliows.
Purple to blue (diode).
1. Place shift levers in C1 gear.

Speed 1R or 2RTan and yellow.
Orange and yellow.
2. Disconnect rod from switch,
Green and yellow.
3. Turn switch counterclockwise to stop. Then turn
There will be continuity between several other wires
back three notches,
in each switch position, but these checks are sufficient.
4. Adjust rod length to this position. Reconnect rod.

Testing Hi-Lo Switch
Disconnect the three wires from hi-lo switch.Use an Test switch again. If it still fails the test, replace it.
ohmmeter or test lamp to test for continuity between

the following terminals.
Speed 1 Bottom and center terminals.

or 3
Speed 2 or 4 Bottom and top terminals.
>

40-30-4 Power Front-Wheel Drive Electrical Repair
Switch Adjustment Continued SYNCRO-RANGE

<
A Console Cover CControl Lever Guide

B Special Screws DSelector Lever Knob
Rg. 8-Acce$s to Transmission Switches

control console cover (A, Fig, 8).
if 2 % U v ti '"MMfl
1. Loosen screws (B) securing

the, three special
ASwitch Mounting Screws PU-Purple
Screws are reached from out-
control lever guide (C).
B^Bell Crank R Red
CSpeed Switch Bracket T Tan side Sound-Gard Body, below right-hand fender,
Fig. 7-Hi-Lo Switch Adjustment 2. Remove the five special screws securing console
cover.
Hi-lo switch plunger should be centered on the
protrusion on the bell crank (B, Fig. 7), If not, loosen 3. Remove rockshaft selector lever knob (D).
the speed switch bracket (C) and center it.
4. Lift up on control lever guide, and remove con-

If adjustment is wrong, loosen switch
plunger sole cover.
mounting screws. Reposition switch and tighten
screws. Test switch as described on preceding page to
be sure it completes the proper circuit in each position.
IMPORTANT: If shift lever supports or switch

mounting brackets are loosened, check switch ad-
justment after they are tightened.

Testing Change Switch

Disconnect the change switch wiring harness. Use
I an ohmmeter or test lamp to test for continuity between
Blue and orange should have continuity in first and

third gears only.
Blue and purple should have continuity in fourth and

seventh gears only.
Blue and green should have continuity in first sec-

ond, third, and fifth gears only.
Testing Range Switch

1. Disconnect clutch pressure switch wiring and
install a jumper wire as instructed on page 240-30-4.
2. Disconnect change switch.

A^-Change Switch BRange Switch
Fig. 9-Syncro-Range Transmission Switches 3. Turn key switch on.
4. Use a voltmeter or test lamp to check for battery

=f-B-
voltage at the following wires.
Orange wire at connector between switches should

have voltage with transmission in third gear and
1 n operating switch in high torque position.
Green wire at connector between switches should

have voltage with transmission in third gear and
operating switch in low torque or with transmission in
GR-
gear and operating switch in high torque. (An open
first
diode will cause no voltage in first gear high torque

position.)
-BL
Purple wire at connector between switches should

have voltage with transmission in first gear and
operating switch in high torque. (A shorted diode wiif
cause voltage also in third gear low torque position.)
AChange Switch BLBlue PU Purple Blue wire at connector between switches or at con-
B Range Switch BRBrown W White
CMovable Contacts nector near solenoids should have voltage with trans-
GRGreen Y Yellow
DOiode O Orange mission in first gear and operating switch in low torque.
Fig. 10-lntemal Connections for Syncro-Range Yellow wire at connector near solenoid should have
Transmission Switches
voltage with transmission in reverse and operating
switch in either high or low torque.
A CAUTION: When electrical checks are

completed, remove the jumper wire and
connect the harness to the clutch pressure switch.
>
TM-1 181 (Sep-77) Litho in USA. Tractors - 4040 and 4240

.
40-30-6 Power Front Wheel Drive Electrical Repair
Switch Adjustment 4. Adjust rod length to this position. Reconnect rod.
If either switch fails the preceding tests, check

Test switch again. If it still fails the test, replace it.
(
switch adjustment as follows.
Replace range switch if a faulty diode is indicated by
the test.
1 Place shift lever in fifth gear.

2. Disconnect rod from switch,
3. Turn switch counterclockwise to stop- Then turn
back three notches.

4 7
6
1
Power Train Repair Specifications and Special Tools 50*00-1
Section 50
POWER TRAIN REPAIR
Page Page
GROUP 00 - SPECIFICATIONS AND SPECIAL GROUP 20 ~ QUAD-RANGE TRANSMISSION
TOOLS (Except Eight-Speed)
Specifications 00-3 Removal 20-1
Special Tools 00-1 Disassembly 20-4
Control and Shift Valve 20-5
GROUP 5 - PERMA-CLUTCH Repair and Assembly
Pressure Regulating Valve Housing 5-1 Clutch and Brake 20-6
Clutch Operating Assembly 5-3 Planetary 20-8
Clutch Pack 5-9 Installation 20-9
Adjustment Range and Speed Selector Assembly
Clutch Valve Operating Rod 5-8 Removal 20-1
Clutch Pack 5-11 Disassembly and Repair 20-1
Repair and Assembly 20-12
GROUP 10 - SYNCRO-RANGE TRANSMISSION Installation and Adjustment 20-13
(also QRT & Creeper Eight-Speed)
Removal GROUP 25 - POWER SHIFT TRANSMISSION
Shifter 10-1 Torsional Damper 25-1
Transmission Drive Shaft 1 0-2 Clutch Pack
Differential Drive Shaft 10-3 Removal and Disassembly 25-2
Countershaft 10-3 Transmission Pump 25-4
Transmission Drive Shaft Assembly and Repair 25-5
Disassembly and Repair 10-4 Planetary Pack
Assembly 1 0-5 Removal and Disassembly 25-9
Countershaft Repair 1 0-7 Repair and Assembly 25-1
Shaft Installation and Adjustment Installation 25-1
Countershaft 1 0-8 Reduction Train, Differential Drive Shaft,
Differential Drive Shaft 10-8 Park Pawl & Tow Disconnect
Transmission Drive Shaft 10-11 Removal 25-1
Shifter Lever (SRT Only) Repair, Assembly and Adjustment 25-20
Removal 10-13 Pressure Regulating and Pedal Valve 25-21
Repair 10-14 Control and Shift Valve 25-24
Adjustment 10-15 Speed Selector 25-26
Adjustments
GROUP 15 - CREEPER TRANSMISSION Oil Pressure Regulating Valve 25-28
(Except Eight-Speed) Pedal Valve 25-28
Planetary Removal and Disassembly 15-1 Pedal Height 25-29
Repair and Assembly 15-2 Speed Selector 25-29
Installation 15-4
Shift Lever GROUP 30 - PTO
Removal 15-5 Perma-Clutch PTO 30-1
Repair 15-6 Lever Adjustment 30-4
Adjustment 15-7 Power Shift PTO 30-5
Lever Adjustment 30-B

2
1
50-00-2 Specifications and Special Tools Power Train Repair
CONTENTS OF THIS SECTIONContinued

Page Page
GROUP 35 - DIFFERENTIAL GROUP 45 - POWER FRONT-WHEEL DRIVE
Removal Removal
Perma-Clutch Differential 35-1 Control Valve 45-1
Power Shift Differential 35-2 Planetary 45-2
Repair 35-3 Wheel Manifold and Motor 45-2
Installation and Adjustment 35-5 Repair
Differential Lock Valve Control Valve 45-3
Removal 35-6 Pivot Pin and Bushing 45-6
Disassembly and Repair 35-7 Motor Housing 45-6
Adjustment 35-8 Installation and Adjustment
Wheel Bearing Adjustment 45-7
GROUP 40 - FINAL DRIVE Brake Piston Housing 45-9
Removal 40-1 Planetary 45-10
Disassembly and Repair 40-1 Oil Manifold Repair 45-1
Assembly 40-2 Wheel Motor
Adjustment 40-4 Disassembly 45-1
Hi-Crop Final Drive (4240 Only) Repair and Assembly 45-1
Removal and Disassembly 40-4 Adjustments 45-1
Repair and Assembly 40-6
Installation 40-9

Power Train Repair Specifications and Special Tools 50-00-3
Group 00
SPECIFICATIONS
PERMA-CLUTCH
SPRING FREE LENGTH WORKING LOAD
Transmission Clutch Valve
u PP er 2.1 in 1.80 in. at 51.3-62.7 lbs.
(53 mm) (45.5 mm at 228-279 N)
Low er 1.1 in 0.6 in. at 14-18 lbs.
(29 mm) (15 mm at 63-77 N)
PTO Clutch Valve
u PP er 2.3 in 1.9 in. at 51-62 lbs.
(58 mm) (48 mm at 224-273 N)
Lower 1-1 in 0.6 in. at 1 1-13 lbs.
(28 mm) (15 mm at 48-60 N)
Clutch Valve Arm Return 7.3 in 8.8 in. at 76.5-93.5 lbs.
(223 mm) (223 mm at 340-416 N)
PT0 4.2 in 4.2 in. at 7.6-9.3 lbs.
(106 mm) (148 mm at 34-42 N)
Pressure Regulating Valve
0uter 2.97 in 1.63 in. at 14.7-17.9 lbs.
(75.4 mm) (41.4 mm at66-79 N)
,nner 5.17 in 3.98 in. at 35-43 lbs.
(131.3 mm) (101.1 mm at 157-192 N)
Cooler Relief Valve 5,9 in 4.54 in. at 36.5-44.5 lbs.
(150 mm) (115.3 mm at 163-198 N)
Lube Reduction Valve 1 .9 in 0.9 in. at 9-1 1 lbs.
(47 mm) (23 mm at 41-51 N)
Transmission Clutch Return 2.6 in 2.3 in. at 170-208 lbs.
(^ mm) (59 mm at 757-925 N)
PTO Clutch Return 1.3 in 0,9 in. at 43-53 lbs.
(33 mm) (22 mm at 192-235 N)
ITEM MEASUREMENT PART DIMENSION

Clutch Separator Plate Thickness 0.395-0.405 in. (10.0-10.3 mm)
PTO Separator Plate Thickness 0.195-0.205 in. (4.9-5.2 mm)
Clutch and PTO Disks Thickness 0.137-0.143 in. (3.4-3.6 mm)
Minimum Thickness 0.110 in. (2.79 mm)
Minimum Facing Groove Depth 0.018 in. (0.46 mm)
Clutch Pedal Height 5-V2 in. (140 mm)
Transmission Clutch Valve O.D 0.7467-0.7473 in.
(18.966 to 18.982 mm)

Valve Bore I.D 0.7495-0.7505 in.
> (19.037 to 19.063 mm)

PERMA-CLUTCHContinued
Clutch Operating Piston Sleeve LD 3.745 in. (95.1 mm)
O.D. 4.035 (102.5 mm)
in.
Clutch Operating Piston f.D 2.709-2.71 1 in. (68.6-68.9 mm)
PTO Operating Piston I.D 3.6650-3.8752 in. (98.17-98.43 mm)
Lube Reduction Valve and Piston O.D 0.685-0.686 in. (17.4-17.5 mm)
Bore in housing 0.687-0.689 in. (17.49-17.50 mm)
CAP SCREW TORQUE SPECIFICATION

Clutch Valve Housing-to-Regulating Valve Housing 20 ft-lbs (27 N-m) (2.7 kgm)
Regulating Valve Housing-to-Clutch Housing 35 ft-lbs (47 N-m) (4.7 kgm)
Ciutch Operating Piston Sleeve-to-Operating Housing 60 in-lbs (6.8 N*m) (0.7 kgm)
Clutch Operating Housing-to-Clutch Housing 35 ft-lbs (47 N-m) (4.7 kgm)
Ciutch Operating Housing-to-Planetary 20 ft-lbs (27 N-m) (2.7 kgm)
Clutch Cover-to-Rywhee! 35 ft-lbs (47 N-m) (4.7 kgm)
Syncro-Range Transmission
tem
*
Measurement Part Dimension
Transmission Drive Shaft O.D. at reverse drive

collar 1 .6243-1 .6249 in. mm)
(41 .257-41 .273
O.D. at rear bearing .... 1.1260-1,1266 in. (28.600-28.616 mm)
O.D. at reverse pinion 1.4895-1.4905
. , in. (37.833-37.859 mm)
O.D. at low range pinion
1.6805-1.6815 in. (42.684-42.710 mm)
O.D. at high-low collar 1.6870-1.6880 in.
. . (42.850-42.876 mm)
O.D. at high range pinion 1.9195-1.9205 in. (48.755-48.781 mm)
O.D. at front bearing 1.6260-1.6270 in. (41.300-41.326 mm)
End play on shaft 0.004-0.006 in. ( 0.102-0.152 mm)
Reverse Pinion LD 1.4945-1.4955 in. (37.96-37.99 mm)
Reverse Drive Collar I.D 1.6225-1.6235 in. (41.21-41.24 mm)
Low Pinion !.D 1.6855-1.6865 in. (42.61-42.84 mm)
High-Low Drive Collar LD 1.6845-1.6865 in. (42.79-42.84 mm)
High Range Pinion I.D 1.9245-1.9255 in. (48.88-48.91 mm)

Synchronizer Disks Thickness 0.070 in. (1 .78 mm)
Minimum Thickness 0.058 in. (1.48 mm)
Minimum Facing
Thickness 0.009 in. (0.23 mm)
Synchronizer Plates Minimum Thickness 0.048 in. (1.22 mm)
Countershaft O.D. at front bearing .... 1.3134-1 .3140 in. (33.36-33.38 mm)
O.D. at rear bearing .... 1.3759-1.3765 in. (34.95-34.96 mm)
O.D. at D-Range gear 3.062-3.063 in. (77.78-77.80 mm)
. .
End play of shaft 0.001-0.004 in. (0.03-0.10 mm)

(
D-Range Gear LD 3.0595*3.0615 in. (77.712-77.762 mm)

Power Train Repair Specifications and Special Tools 50-00*5
Syncro-Range Transm ission Continued

Item Measurement Part Dimension
Differential Drive Shaft O.D, at rear bearing .... 3.3765-3.3775 in. (85.763-85.789 mm)
O.D. for gears 2.6121-2.6131 in. (66.35-66.37 mm}
Preload on Shaft Bearings (also see rolling drag torque) 0.0005-0.0020 in. (0.013-0.056 mm}
A-Range Gear Bushing l.D 2.6171-2.6181 in. (66.47-66.50 mm)
B, C and D-Range Gears
7
l.D 2.6170-2.6186 in. (66.47-66.51 mm)
A-Range Gear l.D 2.770-2.778 in. (70.36-70.56 mm)
Shift Quadrant Shaft O.D 0.873-0.875 in. (22.1 7-22.23 mm)
Shift Lever End Play 0.002-0.020 In. (0.05-0.50 mm)
Shifter Cam Shaft End Play 0.002-0.007 in, (0.05-0.18 mm)
CAP SCREW TORQUE SPECIFICATIONS
Countershaft Front Retainer 35 ft-lbs (47 N*m) (4.7 kgm)

Differential Drive Shaft Front Retainer 35 ft-lbs (47 N-m) (4.7 kgm)
Transmission Drive Shaft Front Bearing Housing 35 ft-lbs (47 N-m) (4.7 kgm)
Transmission Pump Body 20 ft-lbs (27 N-m) (2.7 kgm)
Creeper Planetary
Planet pinion shaft O.D 1.1113 to 1.1117 in.

(28.23 to 28.24 mm)
Transmission input shaft O.D. at clutch shaft 0.9330 to 0.9340 in.
(23.70 to 2372 mm)
O.D. at output sun gear . 1.3245 to 1.3255 in.
(33.64 to 33.67 mm)
Output sun gear bushings l.D 1.3265 to 1 .3295 in.
(33.69 to 33.77 mm)
Clutch shaft bushing l.D 0.9360 to 0.9390 in.
(23.77 to 23.85 mm)
Pressure plate Thickness 0.0504 in. (1,28 mm)
Minimum thickness 0.050 in. (1.27 mm)
Brake disk Thickness 0.098 to 0.1 06 in.
(2.49 to 2.69 mm)
Groove depth 0.030 in. (0.8 mm)
Brake backing plate Thickness 0.178 to 0,198 in.
(4.5 to 5.0 mm)
Brake spring Free length 1 -1 /1 6 in. (27 mm)
Working load 13/16 in. at 10,8-13.2 lbs.
(21 mm at 49-59 N)
>
TM-1181 (Jun~80) Litho in USA. Tractors - 4040 and 4240

,
. .,
QUAD-RANGE Planetary
Shift Valve Detent . 1-7/8 in 0.9 in, at 1 .6-2.0 lbs.
(47 mm) (23 mm at 7-9 N)
Control Valve Detent . . ,. 1.29 in 1-1/16 in. at 15-19 lbs.

(32.8 mm) (27 mm at 69-84 N)
Clutch Spring Washer . ,0.126 in. (free height of one) 0.112 in. at 108-188 lbs.
(3.23 mm) (2,84 mm at 480-836 N)
Brake Return . 0.71 in 0.5 in. at 24-30 lbs.

(18 mm) (13 mm at108-131 N)
Shift and Control Valve . . . . LD. of Bore 0.4995-0.5005 in. (12.69-12.71 mm)
O.D. 0.4977-0.4987 in. (12.64-12.67 mm)
Brake Piston LD 6.498-6.502 in. (165.05-165.15 mm)
O.D. 7.475-7.485 in. (189.87-190.13 mm)
Clutch Piston LD 2.249-2.251 in. (57.124-57.175 mm)
O.D. 4.475-4.485 in. (113.66-113.92 mm)
Brake Disk Thickness 0,087-0.093 in. (2.2-2.4 mm)
Minimum Facing Groove Depth 0.010 in. (0.3 mm)
Minimum Facing Thickness 0.013 in. (0.33 mm)
Clutch Disk Thickness 0.071-0.075 in. (1.8-1.9 mm)

Minimum Facing Thickness 0.012 in. (0.30 mm)
Front Drum Thrust Washer . . Thickness 0.056-0.068 in. (1 .4-1 .7 mm)

Brake Separator Plate . . . Thickness 0.085-0.095 in. (2.2-2,4 mm)
Brake Backing Plate . . . . Thickness 0.245-0.255 in. (6.22-6.48 mm)
Clutch Separator Plate . . Thickness 0.055-0.065 in. (1.4-1.7 mm)
Clutch Drum Bushing . . . Installed LD 2.255-2.258 in. (57.28-57.35 mm)
Planet Carrier Bushings Installed LD 1.384-1 .387 in. (35.15-35.23 mm)
Planet Pinion Shaft O.D 1.1113-1.1117 in. (28.23-28.24 mm)
Planet Pinion LD 1 .5497-1 .5503 in. (39.36-39.38 mm)
Shift Valve Detent Plug 21 ft-lbs (28 N-m) (2.8 kgm)
Brake Oil Tube Clamp 35 ft-lbs (47 N-m) (4.7 kgm)
Planetary Carrier-to-Clutch Drum 20 ft-lbs (27 N-m) (2.7 kgm)
Operating Piston Housing-to-Brake Housing 20 ft-lbs (27 N-m) (2.7 kgm)

Power Train Repair Specifications and Special Tools 50*00-7
Power Shift Transmission
Torsional Damper Pressure Plate 2.1 in 1 .6 in. at 1 98-242 lbs.

(53 mm) (41 mm at 873-1079 N)
Clutch Piston Return Spring Washer (4240) Minimum Free Height

. 0.126 in. (3.2 mm)
Coil Spring (4040) 2.8 in. (71 mm) 1.12 in. at 247-302 lbs.
(28 mm at 1100-1345 N)
B1 , B2, B4 Piston Return 0.83 in 0.625 in. at 23-29 lbs.

(21 mm) (16 mm at 102-130 N)
B3 Piston Return 1 .22 in 1 in. at 22-28 lbs.

(31 mm) (25 mm at 100-123 N)
Clutch Valve Springs

Upper 0.5 in 0.34 in, at 3.3-4.1 lbs.
(13 mm) (8.7 mm at 15-19 N)
Inner 2 in 1.4 in. at 11.7-14.3 lbs.
(51 mm) (36 mm at 52-64 N)
Lower 1.3 in 1 in. at 15-18 lbs.
(33 mm) (28 mm at 68-81 N)
PTO 1.8 in 1.4 in. at 16.6-20.4 lbs
(45 mm) (35 mm at 74-91 N)
Oil Pressure Regulating Valve Housing Springs

Oil Cooler Relief Valve 4.6 in 3.5 in. 35-44 lbs.
at
(116 mm) (90 mm 159-194 N)
at
Check Valve . .2.3 in 0.75 in. at 11-13 lbs
(59 mm) (19 mm at 48-59 N)
Pressure Regulating Valve 5 in 4.44 in. at 58-72 lbs.
(129 mm) (113 mm at 260-319 N)
Transmission Lube Oil Valve 2.8 in 2.13 in. at 11.7-14,3 lbs
(72 mm) (54 mm 52-64 N)
at
Filter Bypass Valve 3.7 in 2.6 in. at 24-30 lbs.
(94 mm) (66 mm at 108-132 N)
Transmission Control and Shift Valve Housing Springs

Dump Valve 1.12 in 0.84 in. at 31.5-38.5 lbs.
(29 mm) (21 mm at 144-174 N)
Shift Valve 1 .4 in 0.81 in. at 6.8-8.4 lbs
(35 mm) (20.5 mm
30-37 N) at
Accumulator (outer) 4.1 in 2.9 in. 185-225 lbs.
at
(104 mm) (74 mm at 822-1000 N)
Accumulator (inner) 3.8 in 2.9 in. at 100-122 lbs.
(96 mm) (74 mm at 445-543 N)
Speed Detent 1.16 in 0.8 in. at 6-7 lbs.
(30 mm) (21 mm 27-32 N)

at
Reverse Detent 1.12 in 0.8 in. at 14-18 lbs.
(29 mm) (20 mm at 65-79 N)
TM-1181 (Jun-SO) Litho in U.S.A. Tractors - 4040 and 4240

Power Shift Transmission Continued

Flywheel Maximum friction drive 0.006 in. (0.1 5 mm)
surface warpage
Maximum stock removal 0.060 in. (1.5 mm)
Maximum depth to drive surface . . 2,158 in. (54.8 mm)
Pressure Plate Maximum warpage 0.006 in, (0.15 mm)
C1, C2, C3, and PTO Pistons

4040 and 4240 (C3) LD 3.125-3.126 in. (79.37-79.40 mm)
O.D 6.600-6.610 in. (167.64-167.89 mm)
4240 (except C3) LD 3.974-3.978 in. (100.95-101 .05 mm)
O.D 7.377-7.387 in. (187.49-187.51 mm)
Brake Pistons (4040)

B1, B2, B4 I.D 9.258-9.262 in. (235.15-235.25 mm)
O.D 11.596-1 1.604 in. (294.54-294.65 mm)
B3 I.D 8.856-8.860 in. (224.95-225.05 mm)
O.D 11 .596-1 1 .604 in.(294.54-294.65 mm)
Brake Pistons (4240)

B1, B3 I.D 8.856-8.860 in. (224.95-225.05 mm)
O.D 11.596-11.604 in. (294.54-294.65 mm)
B2, B4 LD 9.258-9.262 in. (235.15-235.25 mm)
O.D 11 .596-1 1 .604 in. (294.54-294.65 mm)
Clutch Disks (4040)
C1, C2, PTO, C3 Thickness 0.1 12-0.1 18 in, (2.84-3.00 mm)
Groove depth 0.01-0.02 in. (0.254-0.508 mm)
Clutch Disks (4240)
C1, C2, PTO Thickness 0.127-0.133 in. (3.22-3.38 mm)
C3 Thickness 0.1 12-1.1 18 in. (2.84-3.00 mm)
Minimum facing thickness 0,02 in. (0.508 mm)
Brake Disks Thickness 0.117-0.123 in. (2.97-3.13 mm)
Minimum facing groove depth 0.02 in. (0.5 mm)
Clutch and Brake Plates
(except 4040 PTO) ,. . Thickness 0.118-1.122 in. (3.0-3.1 mm)
4040 PTO Plate Thickness 0.085-0.095 in. (2.16-2.41 mm)
Clutch Drums LD. for piston bores (4040) 6.6245-6.6255 in. (168.26-168.29 mm)
O.D. for piston bores (4040) 3.121-3.123 in. (79.27-79.32 mm)
LD. for piston bores (4240) 7.400-7.404 in. (187.96-188.06 mm)
O.D. for piston bores (4240) 3.965-3.967 in. (100.7-100.8 mm)
C3 Front Bushing I.D 1.8565-1.8585 in. (47.155-47.206 mm)

C3 Rear Bushing I.D 1.909-1.91 1 in. (48.489-48.539 mm)
C1 Clutch Shaft O.D. for reduction shaft bushing . 0.735-0.737 in. (18.67-18.72 mm)
C2 Clutch Shaft I.D. of installed bushing (4040). . . 1.1265-1.1295 in. (28.61-28.69 mm)
(4240). . . 1.3265-1.3295 in. (33.693-33.769 mm)

Power Train Repair Specifications and Special Tools 50-0Q-9
Power Shift Transmission Continued

Reduction Gear Shaft LD. of installed bushing 0.752-0.754 in. (19.10-19.15 mm)
O.D. at rear bearing 1,7510-1.7516 in. (44.47-44,49 mm)
O.D. at reduction gear 2.4357-2.4363 in. (61.87-61.88)
LD. of reduction gear 2.4395-2.4405 in. (61.96-61.99 mm)
Bearing Preload 0.001-0.002 in. (0.02-0.05 mm)
Differentia! Drive Shaft (also see roiling drag torque) 0.0005 in. (0.013 mm) end play to 0.0015 in.
(0.038 mm) preload
Clutch Pedal Height 5-1/4 to 5-3/4 in. (133-146 mm)

Clutch Drive Shaft O.D. at pilot bearing 0.6684-0.6690 in. (16.98-16.99 mm)
O.D. at rear bearing (4040) 1.3778-1.3784 in. (34.99-35.01 mm)
(4240) 1.5747-1 .5753 in. (40.00-40.01 mm)
LD. of bushing bore (4040) 0.9370-0.9380 in. (23.79-23.83 mm)
(4240) 1.1435-1.1445 in. (29.05-29.07 mm)
LD. of installed bushing (4040). 0.8765-0.8795
. . in. (22.26-22.34 mm)
(4240)... 1.0025-1.0045 in. (25.46-25.51 mm)
Planet Pinion Bearing Roller O.D 0.1559-0.1560 in. (3.959-3.962 mm)

Length (front) 0.98-1.00 in (24.9-25.4 mm)
Length (rear) 1.17-1.19 in. (29.7-30.2 mm)
Pinion Shaft Thrust Washer Thickness 0.033-0.039 in. (0.8-1.0 mm)
Planet Pinion Shafts O.D 0.8336-0.8340 in. (21.173-21.184 mm)
Planet Pinion LD , 1 .0220-1 .0230 in. (25.95-25.98 mm)
Front Carrier Bushing LD. (4040) 2.130-2.132 in. (54.10-54.15 mm)
LD. (4240) 2.366-2.368 in. (60.09-60,1 5 mm)
B3 Housing Bushing LD 3.7550-3.7575 in. (95.38-95.44 mm)
Shift Lever Assembly End Play .<
0.005-0.024 in, (0,13-0.61 mm)
Pressure Regulating Valve Shim . . Thickness 0.030 in. (0.76 mm)

Torsional Damper Cover-to-Flywheel 35 ft-lbs (47 N-m) (4.7 kgm)
Pump Manifold-to-Clutch Housing 50 ft-ibs (68 N-m) (6.8 kgm)
Backing Plate-to-Cl Drum 20 ft-lbs (27 N-m) (2.7 kgm)
Pump ManifoId-to-Pump Body 20 ft-lbs (27 N-m) (2.7 kgm)
Pump Body-to-Housing 20 ft-lbs (27 N-m) (2.7 kgm)
Differential Drive Shaft Nut 400 ft-lbs (542 N-m) (54.2 kgm)
Planet Carrier Shaft Retainers 35 ft-lbs (47 N-m) (4.7 kgm)
C3 Piston Houstng-to-Drum 20 ft-lbs (27 N-m) (2.7 kgm)
Planetary Pack 35 ft-lbs (47 N-m) (4.7 kgm)
Planetary Pack Hold-Down 35 ft-lbs (47 N-m) (4.7 kgm)
Pedal Valve Housing-to-Clutch Housing 45 ft-lbs (61 N-m) (6.1 kgm)
Pressure Regulating Housing-to-Clutch Housing 45 ft-lbs (61 N-m) (6.1 kgm)
Accumulator Cover-to-Control Valve Housing 35 ft-ibs (47 N*m) (4.7 kgm)
ShiftValve Housing-to-Control Valve Housing 20 ft-lbs (27 N-m) (2.7 kgm)
Reduction Gear Shaft Bearing Retainer 55 ft-lbs (75 N-m) (7.5 kgm)

PTO (PERMA-CLUTCH)
ITEM MEASUREMENT PART DIMENSION i
PTO Shaft O.D. at rear bearing 2.3622-2.3628 in. (59.99-60.02 mm)

O.D. at center bushing 1 ,751 -1 .754 (44.48-44.55 mm)
in.
Drive and Gear Shaft I.D. of installed bushing 1.705-1,708 in. (43.31-43.38 mm)
PTO Brake Piston O.D 1 .9875-1 .9925 in. (50.48-50.61 mm)
PTO (Power Shift)
PTO Shaft O.D. at rear bearing 2.3622-2.3628 in. (60.00-60.02 mm)

O.D. at front bearing 1.737-1 .743 (39.972-39.988 mm)
in.
O.D. at bushing 1 .746-1 .747 in. (44.47-44.56 mm)
l.D. of bushing 1.7510-1.7545 in. (44.475-44.564 mm)
PTO Clutch Gear. . O.D. at front bushing 2.2470-2.2480 in. (57.07-57.10 mm)
O.D. at rear bushing 2.3614-2.3620 in. (59.98-59,99 mm)
O.D. at rear bearing 2.3610-2.3616 in. (59.97-59.99 mm)
Rear Bearing Quill-to-Case 85 ft-lbs (1 15 N^m) (11 ,5 kgm)

Master Shield-to-Drawbar Support 35 ft-lbs (47 N-rn) (4.7 Kgm)
Power Shift Only

PTO Drive Gear Retaining 120 ft-lbs (163 N-m) (16.3 kgm)
Oil Baffle-to-Case 20 ft-lbs (27 N*m) (2,7 kgm)
PERMA-CLUTCH and Power Shift
Countershaft gear I.D 1.8972-1.8982 in. (48.19-48.21 mm)
Countershaft bearing rolier O.D 0.2186-0.2188 in. (5.55-5.56 mm)
Countershaft bearing spacer . . . Thickness 0.686-0.688 in. (17.42 to 17.48 mm)
Countershaft thrust washer Thickness 0.033-0.039 in, (0.8-1 .0 mm)
540 rpm Stub Shaft O.D. at bearing 1.1813-1.1819 in. (30.00-30.02 mm)
Stub shafts (both) O.D. at O-ring seal 1.9997-2.0003 in. (50.79-50.81 mm)
PTO pilot O.D. at oil seal 2.874-2.876 in. (73.00-73.05 mm)
Countershaft gear shaft O.D 1 .4580-1 .4586 in. (37.03-37.05 mm)
Countershaft bearing roller Length 1 .5 in. (38 mm)
<

Differential
Lock Piston Return 0.81 in 0,54 in. at 45-55 IbS-

(21 mm) (13.7 mm at200-245 N)
Pressure Control Valve 2.56 in 1.31 -In. at 9.5-11.5 lbs.
(65 mm) (33.3 mm42-52 N) at

Plunger 2.28 in 1.92 in, at 103-125 lbs.
(58 mm) (48.8 mm at 458-556 N)
Bevel Pinion* I.D 1,2335-1.2365 in. (31.33-31.41 mm)

Bevel Gear Hub inner O.D 2.9812-2.9828 in. (75.72-75.76 mm)
Bevel Pinion Shaft* O.D 1.2295-1.231 1 in. (31.23-31,27 mm)
Bevel Pinion** I.D 1.5655-1.5665 in. (39.76-39.79 mm)
Bevel Pinion Shaft** O.D 1.1897-1.1903 in. (30.22-30.23 mm)
Differential Housing I.D. for pinion shaft* 1.233-1.235 mm)

in, (31.31-31.73
I.D. for pinion shaft** 1.192-1.194 mm)
in. (30.28*30.33
I.D. of piston bore 9.013-9.017 in, (228.93-229.03 mm)
I.D. for bevel gear hub 3.0025-3.0045 in. (76.26-76.31 mm)
Piston O.D 8.999-9.005 in. (228.57-228.73 mm)

I.D 7.073-7.076 in. (1 79.65-1 79.73 mm)
Differential Cover Spring pin protrusion Flush with stepped side of cover
Lock Drive Disk Thickness 0.120-0.130 in. (3.15-3.31 mm)

Minimum facing thickness 0,33 in. (0,013 mm)
Separator Plate Thickness 0.1 1 5-0.125 in. (2.9-3.2 mm)
Lock Pedal Adjusting Screw-to-Release Bar Clearance 0.01-0.03 in. (0.3*0.8 mm)
Pressure Control Valve O.D 0.4978-0.4984 in. (12.64-12.66 mm)

Pfunger O.D 0.555-0.559 in. (14.1-14.2 mm)
Differential Quill Bearings Preload 0.002-0.005 in. (0.05-0.13 mm)

Ring Gear and Pinion Backlash 0.0075-0.0155 in. (0.18-0.39 mm)
Differential Bearing Quill-to-Case 85 ft-lbs (115 N-m) kgm) (1 1 .5

Differential Housing-to-Ring Gear 85 ft-lbs (115 N-m) kgm) (1 1 .5
Differential Housing-to-Bevel Pinion Shaft 85 ft-lbs (115 N-m) (1 1 -5 kgm)

Differential Housing Cover-to-Housing (with lock) 55 ft-lbs (75 N-m) (7.5 kgm)
(less Jock) 85 ft-lbs (115 N-m) (11.5 kgm)
*4Q40 Tractors (Serial No. -6406)

4240 Tractors (Serial No. -15150)
**4040 Tractors (Serial No. 6407- )
4240 Tractors (Serial No, 15151- )

I

.
Final Drive
ITEM MEASUREMENT PART SPECIFICATION
Planet Pinion Shaft O.D 2.0838-2.0845 in. (52.93-52.94 mm)
Planet Pinion I.D 2.5226-2.5240 in. (64.07-64.1 1 mm)
Roller Bearing O.D. 0.2186-0.2188 in. (5.552-5.558 mm)
Seal Spacer I.D 3.3720-3.3759 in. (85.65-85.75 mm)

O.D 4.0602-4.0642 in. (103.13-103.23 mm)
Roller Bearings (outer) I.D 3.3750 in. (85.728 mm)

(inner) I.D 3.2813 in. (83.345 mm}
Axle Shaft O.D. (at outer bearing) 3.3787-3.3797 in. (85.819-85.844 mm)
O.D. (at inner bearing) 3.2828-3.2838 in. (83.383-83.409 mm)
Planet Carrier-to-AxJe 170 ft-tbs (230 N-m} (23 kgm)
Axle Housing-to-Transmission Case 170 ft-lbs (230 N-m) (23 kgm)
Hi-Crop Final Drive
ITEM MEASUREMENT PART SPECIFICATION
Drive Shaft Outer

Pinion Bearing End Play 0.000-0.004 in. (0.00-0.10 mm)
Drive Shaft Inner Pinion

and Output Gear End Play 0.000-0.004 in. (0.00-0.10 mm)
Cap Screw
Axie Nut Initial 200 ft-lbs (271 N-m) (27.1 kgm)
Final (Cooled) 50-ft-lbs (68 N-m) (6.8 kgm)
Drive Shaft Housing-

to-Drive Gear Housing (Stud Nuts) 445 ft-lbs (603 N-m) (60.3 kgm)
Drive Shaft Housing Quill-
to-Drive Shaft Housing 55 ft-lbs (75 N-m) (7.45 kgm)
Drive Shaft Housing-to-
Transmission Case 170 ft-fbs (230 N*m) (23 kgm)

Power Front-Wheel Drive
Solenoid Valve 0.65 in 0.5 in. at 4.8-5.4 lbs.

(16.6 mm) (13 mm at 22-25 N)
Pressure-Control Valve 6,49 in 4.85 in. at 73-90 lbs.
(164.8 mm) (123 mm 325-400 N)
at
Direction Valve 1.68 in 1.4 in.15-19 lbs.
at
(42.7 mm) (35 mm at 67-84 N)
Torque Valve 3.06 in 2.25 in. at 1 1-15 lbs.
(77.7 mm) (57 mm at 48-67 N)
Relief Valve 1.31 in 1.1 in. at 130-150 ibs.
(33.3 mm) (28 mm at 577-668 N)
Manifold Relief Valve 2.37 in 1.13 in. at 20-25 Ibs.
(60.2 mm) (29 mm at 90-110 N)
Check Valve 1 .25 in 0.9 in. at 0.3-0.5 Ibs.
(32 mm) (22 mm at 1.3-2.2 N)
Motor Cylinder 1 .9 in 1 34-40 ibs.
.7 in. at
(47 mm) (42 mm 151-200 N)

at
Planet Brake Return 1 .7 in. at 70-86 Ibs.
(43 mm at 312-383 N)
Neutral Bleed Valve 0.5 in 0.375 in. at 6.25-8.25 ibs.
(13 mm) (9.53 mm at 28-37 N)
Planet Piston Housing Bore ID 1,2510-1.2520 in. (31.78-31.80 mm)
First Planet Pinion LD 1.4106-1.4112 in. (35.83-35.84 mm)

Length 0.748-0.752 in. (19.0-19.1 mm)
Shaft O.D 0.9722-0.9726 in. (24.69-24.70 mm)
Bearing Roller O.D 0.2186-0.2188 in. (5.55-5.56 mm)
Second Planet Pinion I.D 2.0077-2.0085 in. (51.00-51,02 mm)

Length 1.123-1.127 in. (28.52-28.63 mm)
Shaft O.D 1.5068-1.5072 in. (38.27-38.28 mm)
Bearing Roller O.D 0.2498-0.2500 in. (6.34-6.35 mm)
Wheel Hub Bearing Setting 0.004 in. preload to 0.004 in.end play
(0.1 mm preload to 0.1 mm end piay)
Wheel Motor Shaft End Play 0,003-0.006 in. (0.076-0.1 52 mm)
Motor Housing Swash Plate Retaining Dowel Height 0,170 in. (4.3 mm)
Planet Piston Housing-to-Motor Housing 45 ft-lbs (61 N-m) (6.1 kgm)

Brake Backing Piate-to-Planet Piston Housing 35 ft-lbs (47 N*m) (4.7 kgm)
Second Planet Pinion Retainer-to- Planetary Housing 35 ft-lbs. (47 N*m) (4.7 kgm)
Oil Manifofd-to-Motor Housing 35 ft-lbs (47 N-m) (4.7 kgm)
Front Axle-to-Knee 350 ftylbs (475 N-m) (47.5 kgm)
Pivot Pin Cap 35 ft-lbs (47 N-m) (4.7 kgm)
Tie Rod-to-Steering Arm 100 ft-lbs (136 N-m) (13.6 kgm)

:
SPECIAL TOOLS*
tool NUMBER USE
PERMA-CLUTCH AO-01045AA To install bushings, bearings

and seals.
A^JDE-78-1 Clutch Gauge

B-^JDE-78-4 Gauge Ring
R28GS7X C-^JDE-76-3 Gauge Ring
Fig. 1 -Bushing, Bearing, and Seat Driver Set D->JDE-7S-12 Gauge Ring
E^JDE-78-5 Bar Leg
FJDE-78-2 Gauge Bar To adjust PERMA-CLUTCH
operating lever height
* Order from
Service Tools
Box 314, Owatonna MN 55060
r z%m D0502SST To heat bearings and other

press-fitted parts for installa-
Fig. 2-Ctutch Adjusting Tool
tion.
See Fig, 15 (Bearing Heater)

Power Train Repair Specifications and Special Toots 50-00-15
TOOL NUMBER USE
Syncro -Range Transmission A-^JDT-4A Holds shffi blocker springs and balls
compressed during assembly.
Fig. 3Shift Blocker Loading Sleeve
A-^JDT-3 Snap ring retainer plate to hold dif-

ferential drive shaftsnap rings ex-
panded during assembly.
B-^JDT-2 Snap ring expanding cone to insert
retainer plate.
COTC-614 Snap ringexpander to remove and
(JDT-1) install snap rings*
M^W'%
Fig. 4-Snap Ring Expanding Tools
A-^JDT-20-1 Arbor used to install differential drive

shaft parts*
B-^JDT-8-1 Casting used to support arbor.
AD-01045AA To install bushings, bearings and

(See Fig. 1) seals.
Other Tools and Materials Required: (Not Illustrated)
JDT-42 Spring Scale (or equivalent)

To measure differential drive shaft rolling drag torque.
CClamp To hold front differential drive shaft

gear forward in case when removing
shaft.
Fig. 5-Dtfferentiai Drive Shaft installation Tool Set Dial Indicator To measure end play on transmission
shaft
Perma-tex No. 1 To seal OJ>. of shifter cam shaft oil
> seals in outer support.
TM-1181 (Jul-78) Litho in US. A Tractors - 4040 and 4240

50-00-16 Specifications and Special Tools Power Train
TOOL NUMBER USE
Quad-Range Planetary AD-01O45AA To install bushings, bearings and

(
(See Fig. 1)
BConstruct To remove transmission input shaft
as follows:
1/2 IN*
(12 mm) 1.Either, braze a 1/2 in. (13 mm) O.D. (maximum)
DIA. flatwasher on the end of a rod small enough in
diameter to be inserted through the transmission input
shaft;
2. Or, flatten one end of the rod and bend over to

form a hook.
R 28153N
Fig. 6-Shaft Removal Toot
AJDT-24 To compress clutch piston return

spring during removal and installation
of dutch piston.
Fig. 7-Sprmg Washer Compressor
A-^JDT-21-1 To protect clutch and brake piston

B-^JDT-21-2 packings when installing pistons in
housing and drum.
Fig. S-Piston Installing Set
TM-1181 (Jul-78) Litho in U.SA. Tractors - 4040 and 4240

TOOL NUMBER USE
Power Shift Transmission AJDE-52A Shaft and 5/8 in. (16 mm) pilot bearing
adapter plug to align damper with bear-
ing.
BJDE-52-3 Adapter to align torsional damper disk.
3 290I0N
Fig. 9-Torsional Damper Aligning Tool
AJDT-18 To protect transmission oil pump oil seal

when assembling pump and shaft.
R 28162N
Fig. 10-Oif Seal Protector
AJDG-19 Used with slings or chain and overhead

hoist when removing differential and
planetary brake pack.
h-0 AJDT-24
(See Fig. 7)
To compress clutch piston return spring
washers during removal and installation
of clutch pistons.
R 28161N
Fig. 1 1 -Special Mounting Bracket

A D-01061AA To remove reduction gear shaft. Use 1/2
in. (12 mm) collet (No. 33859).
A D-01045AA To install bushings, bearings and seals.

(See Fig. 1)
Other Tools and Materials Required: (Not Illustrated)
JDT-42 Spring Scale (or equivalent)

To measure differential drive shaft rolling drag torque.
Guide Screws To align planetary brake pack parts dur-

ing assembly. Screws must be 3/8in. and
should be 10 in. (254 mm) long.
Rocker-Type Dial To check end play on reduction gear
Indicator Starrett shaft.
i/i/imrfiif R 23 2 64 H
No. 711 HS or
equivalent
Fig. 12-Btind-Hoie Putter Set

JDT-44 2-1/2 in. socket (or equivalent). To re-
move and install differential drive shaft
lock nut.
)

TOOL NUMBER USE
PTO A D-01045AA To install bushings, bearings

and seals.
(See Fig. 1)
AJDG-19 Used with slings or chain and
overhead hoist when removing
Differential differential.
(See Fig. 11) D-17508C1 Dial Indicator Used to measure differential

end play and bearing quill end
play.
Other Tools and Materials Required (Not Illustrated)
A D-01045AA To install bushings, bearings

Final Drive (also JDT-32) and seals.
(See Fig. 1) AJDT-29* To tighten final drive gear

housing-to-axle slotted nut on
Hi-Crop Tractors.
* When using the JDT-29 Wrench, the torque setting

must be adjusted. Use the formula in Fig, 14 to deter-
mine the proper torque reading. The following chart
identifies symbols.
Ta = Torque actually being applied to the nut.

Tw = Torque read on the torque wrench.
A = Application distance from center of torque
wrench to center of wrench opening which
is 3.5 in. (8.9 mm).
R 29 Oil = Length from
L the point of force (center of the
Fig. 13-Lock Nut Wrench

handle) to the center of head of torque
wrench.
L+A = Total effective length of assembly through
which force is applied.
Multiply the length of the torque (L) wrench by the

specified torque (Ta). Divide that number (Ta x L) by
the length of the torque wrench (L) plus 3.5 in. (8.9
mm).
Be sure the torque wrench is kept parallel with the

lock nut wrench as shown in Fig. 14.
R 25076K
Fig. 14-Determining Torque Reading
(See Section 10, Group 20) D05007ST Stand with To remove final drive housing
D05149ST Attachments without removing SOUND-
GARD body.

TOOL NUMBER USE
Final Drive Continued D-05029ST To heat bearings and other press-f rt-
ted parts for installation.
Fig. 15-Bearing Heater/Oven
312 IN. DRILL .938 IN. DRILL-

3/8-16 UNC (2) (2)
1.24 IN. M1N.

(3K 5 mm}
1.50 IN,
(38.1 mm)
l.M IN.
(35. 8 mm)
R 31320
Fig. 16-Hi-Crop Final Drive Bearing Adjustment Tool
To adjust outer drive shaft gear bearings, construct in ma-

chine shop from 1.38 x 3.00 x 12.45 in. CR steel (35 x 76 x 316
mm).

Final Drive Continued

TOOL NUMBER USE
A D-01267AA To remove axle outer bearing (with wheel

Bearing Puller on axle).
B D-01248AA Legs
C D-01 311 AA Push
Puller
D No. 27515 Disk
Fig. 17-Axie Bearing Removal Toots
Power Front-Wheel Drive JDT-34 To install motor housing inner oil seal.
Other Tools and Materials Required: (Not Illustrated}
R28781 Adjusting Screw Bushing

AR52254 Adjusting Screw
Dial Indicator To adjust motor shaft end play
3 lb. (1.36 kg) weight

6 in. (150 mm) by 1/2 in. (12 mm) strap iron (2 needed)
1/2 washers
in. fiat (4 needed)
Straight Edge
Feeler Gauge
Rl?$$88
Fig. 18-Seai installer

Used to hold differential drive shaft in place while installing
front bearing cone.
Construct as follows:
1. Drill a 17/32 in. diameter hole through the center of a 1 in.
diameter steel shaft and tap the shaft with 5/8 in. threads.
2. Grind a taper on one end of the Ready Rod screw.
3. Assemble the parts and lock two 5/8 in. nuts together on
the screw.
R 31637
Fig. 19-Differential Drive Shaft Holding Tool

I 3A in,
R31802
Fig. 20-Axle Jacking Tool

Materia!: 2x4x3/ 16-in. tubing with two 9/16x14-in. studs


.
Power Train Repair Perma Clutch 50-05*1
Group 05
PERMA-CLUTCH
CLUTCH OIL PRESSURE
REGULATING VALVE
Housing Removal
AClutch Operating D PTO Brake

Assembly E Lube
B2-Speed Planetary FClutch
CPTO Drive Gear G PTO Clutch
APTO Operating Rod DTo Main Pump Fig. 2-Operating Adapters (Quad-Range Tractor Shown)
B Clutch Operating Rod E Steering Pump
C Regulating Valve Housing Return Hose 3. adapters from the operating assem-
Pull the four
F Retainer bly. Also planetary adapter (B, Fig. 2), if
pull the long
Fig. 1 'Pressure Regulating Valve Removal equipped with Quad-Range Transmission.

(Battery Box Removed)
1 Remove oil lines and operating rods (Fig, 1 ) from

regulating valve housing.
2. Remove cap screws and pull housing out of the

clutch operating assembly.

: J :
50-05-2 Perma-Clutch Power Train Repair
OIL PRESSURE REGULATING VALVE 3. inspect valve springs (Fig. 3):

Continued
Free Length (Key, Fig. 3) Working Load
Clutch Valve Repair
PTO Clutch Valve (four lands)
1. Remove clutch valve shield and separate clutch
valve housing from regulating valve housing. (Remove (Key)
spring pins and eight screws.) Upper 2.28 In. (58 mm) F 1.89 in. at 51-62 lbs.
(48 mm at 224-273 N)
Lower 1.10 In. (28 mm) H 0.60 in. at 11-13 lbs.
During disassembly, inspect valves and parts for
2.
(15 mm at 48-60 N)
burrs or unusual wear.
Transmission Clutch Valve
(Key)
Upper 2.10 in. (53 mm) N 205 in. at 8,6-10.6 lbs.
..? ^ _. v ^ -rgf Lower 1.13 in. (29 mm) M

(52
0.61
mm
in.
at
at
37-46 N)
14-18 lbs.
(15 mm at 64-78 N)
4. Install PTO lock piston (L).
i;i$*:rj&* 5. Install PTO clutch valve (four lands) (I).

s|tii::miv
M
iff^
m r! .. shortest spring (H), then spacer pin (G),

*
BfafifSpiL*;:;.'.-.1 . ,..: ;i:

:
; 6. Install
r -'
lj;
.
! : : :: : "H^t ;iirH5ir;; :H; J :
Ljî : 5
PTO
r
f||||iz|3| '
longest spring (F), and thrust washer (E) in clutch

It
â^r
valve.
"Uw*-;. :::.:
jitogH;;;* **!;. 7. Retain the assembly with pin through link slot and
*.
hole valve. (Use link (not keyed)
;T^!f"iii!'-"
:
!-?L*;:'-
:|-
v .
* ''^fevfe.^:--
8.
in
Install clutch
,
valve (K) second shortest spring

without notch.)
|ii^liii:::
^\^m:s=
:
(:.:!!:. (red),spacer pin, second longest spring, and thrust

washer.

-
: 1 1 ,i

;

-i ::;:;Hi?;::K=^:^"'':';:": ":'^:i
:
1
Jl i^SP^
''
:
:
"1;'^Jhl 9. Install pin so faces the pressure regulating

.:;;:;::;
v Ht:J:: ?H;; i iHiiS: ^ ':'.
-
: I :Hi|HsIISt: 1 ::SH::::iHT?:*. -::::::;::'
valve housing to allow

ft
full valve bore travel.
10. Assemble valve operating shafts with arms (C

m- ;

': ':iHHlhii|^jg and D) to links and place shaft ends in clutch bores.
!Bshf$2:;
11. Install clutch valve housing gasket over dowef
and assemble clutch valve housing to regulating valve
housing.
12. Assemble outer arms, valve shield T and torque

retaining screws to 20 ft-ibs (27 Nm) (2.7 kgm).
AClutch Valve Outer Arm I PTO Valve

BValve Link (Notched) J Clutch Valve Housing
C Clutch Valve Inner Arm KClutch Valve
DPTO Valve Operating Arm LPTO Lock Piston
EThrust Washers MClutch Valve Spring
F Upper PTO Valve Spring (Lower)
G Spacer Pins N Clutch Valve Spring
H PTO Valve Spring (Lower) (Upper)
(
Fig, and PTO Valve
3-Ctuteh
(with Quad-Range Planetary Adapter)
TM-1181 (Sep-77) Litho in U.S.A, Tractors - 4040 and 4240

. .
Power Train Repair Perma-CIutch 50-05*3
Pressure Regulating Valve Repair 3. Inspect valve springs:
1. If arm shaft oil seals are replaced, install flush

i Free Length Working Load
using a 1-7/16 in. driver (36,5 mm) and a 3/4 in. pilot
disk (19 mm) (OTC No. 27506 and 27495), Pressure Regulating Valve
Outer
Z97 in. (75.4 mm) 1.63 in. at 14.7-17.9 lbs.
1|P (41 .4 mm at 66-79 N)
'II -: :::;
Iffl ':
:'
: ;pH| Hip n ml itill

PI .,,.,....,.,, ,, .
Inner (red)
5.17 in. (131.3 mm) 3.98 in. at35-43 lbs.
(101.1 mm at 157-192 N)
Cooler Relief Valve (red)
5.9 in. 4.54 in. at 36.5-44.5 lbs.

(150 mm) (115.3 mm at 163-198 N)
4. Install inner spring (C) (second longest), outer

spring (D) (shortest), and shims (E) with plug and
washer.
5. Install cooler relief valve (G), long spring (red),

and plug with washer.
Clutch Operating Assembly Removal
d> m
I:r
kfc*j -i
f3& ' " ''"/-'

::;- .:..,::-;siC"3&:
:::"'; -v :: .. .
.:\
ft 26353k ""
v:-,;
:
"
-
""
: ''':;"'
];"',;/ ."' !."."- ,*
:
:
;:
'^ "".'
A Pressure Regulating DOuter Regulating Valve

Valve Housing Spring
B Pressure Regulating E Shims (use as required)
Valve FCooler Relief Valve SB: ??"!fS~; :rr :-.5rrrât: :ri.E:a:5r
C Inner Regulating Valve Spring

Spring GOil Cooler Relief Valve
1 Before separating the tractor, remove plug at the
Fig. 4-Pressure Regulating Valve Assembly rear of the transmissioncase to pull the hex. drive shaft
which extends from the crankshaft through the trans-
2. Check condition of pressure regulating valve (B, mission. (This prevents shaft damage during disas-
Fig. 4) and install in housing bore (small O.D. first). sembly and assembly.)
2. Separate the engine from the clutch housing.

(See Section 10, Group 20 for instructions.)
>
3. Remove pressure regulating valve housing as
instructed earlier in this Group.
TM-1181 (Feb-78) Litho in US.A. Tractors - 4040 and 4240

.
Operating Assembly RemovalContinued Clutch Operating Assembly Disassembly
^\^^rmvû^
AHousing Cap Screws CPlanetary Cap Screws Fig. 7-Rear of Clutch Operating Assembly
BOperating Housing D Transmission Clutch
Shaft 1 Remove snap ring from PTO shaft and gear, then
pull shaft and gear from housing.
Fig, 6-Outch Housing Front View 2. Remove PTO brake piston.
3. Remove retaining rings from bearing retainer
4. Remove cap screws (A,
the six outer Fig. 6) that pins to remove springs and retainer.
hold the operating assembly (B) in place. 4. Remove five small cap screws from rear of
housing that secure piston sleeve.
5. Remove five inner cap screws (C) that retain
two-speed power shift (if equipped with
planetary unit
Quad-Range Transmission),
6. Remove three inner cap screws that retain shifter

assembly if equipped with Creeper Transmission,
7. Remove the clutch operating assembly.
8. Remove transmission clutch shaft (D) from the

rear of the operating assembly (except on Creeper).
AOuter Race F Outer Race

BOperating Piston Housing G Sleeve
C PTO Gear Shaft HLube Reduction
D Bearing Retainer Valve Plug
EClutch Operating Piston I Adapter Holes
J PTO Bearing Retainer (
Fig, 8-Top Front of Clutch Operating Assembly

.
Power Train Repair Perma-CIutch 50-05-5
5. Remove clutch operating piston (E, Fig. 8) from Clutch Operating AssemblyAssembly
housing. and Repair
6. Remove PTO dutch operating piston with bear-
ing assembly (F).
7. Pry bearing retainer tangs (D) up to remove

retainer, bearings, and races from transmission
operating piston.
Lubrication Reduction Valve
t\ 03^JC^
A Sleeve BPacking
Fig. 10-instaHing Piston Sleeve
1. Install clutch operating piston sleeve (A, Fig, 10)
inhousing and torque cap screws to 60 in-lbs (6.8 Nm)

(0.6 kgm). Sleeve diameters are 3.745 in. (95.1 mm)
R ZS552N r
r.
.... , ,;,,.^
and 4.0350 in. (102.49 mm).
Fig. 9-Lube Reduction Valve and Operating Housing
NOTE: When removing lube reduction vafve, piston

isretained by a stop pin. Drive stop pin from front of
housing, Pin will fall through bore on rear side of
housing (See Fig. 9).
1 Install lube reduction valve piston in housing. Be

sure piston isfree in bore and that smaller O.D. faces
out.
2. Install valve piston stop pin from rear of housing,

until flush with rear of housing.
3. Install lube reduction valve (slot inward).
4. Inspect spring and install with plug.
Reduction Valve Spring Free Length Working Load
1.85 in. 0.91 in, at 9-11 lbs.

(47 mm) (23 mm at 41-51 N)

50-05-6 Perma-Cl utch Power Train Repair
Operating Assembly Continued
f^K It JK Jr 'l^' '!Jji'S

:
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l!:jH;:iijiiysB5S!T?:!l?^::!:l
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pfife: :
:
AOuter Race F Outer Race

APacking (2 used) EOuter Race 1 Inner Race BOperating Piston Housing G-^SIeeve
BPTO Piston FRetainer JClutch Piston C PTO Gear Shaft H Lube Reduction Valve
CInner Race GOuter Race KPacking D Bearing Retainer Plug
DThrust Bearing HThrust Bearing EClutch Operating Piston I Adapter Holes
J PTO Bearing Retainer
Fig. 1 1-Operating Piston Assembly
Fig, 12-Operating Assembly
2. Inspect PTO operating piston (B, Fig. 11), bear-

ing (D), and races.
5. Install PTO operating bearing retainer (J, Fig. 12)
aligning tang with slot on piston. Tang should face
3. Install PTO clutch operating piston (with
upward.
its inner
and outer packings) in the housing,
6. Invert housing and install springs, keepers, and
retaining rings.
NOTE: Rotate miffed slot to vertical position. This
aligns the slot with the 1/8 in. (3 mm) tube hole in the
housing. 7. Assemble transmission clutch bearing using Fig.

11 as a guide. Crimp retainer tangs over piston. Note
Assemble the outer race is assembled with the larger outer
4. the bearing using Fig. 11 as a guide.
Large diameter diameter toward the housing.
of outer race should face inward.
8. Invert housing again and install clutch piston (E)

with packing in housing,
9. Inspect bushing in PTO gear shaft. New bushing

ID is 1.706 mm). Drive new bushing 1 1/32 in,
in. (43,3
(9 mm) below end of shaft with oif groove open ends
facing away from driver. Drive using 1-3/4 in. disk
(44.5 mm), and 1-11/16 in. (43 mm) pilot, (OTC No.
27510 and 27511).

Power Train Repair Perma-Clutch 50-05-7
Installing Operating Assembly in Clutch

Housing
I 1. Position the lube passage packing in the upper
right-hand corner of clutch housing with grease so it

will not drop out of place.
2. Check that hex. bushing for transmission oil
pump drive shaft is in place in the transmission input

shaft. (Input shaft is the short shaft in the two-speed on
QUAD-RANGE Tractors.)
3. Install clutch operating assembly and torque cap

screws to 35 ft-lbs (47 IMm) (4.7 kgm).
4. Torque operating housing-to-planetary cap

""lull ^ in '
_, _...,
screws to 20 ft-lbs (27 N-m) (2.7 kgm).
Jl^liil
ASnap Ring C Bearing

B Shaft Snap Ring D Oil Shield
Fig. 13-PTO Cfutch Shaft and Gear
NOTE: tf ball bearing was not removed from PTO

gear shaft (Fig. 13); omit the following three steps.
10. Heat PTO shaft bearing (C) to 300F (149C).
A CAUTION: Oil fumes or oil can ignite

above 380F (193X). Use a thermometer
flame or heating element to be in direct contact
with the oil. Heat the oil in a well-ventilated area. Assembly
Plan a safe handling procedure to avoid burns. BTwo-Speed Planetary F Clutch
C PTO Drive Gear G PTO Clutch
11. Place snap ring (A) in gear, and oil shield (D).
Fig. 14-Operating Adapters - Quad-Range
12. Install hot bearing on shaft with extended inner

5. Check adapter O-rings and install adapters. The
race facing gear. (The oil shield centers on the inner
two-speed planetary adapter (B, Fig. 14) has two
race.) Seat second snap ring (B).
bends.
13. install PTO shaft and bearing in operating

6. Install pressure regulating valve housing and
housing.
torque cap screws to 35 ft-lbs (47 N-m) (4.7 kgm).
14. Seat snap ring through opening in gear and

install transmission clutch shaft from the rear.
>

Clutch Valve Operating Rod Adjustment
Transmission dutch Rod (

1. Check clutch pedal height. Lowest part of pedal
to footrest should be 5-1/2 in. (140 mm). Be sure
clutch pedal return spring is holding valve operating
arm downward against the lower stop,
2. If adjustment is necessary, remove left-hand

cowl from operator control station.
Fig. 16-Adjusting Pedal Height
3, Adjust by removing cotter pin from operating rod

<B, Fig. 15). Rotate the hex-shaped adapter (D) to
obtain the proper pedal height
PTO dutch Rod

1. PTO operating rod (A, Fig. 15) must be installed
in the rear (upper) hole of the two holes of the PTO
lever (C).
2. Be sure PTO lever return spring (E) is in hole in

fever and that the control support is properly mounted.
3. With rear edge of PTO lever (C) 3/4 inch (19 mm)
from rear end of lever slot in instrument panel, and
A PTO Valve Rod C PTO Lever PTO clutch valve operating arm rotated clockwise
B Clutch Valve Rod D Hex, Adapter
against upper stop on valve housing; adjust PTO rod
E Lever Return Spring
until pin at upper end of rod aligns with rear pin hole in
Fig. 15-LH. Cow! Removed lever.

.
Power Train Repair Per ma-CI utch 50-05-9
CLUTCH PACK Disassembly and Repair

IMPORTANT: With proper system pressure to 1 Place the clutch pack on a bench and remove the
prevent slippage, adequate oil flow for cooling, and transmission operating fever lock and adjusting nuts.
correct initial adjustment to provide even loading; 2. Lift assembly carefully
parts from to avoid dam-
the clutch disks will have an extremely long life. If age and friction driving surfaces
to disks of plates. (See
the clutch is operating properly, DO NOT disas- Figs. 19 and 20).
semble clutch for inspection.
3. Use a light abrasive to remove raised or sharp
The clutch is designed so that if facing wear should edges on friction driving surfaces. This prevents dam-
occur, the transmission clutch levers will bottom on the age to clutch facings.
clutch cover before the facing is completely gone. Very
noticeable slippage will result, preventing clutch plate NOTE: The dutch facings normally acquire a darker
damage. color with use.
If disks are worn, readjusting a clutch will destroy 4 T Inspect clutch components:
this and may result in extensive clutch
relationship
damage if the facing wears out. Therefore, disk speci- Component No. Used New Part Thickness
fications must be applied during clutch repair.
Clutch Separator 1 0.395-0.405 in.
(7.13-7.39 mm)
Clutch Pack Removal
PTO Separator 1 0-195-0.205 in.
1 . Separate clutch housing from engine as instruct- (4.95-5.21 mm)
ed in Section 10, Group 20. Be sure to remove the hex.
Clutch Disk 2 0.137-0.143 in.
drive shaft before separating.
(3.48-3.64 mm)
PTO Disk 2 0.137-0.143 in.
(3.48-3.64 mm)
CLUTCH SPRINGS FREE LENGTH WORKING LOAD
Transmission 2.6 in. 2.3 in. ai 170-208 lbs.

(66 mm) (59 mm at 757-925 N)
PTO 1.3 in. 0.86 in. at 43-53 lbs.

(33 mm) (22 mm at 192-235 N)
5.Replace disks less than 0.110 inch (2.79 mm)

any disk that has a facing groove depth less
thick, or
than 0.005 inch (0.13 mm),
6. Note disk clutch release wave of 0.01 1 inch (0.28

mm).
7. Replace any dutch or PTO separator plate that is
warped more than 0.006 in. (0.15 mm) across the plate
diameter. Excessive plate warpage could cause clutch
Fig. 17-Removing Clutch Assembly drag and uneven disk wear.
2. Insert wedge under each operating lever to hold 8. Inspect separator, pressure, and backing plates
pack together during removal if it is not to be serviced. for any apparent roughness. Replace if roughness
cannot be cleaned using a light abrasive. Darkened
3. Remove the six clutch cover-to-flywheel cap areas (if smooth) do not affect the clutch assembly.
screws and withdraw the clutch pack.
TM-1181 (Sep-77) Litho in U.S. A, Tractors - 4040 and 4240

.
CLUTCH PACKContinued
Assembly (
AClutch Backing Plate C^PTO Clutch Hub

BPTO Clutch Disk DClutch Return Spring
(2 used) E PTO Separator Plate
Fig. 19-Clutch Backing Plate and PTO Hub
7. Install clutch backing plate (A, Fig. 1 9) with spring
bosses up.
A^-Bloefcs CClutch Hub 8. Install PTO hub (C).
BOperating Bolt DClutch Disk (2 used)
EClutch Separator Plate
9. Assemble PTO clutch disk over hub followed by
separator plate (E, Fig. 19). Assemble second disk (B).
Fig, 18-Traction Clutch Assembly Be sure separator plate slots align with holes for drive
lugs.
1 Place blocks below operating lever bolt heads (B 3
10. Install three shorter PTO return springs in
Fig. 18) under dutch pressure plate. backing plate bosses.
2. Install traction clutch disk hub (C) (smaller shaft

ID.).
3. Install three longer dutch pressure plate return

springs over operating bolts.
4. Install a traction dutch disk (D) (identified by 22

holes between spline and facing area).
5. Install traction dutch separator plate (E) aligning

slots with pressure plate drive slots. Note that traction
clutch separator plate is thicker than PTO clutch sep-
arator plate.
6. Install second clutch disk (D) over clutch hub as

shown.
NOTE: if clutch drive pins in flywheel are replaced,

A PTO Pressure Plate B PTO Return Springs
pressnew pins in so they protrude 2, 1 1 in. (53.5 mm)
above dutch cover mounting surface. Fig. 20-PTO Clutch Assembly
1 1 . InstallPTO pressure plate (A, Fig. 20) aligning (

slots and with PTO return springs (B) properly posi-
tioned as shown.

1
PTO Clutch Operating Levers
jgi;'^; jgg:!a^;:; zxB^niaTHi^xrr.Uii -.
.
;:
AHeaded Pin (3 used) CAdjusting Nut

BClutch Operating D Bearing Washer
Lever
Fig. 21 -Clutch Cover and Operating Levers

ATransmission Lever Nut BJDE-78-5 Studs
12. Install clutch cover with three transmission Rg. 22-tnstaiUng Clutch Adjusting Tool
clutch operating levers (B) as shown in Fig. 21.
1. Remove PTO levers and loosen transmission
13. Tighten adjusting nuts just enough to hold lever lock and adjusting nuts (A, Fig. 22).
clutch backing plate against clutch cover. This pre-
2. Loosen the three PTO adjusting screw lock nuts
vents front PTO disk from falling off hub when installing
and run the adjusting screws in. Remove clutch cover
clutch.
cap screw nearest part number on clutch cover and the
cap screw opposite it.
14. Install clutch pack in flywheel, aligning separa-
tor plates with flywheel drive pins, 3. Install adjusting screw studs (B) (long end into
clutch). studs so one is in hole nearest part
Install
15. Torque clutch cover-to-flywheel cap screws to number on clutch cover and the second is opposite it
35 ft-rbs (47 Nm) (4.7 kgm). on the cover.
4.Assemble JDE-78-3 (0.466 in.) and 78-12 (0.070

Adjustment
PTO, and JDE-78-4 (0.253 in.) clutch adjusting tool
in.)
IMPORTANT:Careful clutch adjustment is criti- gauge rings on adjusting tool

cal to assure even clutch plate loading and to
IMPORTANT: Be sure gauge ring mounting
prevent wear.
screws are below flush in the ring to avoid im-
proper adjustment.
5. Position adjusting tool with gauge rings on clutch

cover counterbore so the long screw is near part,
number stamped on cover, and so that screw will pass
through hole cross bar. (Be sure none of the three
in
adjusting screws face lips on pressure plate.)
6. Back off the three adjusting screws from PTO

plate.
7. Install cross bar over the tool so hole is over the
> longer of the three screws. Tighten tool stud nuts and
torque cross bar screw to 20 ft-lbs (27 Nm) (2.7 kgm).

Adjustment Continued Transmission Clutch Operating Levers
mm.
=::.!!
îniîâ
iisfe?^
Fig. 24-Adjusting Transmission Clutch Levers
A^-PTO Lever Pivot Pin (3 used) 13. Remove PTO levers, Mark them so they will be
reinstalled in the same positions.
Fig. 23-Adjusting PTO Levers
14. Loosen the three adjusting tool cap screws to

8. Torque the three adjusting tool cap screws disengage the PTO clutch.
evenly to 30 in-lbs (3.4 Nm) (0,34 kgm) to load the PTO
pressure plate. 15. With transmission clutch lever nuts loose check
to see that each head is locked in the pressure
bolt
9. Install one PTO lever and raise it to the adjusting
plate slots to prevent them from rotating.
surface on tool while backing adjusting screw out finger
tight against lever.
10. Carefully mark and remove lever so it will be

installed with its pivot pin (A) in the same position.
11. Tighten lock nut being careful not to move ad-

justing screw.
IMPORTANT: Check adjustment by reinstalling

lever.The pivot pin will fit tight because of adjust-
ing screw stretch when tightening lock nut. Clear-
ance between end of lever and tool should not be
more than 0.010 inch (0.254 mm). If more, readjust
lever to proper clearance by turning adjusting
screw 1/6 turn at a time.
12. Repeat procedure with remaining two PTO

clutch operating levers.

3
Fig 26-0perating Lever

r Assembly
18. Tighten lock nuts against operating bolt nuts.
19. Remove adjusting tool and hold adjusting nuts

while tightening lock nuts.
20- Install remaining two clutch cover cap screws

Fig. 2S~Torque Operating Bolt Nuts
and torque cap screws to 35 fMbs (47 Nm) (4.7 kgm).
16. Bring transmission clutch operating levers up

21. Replace PTO levers, pins and cotter pins in
against surface of tool by finger tightening the nuts.
their marked positions on the clutch cover.
17. Evenly torque operating bolt nuts to 40 in-ibs
(4.5 Nm) (0.45 kgm), then to 70 in-lbs (8 Nm) (0,8
kgm), then to 90 in-lbs (10 Nm) (1.0 kgm).

50-05-1 4 Perma-Clutch Power Train Repair

Power Train Repair Syncro-Range Transmission 50-10-1
Group 10
(Also Quad-Range and Creeper Eight-Speed)
REMOVAL
2. Separate the transmission from the clutch hous-
ing. See Section 10, Group 20 for instructions.
3. Remove transmission cover.
Shifter Removal
NOTE: Both and bottom shifter cams can be

top
removed removing the transmission drive
without
shaft. The top shifter assembly can be removed before
removing the transmission drive shaft, but the bottom
shifter cannot
The following instructions refer to removal of the top

shifters. Remove bottom shifter assembly in the same
manner after removing the transmission drive shaft.
1. Remove detent retainer, spring and bait from
bore behind shifter arm on right-hand side of trans-

mission case.
Fig. 1 -Removing Hex. Drive Shaft
1. Remove the hex. drive shaft through rear of

transmission to avoid damage during separation.
Protect the machined end from damage and re-
move, using a small pliers.
A Shifter Cam CShifter Shafts E Clutch Housing-to-

BShifters DShaft Nut Case Cap Screws
Fig. 3- Speed Shifters and Shifter Cam
2. Lower shifter arm so shifter cam (A, Fig. 3) is in
its lowest position and remove nut (D) and shifter cam
U
shaft noting V" marks on shaft. Avoid damaging oil
seal.
3. Remove shafts (C), rotate shifters (B) upward

and remove shifters.
I ATransmission Drive Shaft CCountershaft

BDifferential Drive Shaft DPTO Shaft
Fig. 2-Ciutch Housing Removed
TM-1181 (Sep-77) Litho in US, A. Tractors - 4040 and 4240

50*10-2 Syncro-Range Transmission Power Train Repair
REMOVALContinued 1. With the preceding Removal steps completed,
remove the rockshaft. (See Section 70, Group 15.)

Transmission Drive Shaft Removal
2. Remove transmission oil pump outlet oil line (A t
Fig. 5).
3. Remove oil line (B) which extends through the

transmission case and remove the transmission oil
pump. Differential drive shaft oil line (E) must be re-

moved as pump manifold (D) is removed.
4. Tape synchronizers together to avoid separation

during shaft removal.
5. Remove front transmission drive shaft bearing

cup housing (C, Fig. 4) from transmission case. U*e a
brass drift to drive transmission drive shaft to rear urn/
gears on transmission drive shaft contact gears on
countershaft.
6. Shim between bearing cup and cone and drive

rear bearing cup from transmission case.
A Bushing E Countershaft
BTransmission FDifferential Drive
7. Move shaft to rear, tilt upward at front, and re-
Drive Shaft Shaft Front Bearing
move from transmission case.
CBearing Housing G-Pfate
D Bearing Retainer HShifter Shaft
Fig. 4-Front of Transmission Case
NOTE: The transmission shafts can be removed in

oniyone sequence: transmission drive shaft (B, Fig. 4)
first, then differential drive shaft (F), and finally coun-

tershaft (E).
A Pressure Outlet Line D Pump Manifold

B Oil Cooler Line E Dfff. Lube Line
CPump Body F Dfff, Housing
Rg. 5-Transmission Oil Pump and Oil Lines

.
Power Train Repair

Syncro-Range Transmission 50-10-3
Differential Drive Shaft Removal

NOTE: Differential must be removed to remove dif-
ferential drive shaft. Refer to Group 35 of this Section
for instructions.
1 Place the lower shifter arm on side of transmis-

sion case in Park position.
2. Remove plate (G, Fig. 4) at front of shaft and

remove lower shifter. (See Shifter Removal.)
Fig, 7-Removing Snap Rings
5. Remove snap rings from grooves using a snap

ring expander.
6. Continue driving shaft while sliding gears,

wash-
ers and snap rings forward on shaft.
NOTE: There are four snap rings on the differential

drive shaft. Drive the shaft free after the rear snap ring
is moved out of its groove.
ADifferential Drive Shaft C Bearing Cone

&Brass Drift 7. Remove front bearing cup using 3 inch (76 mm)
driver disk (OTC No. 27531).
Fig. 6-Removing Differentia! Drive Shaft
Countershaft Removal
3. a C-clamp through hole in transmission
Install
case to hold front fourth and seventh speed (QRT 1- Remove countershaft front bearing retainer and
C- Range) gear forward against case. drive front bearing cup forward using brass drift.
Drive differential drive shaft to rear using a soft

4, 2. Slide countershaft forward, turn and remove.
hammer and brass drift. While driving, tighten C-clamp
until bearing cone is free.

50-10-4 Syncro-Range Transmission Power Train Repair
TRANSMISSION DRIVE SHAFT DISASSEMBLY, REPAIR AND ASSEMBLY

Disassembly and Repair NOTE: Minimum groovedepth on the disk facings
is0.006 in. (0.15 mm). Minimum facing thickness is
NOTE: The illustrations under Assembly show the 0.009 in. (0.23 mm).
transmission drive shaft in different phases of assem-
bly. Refer to these illustrations in reverse order of their The high speed side of the synchronizer blocker has
appearance to cfarify any of the following Disassembly three disks while the low speed side has five disks.
steps,
6. Pull rear bearing cone to complete transmission
1.To remove synchronizer assembly, remove front drive shaft disassembly. (Fig. 10).
snap ring from shaft and use a press or puller to
remove front bearing cone. IMPORTANT: Do not attempt to remove reverse
range drive collar by pulling on low range pinion.
2. Remove high pinion and high speed synchro- Attach puller to collar only.
nizer drum. (Fig, 12)
7. Clean all shaft passages.
3. Remove synchronizer and blocker assembly
from shaft. (Fig. 11) 8. Inspect bushing in Quad-Range front bearing
housing. Bushing LD. is 2.255 to 2.258 in. (57.2 to 57.5
NOTE: When blocker is removed from shaft, four mm). Press new bushing 1/16 inch (1.6 mm) below
spring-loaded detent balls will be released from front edge of housing.
blocker DO NOT lose baits and springs,
9. Inspect blocker and drums.
4. To remove synchronizer disks and plates from
blocker, pry retainers from each end of blocker with a 1 0. Check transmission drive shaft outer diameters
small screwdriver. (Fig. 11) for wear using Fig. 8 as a reference.
5. Inspect synchronizer plates and disks for glazing

and excessive wear. If grooves in disks are not dis-
tinctive, or if the following specifications are not met;
replace.
Plate New Part Thickness Minimum Thickness
(6 used) 0,048 in. (1 .2 mm)
Disk
(8 used) 0.070 in. (1 .78 mm) 0.058 in. (1.48 mm)
1.4895-1.4905 in.
(37.833-37.859 mm)
(g} 1.6805*1.6815 i
1.91 95-1.9205 in.
(42.684-42.710 -J (48 - 755-48.781 mm)
1.1260-1.1266 in,
(28.600-28.616 mm) 1.6243-1.6249 in. 1.6260-1.6270 in.
R2S670
(41.257-41.273 mm) 1.6870-1.6880 in.
(42.850-42.876 mm) i (41.300-41.326 mm)
A Rear Cone C Reverse Drive Collar E Low and High F High Pinion
BReverse Pinion DLow Pinion Drive Collar G Front Cone (
Pig. 8-Transmission Drive Shaft Outer Diameters

Assembly <s^p-
ASnap Ring L Low Plates V Woodruff Key (2 used)

B Bearing Cup M Blocker W Transmission Drive Shaft
C Bearing Cone N Spring and Ball X High Pinion
D Reverse Pinion (4used) Y
Bearing Cone
E Reverse Shifter Collar O High Disks Z Bearing Cup
FSnap Ring P High Plates AASnap Ring
G Reverse Drive Collar Q Disk Retainer BBShim - 0.006 in. (0.15 mm)
H Snap Ring R High Drum and 0,010 in. (0.25 mm)
I Low Pinion S Snap Ring CC Front Bearing Housing
J Low Synchronizer Drum T Low and High Drive Collar DDBushing
K Low Disks U Woodruff Key (2 used) EECap Screw (3 used)
Fig. ^Transmission Drive Shaft Pan's (Creeper Locking Plate - Not Shown)
1. Press hi-io drive collar (T, Fig. 9) over smaller
diameter shaft end with two woodruff keys. Install snap

ring in groove.
2. Install low pinion (I), round snap ring; and place

low drum (J) over pinion. Note that low drum is wider
than high drum.
3. Install reverse range drive collar (G) over two
woodruff keys (recessed side toward snap ring).

,"*
*?^4tm8fabit.is. t y i i. :. *.*"****
-
,
4. install snap ring in groove at drive collar.
Fig. 10-Reverse Pinion and Collar
5. Install reverse pinion and shifter collar. Be sure

helical gear cut is outward.
6. Install smaller diameter bearing cone using a
press and install snap ring in groove.

.
Transmission Drive Shaft Assembly

Continued
NOTE: Blocker and snap ring should be replaced

together. Both parts come assembled. Snap ring is
difficult to remove and install
7. Install five disks and four synchronizer plates

alternately over snap ring on blocker. Be sure this
larger portion of disks and platesis installed over end
of biocker with longer splined area.
8. Install a synchronizer retainer over the disks

and plates. Be sure to align retainer dimple in slot in
blocker to prevent retainer rotation.
9. Stake the retainer LD. in at least four equally

spaced locations. Stake so the retainer is fixed inside
the ridge on the blocker I.D.
:.;':
:
:
'K:-: Jfr.H. % &*$&&.,
in ffitil Sfllik
;.i;i.v.?;i.vtfv.'.&j
:P?j
iii
ludiJ/ ci &
A High Drum E Plates (6 used)

BJDT-4A Loading Sleeve F Low Drum
C Retainer {2 used) G Drive Collar
D Disks (8 used) H Snap Ring
Fig. 12-Transmission Drive Shaft Assembly
12. Install assembled synchronizers and blocker

overdrive collar (G, Fig. 12) using JDT-4A sleeve (B)
to load and transfer the four springs and balls to the
drive collar.
13. Install short-slotted synchronizer drum (A) and

snap ring.
14. Install high-range pinion,

A Blocker C Retainer
B Retainer Dimple 0 Disks and Plates 15. Press on bearing cone and install thickest snap
ring that will fit in groove in shaft.
Fig. 1 1 -Staking Synchronizer Retainer to Blocker
and two plates

10. Install the remaining three disks
over the opposite side of the large snap ring
alternately
on the opposite end of the blocker.
1 1 Stake the retainer in at leastfour equally spaced

locations inside the ridge on the blocker LD. (see Fig.
15). Be sure dimple (B) is aligned with slot in blocker

Power Train Repair
Syncro-Range Transmission 50-10-7
Countershaft Disassembly and Repair Differential Drive Shaft Repair
1. Check bushing in first and third

speed (QRT-A-
range) gear (5, Fig. 14), for scoring or unusuaJ wear.
I.D. of bushing is 2.6171 to 2.6181 inches
(66.474 to
66.500 mm), ff bushing is badiy scored or grooved,
gear with bushing must be replaced.
2. Inspect differential drive shaft for wear.

O.D. of
gear mating surface is 2.6121-2.6131 inches (66.35-
66.37 mm). Be sure oil passages are not plugged.
1Rear Bearing Cup 7Second and Frfth
2-Rear Bearing Cone Speed (B-Range) Gear
3Snap Ring 8 Fourth and Seventh
4 Sixth and Eighth Speed (C-Range) Gear
Speed (D-Range) Gear 9Countershaft
5 First and Third 10 Front Bearing Cone
Speed (A-Hange) Gear 11 Front Bearing Cup
6Woodruff Key 12Shims
13Front Bearing Retainer
Fig, 13-Countershaft Paris
1. Remove snap ring and press off large sixth and

eighth speed gear (QRT-D range gear) and remove
Woodruff key (6, Fig. 13). The remainder of the gears
are part of the shaft.
2. To assemble gear, Install key

(6), press on gear
and bearing cones, and replace snap ring.
26034N
1Differential Drive Shaft with 8Rear Shifter

Ring Gear
Gear 16Front Bearing Cup
9Snap Ring 17Shim (use as required)
2Rear Bearing Cone 10Shrth and Eighth-Speed
3Rear Bearing Cup 18Thrust Washer
(D-Range) Gear 19Fourth and Seventh-Speed
4Shim (use as required) 11Tnrust Washer (3 used)
5First and (C-Range) Gear
Third Speed 12Snap Ring 20Front Shifter Gear
(A-Range) Gear 13Cap Screw (2 used)
6Snap Ring 21Snap Ring
14 Plate 22Second and Fifth-Speed
7Shifter Collar (2 used) 15Front Bearing Cone (B-Range) Gear
Fig. 14-Differentiai Drive Shaft Parts
TM-1181 (Jui-78) Lftho in U.S.A.

SHAFT INSTALLATION AND ADJUSTMENT

NOTE: Shafts must be installed in the following 2. Install front bearing cup in transmission case
sequence. using a 3-11/16 inch (94 mm) driver disk, (OTC No.
27542 disk). Be sure cup is properly seated.
Countershaft Installation and Adjustment
1. Install countershaft and bearing cup. A CAUTION: Oil fumes or oil can ignite
above 380F (193C). Use a thermometer
2. Install front bearing retainer with shims and flame or heating element to be in direct contact
torque retainer cap screws to 35 fMbs (47 Nm) (4.7 with the oil. Heat the oil in a well -ventilated area*
kgm). Plan a safe handling procedure to avoid burns.
3. Heat rear bearing cone to 300F (155C) and

install bearing on differential shaft tight against bevel
pinion.
4. Seat bearing cups by installing shaft with bear-

ings and torque
retainer cap screws to 35 ft-lbs (47
Nm) (4.7 kgm). Strike each end of the shaft with a lead
hammer and retorque the retainer cap screws. Repeat
several times to be sure cups are seated.
Ftg. 15-Checking Countershaft End Pfay
3. Mount a dial indicator and check countershaft

end play of 0.001 to 0.004 inch (0-025 to 0.102 mm).
Adjust end play by adding or removing shims under
front bearing retainer.
Differential Drive Shaft Assembly, Repair

and Adjustment
NOTE: If the differential drive shaft is replaced, the

gear must also be replaced since they
differential ring
are supplied as a matched set Use both new parts
when replacing either. (See Group 35 of this section for
complete adjustment procedure.)
1 . Install cup with shims in transmis-

rear bearing
sion case. If cone or differential
the rear bearing cup, A Differential Drive Shaft BHolding Tool
drive shaft is replaced; determine the proper shim pack
as follows:
Rg. 16-tnstatling Holding Tool (4840 PST Shown)
a) Subtract the number etched on the pinion end NOTE: When installing front bearing cone on shaft,
of the differential drive shaft from 8.326. be sure shaft held forward tightly to prevent damage to
the rear bearing. See Group 00 to construct the holding
b) The difference is the correct shim pack to use tool shown in Fig. 16.
in front of the rear bearing cup in inches.
5. Remove the shaft. Use a brass drift to drive shaft
through front bearing cone.
TM-1181 (Jul-78) Litho in U.S.A. Tractors - 4040 and 4240

. .
Power Train Repair Syncro-Ra nge Transmission 50-1 0-8a
Rolling Drag Torque Adjustment 9. Grasp the pinion end of the differential drive shaft
and rotate
it in each direction several times while
IMPORTANT: Use a spring scale as directed pushing fonward to seat the rear bearing rollers.
below to obtain the specified rolling drag torque.
The spring scale reading required to obtain the NOTE: When rotating shaft, be sure that dial indi-
specified rolling drag torque is provided. cator pointer is not disturbed,
1 Clean differential drive shaft and its parts from all 10. Align the mark on the retainer plate with the
nicks and burrs* Lightly oil the front and rear bearings. mark on the case wall (A) and while holding the shaft
forward, zero the dial indicator (F).
2. Install differential drive shaft without gears in
case. Install holding tool as in Fig. 16.

1 1 Rotate the shaft several times in each direction
3. Install thrust washer at front of shaft with bevel while pulling it rearward to seat the front bearing
side forward. rollers. Again use care not to disturb the dial indicator.
4. Install enough front shims to provide a measur-

12. Align themark on the retainer plate with the
able amount of end play.
mark on and while holding the shaft
the case wall (A)
5. Heat front bearing cone to 300T (150C) and rearward, read the dial indicator. Note end play.
install on shaft (see Fig. 16).
13. Remove dial indicator, front retainer cap screws
(C) and retainer plate.
14. Using a large brass drift, drive shaft rearward

through the front bearing.
IMPORTANT: Use care not to lose any of the

front bearing shims.
15. Remove enough front bearing shims to equal

the end play measured plus 0.0005 to 0,0020 in.
preload (0.013 - 0.056 mm).
IMPORTANT: Measure shims individually using

may vary.
a micrometer. Shim thickness
16. Install differential drive shaft through front thrust

washer and install the shim pack determined in step
15.
17. Repeat steps 5 through 12.

AAlignment Mark DRetainer
BBearing Cone EBearing Cup a) end play is measured, repeat steps 13
CCap Screws
If
FDial Indicator
through 17.
Fig. 16a-Checking Differential Drive Shaft End Play
b) If zero end play is determined, continue on
6. Install retainer (D, Fig. 16a) and torque retainer through the following steps to check rolling drag
cap screws (C) to 35 ft-!bs (47 Nm) (4.75 kgm). torque.
7. Mount a dial indicator (F) so pointer rests on a

smooth portion of the retainer plate (D).
8. Mark the retainer plate and the transmission case

(B) so end play can be checked at the same point on
the retainer plate.
TM-1181 (Jul-78) Litho in USA. Tractors - 4040 and 4240

.
5<Mf>8b Syncro-Range Transmission Power Train Repair
Rolling Drag Torque Adjustment- a string (approximately 6 ft. [2 m] long)

18. Tie
Continued around differential drive shaft just to the rear of
tightly
the rear snap ring groove (F, Fig. 16b).
19. Rotate the shaft (A) to wrap the string around

the shaft.
20. Attach a JDT-42 spring scale (or its equivalent)

(D) to the end of the string. Be sure the spring scale is
zeroed.
21 Raise the spring scale rotating the shaft a max-

imum ofone revolution per second while reading the
spring scale. Repeat several times for an accurate
reading.
a) If the spring scale reading is not within 8 to

15 lbs. (3.63 to 6.80 kg), repeat the entire adjustment.
Be sure shaft components have no nicks, burrs or
brass shavings.
NOTE: The 8 to 15 lb, (3,63 to 6.80 kg) spring scale

reading provides the specified rolling drag torque of 10
to 20 in-lbs (4.6 to 9. 1 kg).
b) If rolling drag torque is within specification,

remove the shaft to complete the assembly and in-
stallation.
IMPORTANT: Do not lose or misplace the front

bearing shims. If the shim pack is in question after
assembly the adjustment procedure and assembly
procedure must be repeated.
R 31546
ADifferential Drive EString

Shaft F Rear Snap Ring Groove
BRear Bearing Cup GCone Point Shims
CTransmission Case Wall HRear Bearing Cone
D Spring Scale
Ftg. 1$b-Measuring Rolling Drag Torque
TM-1181 (Jul-78) Litho in U.S.A. Tractors - 4040 and 4240

Differential Drive Shaft Installation
1 .File the ends of the four differential drive shaft

snap rings so they will fit squarely on retainers.
ASnap Rings B-JDT-2 Cone C-JDT-3 Retainers
Fig. 17-Expanding Differential Drive Shaft Snap Rings
Fig. 18-lnstaIling Dummy Shaft and Support

2. Expand snap rings (A t
Fig. 17) using OTC-614
snap ring pliers over JDT-2 special cone (B).
5. Install JDT-8-1 arbor support (Fig. 18) on front of
transmission case.
IMPORTANT: Do not expand snap rings more
than necessary to insert retainers. Rings may take
6. Install JDT-20-1 sleeve in arbor support. Do not
a permanent set if expanded too far.
use bushing furnished with arbor. Insert a bar through
holes in arbor for a handle.
3. Install expanded snap rings on JDT-3 retainers
(C) to hold them while they are being installed on the
drive shaft.
4. The differential drive shaft snap rings are of

different thicknesses to allow the rear and center snap
rings to slide over the front grooves without dropping in
them. The thinnest rings are at the front to the thickest
at the rear as follows:
Front of Shaft
0.142 in. (3.61 mm)
0.157 in. (3.99 mm)
0.172 in. (4.37 mm)
0.188 in. (4.78 mm)
Rear of Shaft

Differential Drive Shaft Installation

Continued
AArbor Support F Second and Fifth Speed KThickest Snap Ring

BFourth and Seventh Speed (B -Range) Gear LRear Shifter Gear
(C-Range) Gear G Second Thinnest Snap Ring MFirst and Third Speed
CFront Shifter Gear HSixth and Eighth Speed (A-Range) Gear
DFront Shifter Collar (D-Range) Gear NDeferential Drive Shaft
EThinnest Snap Ring I Second Thickest Snap Ring 0Countershaft
J Rear Shifter Collar
Fig. 19-DifferentiaI Drive Shaft Assembly
7. Install first and third speed (QRT-A-Range) gear 14. Install rear shifter collar (J) thin lip to front (rear is
(M). stamped).
8. Install fourth and seventh speed (QRT-C-Range) 15. Insert differential drive shaft (N) through rear
gear (B, Fig. 19) after thrust washer. Install with helical bearing cup and push into position displacing the arbor
gear section to front. sleeve.
9- Install front shifter gear (C) (snap ring recess to 16. Remove snap ring retainers and seat snap rings
rear), in their grooves.
10. Install shifter collar with even lips (D), thinnest 17. Remove arbor and support (A).
snap ring (E) and thrust washer.
18. Install front thrustwasher (chamfer forward) and
11. Install second and fifth speed (QRT-B-Range) install front bearing shims as determined on page 8.
gear (F), thrust washer, and second thinnest snap ring G
19. Heat front bearing cone to 300 F (150C).
(G)-
20. Install front bearing cone on shaft and install
12. Install thrust washer, sixth and eighth speed
front retainer plate. Torque front retainer cap screws to
(QRT-D-Range) gear (H) helical section to front, and
45 ft-lbs (61 Nm) (6.1 kgm).
second thickest snap ring (I).
21. install differential as instructed in Group 35.

13. Install rear shifter gear (L) with snap ring recess
to rear and install thickest snap ring (K).
TM-1181 (Oct-78) Lttho in U.S.A. Tractors - 4040 and 4240

Power Train Repair Syncro- Range Transmission 50-10-11
Transmission Drive Shaft and

Shifter Installation
Fig. 22-instalting Lower Shifters
Fig. 20-Transmission Drive Shaft and Shifters Removed 5. Tighten shaft nut and adjust shifter arm on shaft
to 0.002 to 0.007 inch (0.05 to 0. 1 8 mm) shaft end play.
1. Position shifter collars as shown in Figure 20.
IMPORTANT: Avoid excessive cam shaft shifter
2. If cam shaft support oil seals are replaced,
shifter end play. Excessive end play allow shifter
will
coat O.D. of new seals with Permatex No. 1 and drive detent springs to force shifters out of proper
seals (spring side away from driver} using 1-1/2 in. (38 operating position.
mm) driver disk and 7/8 in. (22 mm) pilot disk (OTC no.
27507 and 27497). 6. Place lower shifters into grooves in shifter collars.
Position rear shifterfirst, then front shifter in cam slots,
7. Install shifter shaft.
8. Install shifter detent ball, shorter detent spring,

detent retainer, and retainer screw,
9. Install front housing bearing cup using 2-7/16 in.

(62 mm) driver disk and 2-1/4 in. (57 mm) pilot to
bottom of chamfer (OTC disk No. 27522 and 27519).
Fig. 21 -Installing Lower Shifter Cam
3. Install lower shifter cam spring (long end to cam

hub) and spring pin.
4. Install lower shifter cam, if removed, and shaft.

Align "V" mark on cam with "NT mark on end of shaft.
Avoid damaging shaft oil seal.

.
Transmission Drive Shaft and Shifter

Installation Continued
10. Install transmission drive shaft in case and in-
stall front bearing housing with shims.
11. Draw rear bearing cup into place in case with

transmission pump body cap screws (A, Fig. 24}
torqued to 20 ft-lbs (27 N-m) (2.7 kgm).
A Pump Body Cap Screw B Pump Pressure Line

Fig. 24-lnstaIfing Upper Shifters
15. install top shifter cam as instructed in Steps 1 -
5 on page 1 1
16. Install top shifters together with hUo shifter

below reverse shifter and install shifter shaft.
Fig. 23-Checking Transmission Drive Shaft End Play

17. Install lube oil line through case and to trans-
mission oil pump.
12. Torque front bearing housing cap screws 35
ft-lbs (47 N-m) (4.7 kgm}.
18. Attach clutch housing to transmission case.
(See Section 10, Group 20.)
13. Use a dial indicator with extension to check
transmission drive shaft end play of 0.004 to 0.006 inch
(0.1 to 0.1 5 mm). Adjust by adding or removing shims
under front bearing housing.
14. Remove tape from synchronizer assembly.

.
Power Train Repair SyncroRange Transmission 50-10-13
SHIFTER LEVER
(Syncro- Range Transmission)
NOTE: See Group 15 for information on Creeper

shifter assembly or Group 20 for information on Quad-
Range shift assembly.
Removal
NOTE: To remove shift iever the consoie must be

disassembled.
1 Loosen the three cap screws under right wheel

fender.
2. Remove six cap screws holding sheet metal

around console guide.
3. Remove load control selector lever knob and

console cover.
AHeaded Pins D Bracket

BQuadrant Cap Screws E Collar
CQuadrant
Fig. 26-Quadrant and Control Lever
5. Remove cotter pins and headed pins (A, Fig. 26)

from shifter control rods and cap screws (B) securing
ACotter Pin CThrottle Lever quadrant. Remove quadrant (C), bracket (D) and collar
BLever Cap Screw (E).
Fig. 25-Bemoving Throttfe Control Lever
4. Disconnect speed control rod (A, Fig. 25), re-

move throttle control lever cap screw (B), and remove
throttle lever (C) out top of control lever guide.

; " j .
Repair 1 If replaced; place shift lever

shift iever or pivot is
s;?:?V.i?ssii:ii
:
.
assembly in a 5/32-inch (4 mm) cotter
a vise and slip
pin (A, Fig. 27) inside each spring to prevent damaging

Is^-iiJi^'Llv;":---.
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:
.

:;*:::\:sH5t"::::::
pin during removal.
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2. Withdraw spring pins (B) using a vise-grip pliers,
.;-
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.; ::
; -
:.:.%.
" ste =
.
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:
3. Drive 1 /4 by 1-1/2-inch (6 by 38 mm) spring pins
-.;:..: -; -. ;:- ;.: :::;:::*&::..:"";:.:;:
' tTt ::t;,:: :; ; . :;:;; -; ::;;;;: ;;;;!B:sjk :;*:;;:;:;;; into place with 7/16 inch (1 1 mm) protruding from each
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.:;;:*;:::;:::: :t :; -. :::;;;;;. :?; :::;;:;* ;;$!
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4. When installing spacer (A, Fig. 28), be sure

: * . :::-.-::- ::n '
: . ::
S-fc :

;: :
"i-r.IiigjglgiBi
;::?:;: :;:HE3E^:
shoulder faces lever.
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:
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::::::. '
:::;:;;::::: :.r:.:::tS
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S#S| shim washers (B) between
;:
^:i:; :i^^-;;::r::-;j ;; .i|l

5. Install shift lever pivot
:
lljpi^M^.
|prsiji:!S:s!;.-
inner arm spacer (A)and inner thrust washer (C) to
EpM#&J -.pfet^*~;
RPISîii*
:
>E; ::.:;:;::: .;:;:;;

provide 0.002 to 0.024 in. (0.05-0.61 mm) end play.
H*y :. ::. ;;':. :r
:
nStT :
ACotter Pin B Spring Pin

Fig. 27-Removing Shift Lever Spring Pins
R 29324N
ASpacer FLatch KShift Lever POuter Support (With
BShim Washer GSpring Pin LThrust Washers Sound-Gard Body or Roll Gard)
CThrust Washers HInner Support MSpring Pins QOuter Support (Less
DCap Screw I Bushings N Lever Pivot Sound-Gard Body or Roll-Gard)
ENut JSpeed Change Quadrant OSpeed Range Quadrant
Fig. 28-Shiher Control Assembly

.
Power Tram Repair Syncro-Range Transmission 50-10-15
Shifter Rod Adjustment
"
h I g :
REV"
"4-7
"TOW
"6-8 11
R29Z2 5&
A Upper (Range) Arm B Lower (Change) Arm
Fig. 29-Shift Selector Arm Detent Positions
Speed Range Shifter Rod Adjustment

1 Piace upper (range) shifter arm (A, Fig. 29) on
-
right-hand side of transmission case in the second

detented position down "N M (topmost position is not
detented).
A Speed Range Shifter Rod CSpeed Change Shifter
Piace
B Shift Lever Rod
2. shift lever (B, Fig. 30) in second and fifth
neutral position in quadrant. Fig. 30-Shift Quadrant and Rods
3. Adjust shifter rod yoke until yoke is in line with Speed Change Shifter Rod Adjustment
hole in arm (A, Fig. 29).
5. Piace lower (change) shifter arm (B, Fig. 29) on
right-hand side of transmission case in third detented
4. Install headed pin, cotter pin, and lock yoke jam
position down from topmost position of arm ("2-5")
nut.
6, Place shift lever (B, Fig. 30) in fifth-speed posi-

tion.
7. Adjust iower (speed change) shifter rod yoke until

hole inyoke is in line with hofe in arm.

nut.
I
TM-1181 ($ep-77) Litho in USA. Tractors - 4040 and 4240


Power Train Repair Creeper Transmission 50*15-1
Group 15
CREEPER TRANSMISSION
NOTE: See Group 10 of this Section for repair ..!'!'*<!!! "^vJrvv f/T."'''. mi- ...vi-.vi-'vl:!!;!!:!-
'.
information on the Creeper eight-speed,
CREEPER PLANETARY
'
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-71' :
Planetary Removal ...

m **& * /'
':
"'"'A '
:
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1. Separate dutch housing from engine. (See Sec-

tion 10, Group 20 for instructions.) :-^p^- :-:;-..T-:
-.|1
2. Remove three cap screws holding planetary to

operating bearing housing, and remove operating
bearing housing as instructed in Group 5 of this sec-
tion.
!'-;}>!,
".i,;vof-''
3. Removelower control rod from shifter shaft arm

on right-hand side of transmission case.
fe
*" ;:
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.
;
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:
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A Bearing Quill B Locking Plate
Fig. 2-Bearing QuiH and Locking Plate
8. Inspect transmission drive shaft front bearing

quill (A, Fig. 2) and locking plate (B).
Disassembly
1. Remove shifter collar from planetary output sun
gear shaft.
2. Remove snap ring retaining shifter collar plate

and remove plate from carrier,
3. Remove other snap ring and rear sun gear with

input shaft.
A Shrfter Shaft C Planetary

BClutch Shaft D Shifter Assembly 4. Remove planet pinion shafts and pinions with
roller assemblies from carrier.
Fig. 1-Removing Shifter and Planetary
5. Remove front sun pinion.
5. Pull control shaft out enough to remove shaft (A,
Fig, 1) from shifter support. 6. Drive spring pins out enough to remove spring-
loaded snubber backing plate.
6. Using dutch shaft (B) as a handle, pull planetary
(C) forward enough to remove shifter assembly (D) 7. Remove snubber disk, pressure plate, and six
from planetary. yellow springs from planetary.
7. Remove planetary from clutch housing.

I
TM-1181 (Jun~80) Litho in U.S.A. Tractors - 4040 and 4240

50-15-2 Creeper Transmission Power Train Repair
Repair Assembly
1 . Inspect snubber brake parts and replace as nec-
(
essary.
Part Thickness
Backing Plate 0.178-0.198 in. (4.53-5.03 mm)
Pressure PJate 0.050 in. (1.27 mm) minimum
Brake Disk 0.098-0.106 in. (2.49-2.69 mm)
Spring Free Length Working Load
1-1/16-in. (27 mm) 13/16 in. at 10.8-13.2 lbs.
(21 mm at 49-59 N)
2. Remove snap ring securing clutch shaft to plan-

etary and remove clutch shaft.
3. Inspect clutch shaft bushing for wear. ID of new

bushing is 0.937 in. (23.8 mm). Press new bushing to
0.040 In. (1.02 mm) below end of shaft.
4. Inspect sun gear bushings. New bushing ID is
1.328 mm). Press new bushing 0.55 in. (13.9

in. (32.4
mm) below end of pinion, and bushing at splined end Ftg. 3~Clutch Shaft and Carrier
0.37 in. (9.4 mm) from end of pinion.

1 . Insert clutch shaft into planetary carrier and in-
stall snap ring on shaft.
2 216^3 W
1 Transmission Input Shaft 11Front Sun Gear 21 Needle Bearings (G used)

2 Snap Ring 12 BackingPlate 22 Ball (3 used)
3Thrust Washer 13Snubber Brake Disk 23Pinion Shaft (3 used)
4 Locking Plate 14 Pressure Plate 24Thrust Washer
5 Shifter Collar 15Spring (6 used) 25 Bushing
6 Shifter Yoke 16Thrust Washer 26Hex. Bushing
7Snap Ring 17 Snap Ring 27Clutch Shaft
8 Carrier Locking Plate 1SCarrier 28 Rolled Spring Pin (3 used)
9 Bushing 19 Snap Ring 29 Planet Pinion (3 used)
10 Rear Sun Gear and Shaft 20Thrust Washer (6 used}.
(
Fig. 4-Creeper Gear Parts
TM-1181 (Jun-80) Who in USA. Tractors - 4040 and 4240

&
Power Train Repair Creeper Transmission 50-15-3
2. Install thrust washer on end of shaft and place

springs in holes in carrier (A, Fig. 5).
>
3. Place pressure plate (B) (tangs outward), brake
disk (C), then retaining plate (D) on springs.
4. Place carrier and parts on a press (A, Fig. 6) with

a pipe (B) large enough to fit over retaining plate.
5. Compress assembly until spring pins (C) in car-

rier can be installed to hold retaining plate.
6. Drive spring pins in until approximately 7/32 in.
(5.5 mm) protrudes inside carrier.
7. Remove from press and install hex. bushing in

A Spring C Brake Disk clutch shaft.
B Pressure Plate D Backing Plate
Fig. 5-Snubber Brake Assembly NOTE: On Creeper transmissions, no bushing is
used in front of the transmission drive shaft.
?^53A-
' , ..'1 A :^=ofi , VJ,.;iM "-;-.- wV-> *:;= :
';;;.- ., :&f - * 3 1 'fflSs^Wy-
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Fig. 7-lnstailing Front Sun Gear
8. Install front sun gear on snubber brake.
A Press B Pipe C Pin Driven Into Groove
Fig. 6-lnstalfing Spring Pins
TM-1181 (Jun-BO) Litho in U.S.A. Tractors <-

4040 and 4240
. .
Assembly Continued 1 0. Install snap ring (B, Fig. 9) on transmission input

shaft and install shaft in front sun gear.
(
1 1 Install rear sun gear (A) over transmission input
shaft and install one snap ring in lower snap ring
groove in carrier.
&&&&?&
Fig. 8-Timing Planetary
9. Install planet pinions in carrier aligning timing

marks with marks on front sun gear.
;^ ^^*^'t^:'. \^
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AShifter Collar Plate BSnap Ring
Fig. 10-lnstaiiing Shifter Cottar Ptate
12. Place shifter collar plate (A, Fig. 10) in carrier

and install remaining snap ring (B).
13. Install shifter collar on rear sun gear splines.
Installation
1 Place transmission input shaft end of planetary in

clutch housing tilting it enough Creeper gear to allow
shifter to be installed. Install with shaft on shifter yoke
in rear detent position
2. Using clutch shaft as a handle, install planetary in
transmission quill and drive shaft.
3. Move shifter shaft forward to front detent posi-

tion.
AOutput Sun Gear BSnap Ring
i
Fig. 9-lnstalIing Output Sun Gear

.
4. Push hex. shifter shaft in until shaft is installed in

hole in shifter support. Shifter shaft arm should be
slightly to the left of bottom center when installed.
5. Torque shifter shaft retainer cap screw to 20

6. Install clutch operating bearing housing as in-

structed in Group 5 of this section.
7. Secure planetary to operating housing with three

cap screws.
8. Join tractor (See Section 10, Group 20.)
SHIFTER LEVER
Removal
NOTE: To remove shift lever the console must be

disassembled.
1 Loosen the three cap screws under right wheel

fender
2. Remove six cap screws holding sheet metal

around console guide.
AQuadrant D Bracket
3. Remove load control selector lever knob and BHeaded Pins ECollar
console cover. CCap Screws
Fig. 12-Quadrant and Control Lever
5. Remove cotter pins and headed pins (B, Fig. 12)

from shifter control rods and cap screws (C) securing
quadrant. Remove quadrant (A), bracket (D) and collar
<E).
ACotter Pin CThrottle Lever

BLever Cap Screw
Fig. 1 1-Removing Throttle Control Lever
4. Disconnect speed control rod (A, Fig. 11), re-

move throttJe control lever cap screw (B) s and remove
throttle lever (C) out top of control lever guide.

Repair 1. If shift lever or pivot is replaced; place shift lever

assembly ina vise and slip a 5/32-inch (4 mm) cotter
pin (A, Fig. 13) inside each spring to prevent damaging
pin during removal.
2. Withdraw spring pins (B) using a vise-grip pliers.
3. Drive 1 /4 by 1-1 /2-inch (6 by 38 mm) spring pins

into place with 7/1 6 inch (1 1 mm) protruding from each
side.
ACotter Pin BSpring Pin
Fig, 13-Removing Shift Lever Spring Pins
R 29331N
ASpacer GSpring Pin MChange Quadrant R Range Quadrant
BThrust Washer (2 used) H Spring Cap NThrust Washer (2 used) S Outer Support (With
CQuadrant Latch I Pawl Spring 0Shift Lever Sound-Gard or Roll-Card)
DSpring Pin J Interlock Pawl PSpring Pin (2 used) T Outer Support (Less
E Inner Support KShim Washer Q Lever Pivot Sound-Gard or RoU-Gard)
F Creeper Lever L Bushing (2 used)
Fig. 14-Shifter Control Assembly

Shifter Rod Adjustment
"LOW
"HIP
"REV"
R2 9Z2 5H
AUpper (Range) Arm B^Lower (Change) Arm
Ftg. 15-Shift Selector Arm Detent Positions
Speed Range Shifter Rod Adjustment

1. Place upper (range) arm (A, Fig. 15) on right-
hand side of transmission case in the second detented
AChange Shifter Rod DCreeper Lever
BShHt Lever EInterlock Pawl
position down "NT (topmost position is not detented). C Range Shifter Rod
Place Fig. IB-Creeper Shift Quadrant and Rods
2. shift lever (B, Fig. 16) in second and fifth
neutral position in quadrant.

Speed Change Shifter Rod Adjustment
3. Adjust shifter rod yoke until yoke is in line with 5. Place lower (change) shifter arm (B, Fig. 15) on
hole in arm (A, Fig. 15). right-hand side of transmission case in third detented
position down from topmost position of arm ("2-5").
nut 6. Place shift lever (B, Fig. 16) in fifth-speed posi-
tion.
7. Adjust lower (speed change) shifter rod yoke until

hole in yoke is in line with hole in arm.

nut.
TM-1181 (Feb-79) Litho in US. A Tractors - 4040 and 4240

.
Adjustment Continued
Creeper Control Adjustment
9. Place gear shift lever in fourth gear position and

rotate Creeper control lever (D, Fig. 16) untilit stops on
interlock pawl (E).
A Adjusting Yoke CShifter Arm

BBelfcrank
Fig. 17-Adjusting Lower Shift Linkage
10. Shift Creeper control arm (C, Fig. 17) and shaft
to its forward position (lower control rod should be
located in inner hole).
1 1 Adjust yoke (A) to align with bellcrank holes (B)

and install headed pin, cotter pin, and lock yoke jam
nut
TM-1181 (Feb-79) Utho in U.S.A. Tractors - 404O and 4240

.
Power Train Repair Quad-Range Transmission 50-20*1
Group 20
REMOVAL
Remove Oil Pressure Regulating
Valve Housing
AClutch Operating Assembly D PTO Brake

B2-Speed Planetary E Lube
C PTO Drive Gear FClutch
G PTO Clutch
Fig. 2-Operating Adapters
A PTO Operating Rod
D To Main Pump
BClutch Operating Rod ESteering Pump Return Remove Clutch Operating Assembly

C Regulating Valve Hose
Housing F Retainer
Fig, 1 -Pressure Regulating Valve Removal
(Battery Box Removed)
1 Remove oil lines and operating rods (Fig. 1) from

2. Remove screws and pulf housing out of the

clutch operating assembly.
3. Pull the four adapters from the operating assem-

bly, also the planetary adapter (B, Fig. 2).
Fig. 3-Removing Hex Drive Shaft
1 . Before separating the tractor, remove plug at the

rear of the transmission case to pull the hex. drive shaft
which extends from the crankshaft through the trans-
mission. (This prevents shaft damage during disas-
sembly and assembly.)
TM-1181 (Sep-77) Lithe in U.S.A. Tractors - 4040 and 4240
50-20-2 Quad-Range Transmission Power Train Repair
Operating Assembly Removal Removing 2-Speed Planetary Assembly

Continued
IMPORTANT; Outer arm on control valve oper-
ating shaft must be installed to point upward. Note
position of arm prior to removing planetary link-
age. Arm shaft can be installed incorrectly by 180.
" ^sB^-jLC "

jm 1
A Housing Cap Screws CPlanetary Cap Screws

&Operating Housing DTransmission dutch
Shaft
Fig. 4-Cfutch Housing Front View A Arm Shaft DPacking F PTO Drive Gear
BInner Arm E Input Shaft and Oil Shield
CPacking G2-Speed Planetary
2. Separate the engine from the dutch housing as
instructed in Section 10. Fig 5-2-Speed Planetary (in
r dutch Housing)
3. Remove the six outer cap screws (A, Fig. 4) that Remove hex. bushing from planetary unit
1. did if it
hold the operating assembly (B) in place. not come out with clutch shaft. Also remove packings
(C and D Fig. 5).
f
4. Remove five inner cap screws (C) that retain

2-speed power shift planetary unit- NOTE: The planetary can be removed from the
clutch housing without removing PTO drive gear (F).
s' Remove the clutch operating assembly.
2. Align splines on O.D. of input shaft (E) with inner
6. Remove transmission clutch shaft (D) from the splines of front sun gear.
rear of the operating assembly.

Power Train Repair Quad-Range Transmission 50-20-3
Fig. 6-Removmg Transmission input Shaft and Spring Pin Fig. 7~Removing 2-Speed Planetary
3. Insert too! through input shaft and hook end of 6. Using clutch shaft as a handle, pull out on plan-
toolover rear of input shaft. Instructions on making etary unit and turn slightly to remove over PTO gear
removal tool are given on Page 00-16 under Special and shield-
Tools in this Section.
4. While pushing slightly up and on planetary

to rear
unit, pull input shaft out through front sun gear splines.
5. Drive control valve operatingarm shaft spring pin

up until shaft can be removed from clutch housing.

A Transmission Drive Shaft B Countershaft
C Differential Drive Shaft
Fig, 8-Cfutch Housing, Planetary Removed

.
50-20*4 Quad-Range Transmission Power Train Repair
2-Speed Planetary Disassembly
Fig. 9-2-Speed Planetary Unit A Retaining Balls BRear Sun C Planet Pinion
Fig. 11 -Planet Pinion Disassembly

1 Place planetary unit on a bench, brake housing
down. 4. To remove planet pinion and sun gear from car-
rier, push planet pinion shafts out with retaining balls
2. Remove six cap screws holding planet pinion (A, Fig. 11) and remove sun pinion and planet pinions
carrier to clutch drum. (C).
A Clutch Drum CPlanet Pinion

B Front Sun Pinion with Huh
Fig. 10-Planetary and Hi-Low Pack
3. Lift carrier off dowel pins in clutch drum.

Fig. 12-Brake Housing (Backing Plate Removed)
5. Remove six backing plate cap screws and re-

move plate from brake housing.
6. Remove brake separator plates and disks, and
six piston return springs. (
7. Remove clutch shaft gear with hub.
8. Remove clutch plates and disks from drum.
TM-1181 (Sep-77) Litho in U.S. A. Tractors - 4040 and 4240

.
dX - iU ;
;;
A Clutch Drum BSealing fling
Fig. 15-Ciutch Drum Assembly
11. Remove clutch piston which is located on a
dowel in the drum (A, Fig. 15) and has a metal sealing
ring (B) on its O.D,
Control and Shift Valve Disassembly

ASpring Washers B-ÎOT-24 C Snap Ring
Fig. 13-Removing Spring Washers
9. Compress spring washers (A) on drum using

JDT-24 compression tool (B), remove snap ring (C)
and remove tool and spring washers.
A Control Valve Detent and Spring B Shift Valve Detent
Fig. 16-Control and Shift Vaive Assembly
R%?Snz "
1 "";";" " '
../
" *
1 Turn control valve 90 so flat side of outer end of

APackings B Clutch and Brake Drum and Housing valve faces up. Remove vatve. Detent still drags on
vafve so valve may pull hard.
Fig. 14-Brake Housing Assembly and dutch Drum
2. Remove clamp and oil pipe from housing. Control
valve detent and spring (A, Fig. 16) will be in pipe and
10. Remove
brake piston from housing. There is
in detent bore.
packing (A, Fig. 14) on O.D. and I.D.
3. Remove plug, shift valve detent spring, and ball.
4. Drive spring pin from flat side of housing to

remove shift valve plug, and shift valve (B).
7M-1181 (Sep-77) L'ttho in U.S.A. Tractors - 4040 and 4240

' ;
CONTROL AND SHIFT VALVE 6. Torque special screw (K) to 21 ft-lbs (28 Nm) (2.8
kgm).
Repair and Assembly
7. Install control valve detent spring (F) in top oil
tube hole, then detent pin (G).
8. Inspect control valve (E). Valve O.D. is 0.4977-

0.4987 in. (12.64-12.67 mm). ID. of valve bore is
0.4995-0.5005 rn. (12.69-12.71 mm).
9. While holding control valve detent pin in against

lP^Ssfllii|:'1i the spring (F) T install control valve with flats on valve
diameter (E) rotated to face detent pin (G). Push valve
in until the outer land bottom against detent.
\& [:
: _
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:
:: :; : : :. Jgl'JU^ .i^J :
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10. install oil tube with clamp. Torque clamp cap
screw to 35 ft-lbs (47 Nm) (4.7 kgm).
Brake and Clutch Assembly
:i;îii :t
: " ;!
Hifchii*J:vii:!J!
r : : :
: : ;;t :;r : :
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:! ; :\\ :
.fry . .;_... . ::
A Spring HOil Tube |i:Hl

i:;
Pin l- --l! llil :
. *!
BValve Plug I Tube Retaining Screw iiH^ jt-i^jH
:: !t :;
:;:-:^s||^^P: wnKomn&
gp. .*:.
B||js".:'
. .:. .:
;La.|T!
C Shift Valve J Clamp Spacer
iSlipili: :;;:
D Spring Pin K Detent Screw nj&fl^Mrxr~ ^ÊiBM 7:
I|Hf jjH
Driving Hofe LDetent Spring Be-
E Control Valve Flats MDetent Ball :
;
:
:!
ii- ; ;::;:;;:E
fifel
.;..;.
Hlx! Sf1P" :
F Detent Spring N Detent Bore MsdAytssu

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"0j|
^^t:::fe:K'
G Detent Pin
1.
Fig, 17-Controi
Inspect shift valve (C, Fig, 17). Valve O.D.

and Shift Valve Assembly
is
sM|
r
/
rpr*Jftj/flHiter555
r
"
E ^
Êj|R
- .dEL
Kiitiriiiiiiiiiii'
J::-i:ii:i ii;=:: ;:
: --
0.4977-0.4987 in. (12.64-12.67 mm). I.D. of valve bore

!:;:&
!
:
=="
pllP
;=
lis*!' =
n E= i
^^^Sn Hyy $\'\ |ipp|, ,;" :
is 0.4995-0.5005 in. (12.69-12.71 mm). :::::::|feÊFnn::
J|^K Î^Êlff^--:
~ :
;-ss::::::!"": i:";:;^:.i::T::^::i::H:=;iT;;
::
i .;;
2. Install the shift valve in the housing with its
countersunk end in. i::i:::J::i:::i':::::::i^:i::

:
'"':.'"
.i&?
w* UV.ltlV.i".
NOTE: Coat all parts with John Deere Hy-Gard A Brake Piston CJDT-21-2 Protector
Transmission and Hydraulic Oil.

BJDT-21-1 Protector D Piston Housing
3. Install shift valve plug (B) aligning hole in plug Fig, 18-lnstailing Brake Piston and Packings
with hole in housing (D). Install spring pin (A) through

hole (D) and drive into housing until flush with opposite 1. Inspect brake piston. I.D. is 6.498-6.502 in.
side of housing, (164.6-165.6 mm). O.D. is 7.475-7.485 in. (189.9-

190.1 mm).
4. Inspect detent springs:
2. Replace packings on I.D. and O.D. of piston.
SPRING FREE LENGTH WORKING LOAD Coat packings, piston, and housing mating surface
Shift Valve 1-7/e in. 0.9 in. at 1.6-2.0 lbs. with John Deere Hy-Gard Transmission and Hydraulic
(Key L) (47 mm) (23 mm at 7-9 N)
Oil,
Control Valve 1-5/16 in. 1-1/16 in. at 15-19 lbs

3. Install piston (A, Fig. 18) with packings using
{Key F) (33 mm) (27 mm at 69^84 N) JDT-21-1 and JDT-21-2 Tools to protect packings.
5. Install shift valve detent ball (M), spring (L), and 4. Inspect bushing in front of clutch drum. I.D. is
special screw (K) in hole (N) (third hole from bottom). 2.255-2.258 in. (57.28-57.35 mm). Install new bushing
using 2-1/4 in. (56 mm) pilot disk and 2-3/8 in. (60
mm) driver disk (OTC No. 27519 and 27521).

,
NOTE: Spring washers should have some load on

them withsnap ring installed. Minimum free height of a
spring washer is 0. 126 in. (3.2 mm).
9. Install clutch piston return spring washers (A, Fig.
20) using JDT-24 Tool (B) to compress them enough to

install snap ring (C). Assemble springs alternately with
convex side of first spring facing piston.

10. Install thrust washer in brake housing on clutch
drum surface and install drum in housing.
ft zmm,
ASealing Ring DInner Piston Packing
BClutch Piston E Snap Ring
CClutch Drum F Spring Washers (8 used)
Fig. 19-Cfutch Drum Assembly
5. Replace clutch piston inner packing (D, Fig. 19)

and coat all mating surfaces with Hy-Gard Oil.
6. Inspect piston (B). LD. is 2,249-2.251 in.
(57.129-57.175 mm) O.D. is 4.475-4.485 in. (113.66-
113,92 mm).
7. rings on front of drum and re-
Examine sealing
place as necessary. Thrust washer thickness is
0.056-0.068 in. (1.4-1.7 mm).
8. Install piston (B) with sealing ring (A) in drum. AClutch Plates CClutch Drum E Brake Return Springs
B Brake Plates DInput Sun FSeparator Plate
Fig. 21 -Clutch and Brake Assembly
11. Inspect disks, plates, and brake return springs.
Clutch Disks Thickness

3 used 0.071-0.075 in. (1.8-1.9 mm) - New
0.057 in. (1.45 mm) - Minimum
Clutch Separator Plates

4 used 0.055-0.065 in. (1.4-1.7 mm)
Brake Disks Thickness
2 used 0.067-0-093 in. (2.2-2.4 mm)
0.070 in. (1.78 mm) Minimum
Brake Separator Plates
3 used 0.065-0.095 in. (2.2-2.4 mm)
Brake Backing Plate 0.229 in. (5.82 mm)
BRAKE RETURN
SPRINGS Free Length Working Load
6 used 0.71 in. (18 mm) 0.52 in. at 24-30 lbs.
(13 mm at 110-133 N)
12. Install dutch plates (A, Fig. 21) and disks alter-
nately over clutch hub.
13. Assemble first brake separator plate (F) over
A^-Spring Washers B-^JDT-24 O-Snap Ring guide pins.
14. Assemble remaining disks and separator plates
Fig 20-lnstaIfing Spring Washers brake housing slots (not over guide
r
so tangs are in
pins).

50-20-fi Quad-Range Planetary Power Train Repair
PLANETARY
Repair and Assembly Continued
-?Jfi~-a??*"
A Planet Carrier C Brake Backing Plate

BThrust Washer DCap Screws (6 used)
Fig. 23-lnstallmg Planetary (4640 Shown)
4. Install brake backing plate (C, Fig. 23) and torque

cap screws (D) to 21 ft-ibs (28 Nm) (2.8 kgm).
Hold planet pinion shafts in place while placing

5.
planetary on brake housing and install thrust washer
A Thrust Washers C Planet Pinions EShaft and Ball (B) on carrier.
BPinion Carrier DSpacer FNeedle Bearings
Fig. 22-Pianetary Assembly
NOTE: Coat aft friction parts with hydraulic oil to
ease instaiiation and to prevent wear
1, Inspect carrier bushings. New bushing ID is
1.379 (35.05 mm). Drive using 1-7/16 in. (36.6 mm)

in.
driver disk and 1 -3/8 in. (34.9 mm) pilot disk (OTC No.
27508 and 27505). Drive flush on bottom, and drive top
bushing to dished out area 0.378 in. (9.6 mm) deep.
2, Place sun pinion in center of planet pinion carrier

<B).
3, Install pinion bearings (F Fig. 22)

a
in pinions (C)
and place pinions in carrier with pinion thrust washers
(A), shaft and retaining balls (E).
Fig. 24-Gamer-to-Drum Cap Screws

IMPORTANT: Be sure to align V marks on plan*
etary pinions with retaining ball grooves on carrier.
6. Torque planet carrier-to-clutch drum cap screws
to 20 ft-lbs (27 Nm) (2.7 kgm).

j^î^rv:^^^^^^^^ *
-' "''' J
ATesting Clutch BTesting Brake

R 23709N
Fig. 25-Air Testing Planetary Clutch and Brake
A Bell Crank C Control Valve Outer D Attenuator

7. Test assembled planetary unit using 50 psi (3.5 B Rod and Yoke Operating Arm
2
bar) (3.5 kg/cm ) air pressure at the pressure pas-
sages. The corresponding pack should respond with Fig, 26-lnstalting Control Valve Outer Operating Arm Shaft
the control valve shifted as shown in Fig. 25.
2. Install control valve operating arm shaft into
Installation dutch housing from outside of housing.
1 . Reverse the steps of Removal (on pages 1-3) to

IMPORTANT: Arm (C, Fig. 26)on outer portion
install the 2-speed planetary unit.
of rodmust point up on clutch housing.
3. Torque dutch operating piston housing-to-plan-

etary brake piston housing cap screws to 20 ft-lbs (27
Nm) (2.7 kgm).

RANGE AND SPEED SELECTOR ASSEMBLY

Removal
1. Loosen three hex screws under right fender and
remove six cap screws retaining quadrant cover.
2. Remove load control selector knob and remove

console cover.
NOTE: Do not disturb shift lever guide plate unless

necessary.
Fig, 28-Shift Removed
8. Remove three cap screws that fasten outer sup-

port to mounting structure. One of these screws is
accessible through a rubber plug in fender wall.
9. Remove shift lever knobs and position levers

close together to remove shifter assembly out through
console guide bottom.
El -.
tt?;??.'.""".:
I '' " Sk^f;

KllM: IPlll^S$f [
|P :
Fig. 27-Removing Shift Rods From Selector Assembly
3. Disconnect control rod from throttle control lever

and remove cap screw, spring and retainer from outer
shifter support shaft.
4. Pull throttle control lever up and out of plastic

guide.
5. Disconnect the two -speed planetary control rod

from bellcrank.
6. Disconnect range shifter rod from its lever arm.
7. Disconnect speed selector rod from its lever arm.

.
SELECTOR ASSEMBLYContinued
Disassembly and Repair
:jjp:i-|- ^ksa I
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"^^^Kk
R$S4$!f riSirjfeffiTSi
Fig, 29~Shrft Lever Disassembly
1 Back out the two inner guide plate cap screws far Fig, 31 -Removing Range Arm
enough to allow inner support to be removed.
5. Disconnect lock-out latch rod from range selector
2. Remove lower bolts and remove inner support. arm.
6. Remove cotter pin and pivot pin with spring.
7. Pull lever up and remove arm,
8. If range selector arm bushing is replaced, center

it in its bore.
9. Inspect speed selector arm bushing. Center new

bushing in arm bore.
R2894?S
Fig, 30-Removing Speed Shifter Arm
3. To remove inner (speed selector) lever shifter
arm, spring, or bushing in shifter arm; remove cotter

pin from pivot pin and remove pivot pin.
> 4. Pull lever up to separate from arm, pull arm off

shaft and remove inner spring.

Repair and Assembly
Hg. 34-tnstatlmg Lock-Out Latch Rod
5. Attach lock-out latch rod to range selector arm.
Fig. 32-Lock-Out Latch Assembly
1. Assemble lock-out latch with bushing and install
on outer support.
2. Install a thrust washer over outer support shaft

before outer (range selector) arm.
Fig, 35-tnstaifing Speed Selector Lever
6. Assemble speed selector lever to its arm and

install pivot pin with spring and retaining ring.
7. Install speed selector assembly lever through

control lever guide and over support shaft.
8. Installthrust washer, shim and outer spacer

(larger O.D. inward).
Fig. 33-Range Selector Lever
9. Install inner support, two inner support-to-outer

3. Assemble range selector lever to arm with pivot
support bolts at bottom, and install inner support-to-
pin, facing, and spring. Install range selector lever and
lever guide cap screws.
arm.
4. Install second thrust washer over support shaft.

.
SELECTOR ASSEMBLYContinued
Installation and Adjustment
Q.10 IN.
(2.5 mm)
A Range Arm r>-Shrft Arm Shafts

S17M1
B Speed Selector Arm D--Outer Planetary Control
Arm
ASpacer C Range Selector
B Speed Selector D Latch Rod Yoke Fig. 37-SNfter Arm Shafts
Fig. 36-Adjusting Lock-out Latch Clearance
Mount a dial indicator on inner bracket and check

1
for0.002 to .020 inch (0.05-0.50 mm) end play. Check

on end of spacer (A, Fig. 36) while moving levers.
2. If end play is not correct, adjust with shims be-

tween spacer (A) and inner lever arm thrust washer.
3. Place speed (inner) selector lever (B) in position

1 or 2 and place range (outer) selector (C) in A-range
position against the rear stop.
4. Adjust lock-out latch rod yoke (D) until there is

0.10 in. (2.5 mm) clearance between inner edge of
lower tab on latch and outer radius of flange on speed
selector lever arm. Pin should slip into yoke freely.
Install cotter pin.
5. Adjust shifter shaft end play at side of transmis-

sion case (Fig. 37) to 0.002-0,007 inch (0.05-0.18
mm).
A Range Shifter Rod C Planetary Control Rod

BThrottle Rod DSpeed Selector Rod
Fig. 38-Console Control Rods
6. install control rods (Fig, 38). Be sure boots are in

place.

.
Adjustment Continued 12. Also adjust lever guide plate outer edge is flush
with outer edge of plastic lever guide. Tighten guide
plate retaining cap screws.
"3-V
''^V
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N -^.
-
/^^"^
N_
I- 2
-\u;
'?>
IR -2R
1
'vO>
R 28151N
ASpeed Change Selector Ami B Speed Range Selector Arm

Fig, 40-Shift Selector Arm Detent Positions
A Speed Selector Lever ESpeed Rod
BRange Selector Lever F Planetary Control Rod Speed Change Rod
CThrottle Lever G Range Rod
OThrottle Rod HClothes Pin 13. Place upper arm on side of transmission case
(A, Fig. 40) in "1-2" speed detent.
Fig. 39Adjusting Speed Selector Rod Yoke
14. Connect speed selector rod (E, Fig. 39) as

7. Install shifter assembly through lever console
shown.
guide in tractor and install lever knobs.
8. Tighten three support cap screws that fasten 15. Adjust yoke at lower end of speed selector rod
outer support to mounting structure. Note that one so it aligns with speed selector arm (A, Fig. 40) and so
screw is installed through fender waff pfug. inner shift fever is centered front-to-rear in the "1-2"
position on the lever guide plate,
9. Connect 2-speed planetary operating rod (F, Fig.
39).
16. install yoke on arm and tighten yoke jam nut.
NOTE: If has not been disturbed
lever guide plate Remove clothes pin.
and does not require adjustment, proceed to step 13.
Guide Plate Adjustment

10. Center lower tab on lock-out iatch in notch in
outer radius of speed selector lever arm. Use a
spring-type dothes pin to hold tab in center (H).
1 1 Adjust guide plate so inner lever (B) is centered

between "1-2" slot and "3-4" slot in plate.

.
Speed Range Rod

17. Place lower (range) arm (B, Fig. 40) in "B"
detent.
18. Adjust yoke at lower end of range selector rod

so it aligns with range arm (B) and so outer (range)
shift lever is centered front-to-rear in the "B" position
on the lever guide plate.
19. Install yoke on arm and tighten yoke jam nut.
Final Adjustments
1 Install throttle lever with friction plates, spring and
guide.
2. Tighten throttle lever spring screw so an eight lb.
(3.5 kg) (0.35 N) pull is required to move the lever. Be

sure anchor pin in inner support passes through friction
plate tangs. R 2B709N
3. Place inner (speed) selector in "2" position so it A Planetary Bell Crank CControl Valve
is contacting the guide plate. B Rod and Yoke Outer Arm
DAttenuator
Fig, 41-2Speed Planetary Lower Control Linkage
4. Position the upper control valve operating rod

boot so it does not pull down on rod.
5. Rotate control valve operating shaft arm (C, Fig.

41) to its rear detent and forward one detent
6. Adjust rod yoke (B) until hole aligns with the

lower bellcrank hole. Turn yoke one turn to lengthen
the rod.
7. Lock the yoke jam nut and install cotter pin.
8. Tighten the three control guide to fender cap

screws and console cover.
install
9. Check to see that the control lever guide aligns

with shift guide plate. The speed selector should not
contact the plastic lever guide.
10. Check for proper shifting. If all speeds (one

through four) cannot be obtained, lengthen rod one
more turn and repeat steps 7-10.

50-20-1 6 Quad-Range Transm ission Power Train Repair
TM-1181 (Feb-78) LHho in US. A Tractors - 4040 and 4240

.
Power Train Repair Power Shift Transmission 50-25-1
Group 25
TORSIONAL DAMPER Repair
Removal and Disassembly 1 If the pressure plate is worn at the drive pin holes,
or if its surface is not true within 0.006 in. (0.15 mm), or
1. Separate the clutch housing from the engine as is scored or grooved; replace the plate.
instructed in Section 10, Group 20. 2. Inspect springs. They should be free of rust,
pitting or distortion.
Free Length Working Load
9 used (4040) 2.1 in. 1.6 in. at 198-242 lbs.

12 used (4240) (53 mm) (40.5 mm at 880-1079 N)
AInner Springs B Jack Screws

Fig. 1-Torsional Damper with Jack Screws Installed
(4240 Shown)
2. Remove three alternately spaced cap screws

nearest spring retainers.
3. Install jack screws with nuts (B, Fig. 1) in cap
screw holes and tighten nuts against pressure plate. ADrive Surface BPin CPilot Bearing
IMPORTANT: Do not install jack screws in cap
Fig. 2-Flywheet and Pilot Bearing
screw holes between spring retainers. Cover plate
could warp if uneven pressure is applied to cover
3. Inspect flywheel friction driving surface (A, Fig. 2).
plate.
If it is out of true more than 0.006 inch (0.15 mm),
4. Remove remaining three cap screws and loosen
scored or grooved, replace it.
nuts on jack screws to relieve spring pressure.
IMPORTANT: Clutch assembly parts are loose
4. Check pilot bearing (C). New bearing is a sealed
when cover plate is removed. Do not let pressure
bearing and requires no lubrication. Drive new bearing
plate or clutch disk drop on floor.
into flywheel using OTC driver No. 27488 with 1-9/16
in. (39.7 mm) driver and 5/8 in. (15.9 mm) pilot disk
(OTC No. 27508 and 27493).

50-25-2 Power Shift Transmission Power Train Repair
Torsional Damper Continued 1. With flywheel mounted on engine crankshaft,

place disk (A, Fig. 4) in flywheel with short side of hub
out.
2. Install damper disk aligning tool JDE-52A with

JDE-52-3 adapter (B).
3. With disk aligning tool in place, install the pres-

sure plate assembly using the jack screws with lock-
nuts.
4. Install the three alternately spaced cap screws

and torque to 35 ft-lbs (47 Nm) (4.7 kgm).
5. Remove jack screws and install remaining cap

screws.
CLUTCH PACK
Removal
1 . Separate clutch housing from engine as instruct-
AStraightedge C Pin ed in Section 10, Group 20,
BCaliper DCover Mounting Surface
Fig. 3-Measurfng Flywheel Pin Projection
5. If pins (C, Fig. 3) are replaced, Install new pins so

they project 0.43 in. (11 mm) above clutch cover
mounting surface on flywheel.
6. If flywheel was removed, torque flywheel-to-
crankshaft cap screws to 85 ft-lbs (115 Nm) (11.5
kgm).
Installation
Fig, 5-Cfutch Pack Housing Cap Screws
2. Remove clutch pack-to-ciutch housing cap

screws and remove clutch pack from housing.
ADamper Disk BJDE-52-3 Aligning Tool Adapter

(
Fig. 4-Disk Aligning Tool

Disassembly
1. Remove C1-C2 shafts from rear of pack if they
did not remain in planetary.
A Snap Ring B Retaining Ring
Fig. 7-Removing Clutch Shaft from Pump
7. To remove clutch shaft from transmission pump,

ADutch Shaft F PTO Plates
BPump Housing remove second snap ring (A, Fig. 7) at pump.
OC1-C2 Separator
C-ManHold Plate
DCI Plates HBacking Plate 8. Remove clutch shaft and bearing from housing.
EC2 Plates [Hub
fig. 6-Clutch Pack and Transmission Pump (4240 Shown)
2. Place clutch pack on bench or in a fixture with

front (clutch shaft) (A, Fig. 6) down.
3. Remove backing plate (H), PTO plates (F), disks,

and hub (f).
4. Remove C2-PTO clutch drum, C2 clutch plates

(F), and disks.
5. Remove C1-C2 separator plate (G), C1 disks,

plates (D) and hub.
6. Remove snap ring from end of clutch shaft and lift
C1 drum from clutch drive shaft and transmission

pump assembly.

TRANSMISSION PUMP
Fig. 9-lnstalisng Oil Seat
4. Install oil seal (A, Fig. 10}in pump body using

JDT-33 driver for4240 or disk Nos. 27501 (1-1/8 in.),
27503 (1-1/4 in.) and 27515 (2 In.) for 4040 Tractor.
A PTO BLube O-CI DC2 EInlet F Outlet

Rg. 8-Transmission Oil Pump Passages
NOTE: Figure 8 shows the transmission pump oil

passages. Use as a reference when checking dutch oil
flow problems, incorrect duai engagement could indi-
cate leakage at pump housing gasket.
1. Inspect transmission pump noting any blocked or
otherwise damaged passages that could indicate

cause of hydraulic malfunction.
2. Remove six manifoid-to-pump housing cap

screws and carefully remove oil pump manifold from
pump housing.
AOil Seal C Spur Gear
3. Remove special screw retaining pump body to B Internal Gear Packing
housing and inspect pump parts. (See specifications in
Fig. 10-Pump Body Assembly
Section 70.)
5. install outer gear (B), and inner gear (C), with

NOTE: Coat mating parts with John Deere Hy-Gard
chamfers down.
Transmission and Hydraulic Oil to prevent unneces-
sary wear and to ease assembly.
6. Install packing (D) over pump body and place
pump housing over pump body aligning hole in housing
with hole in body crescent.
7. Install housing-to-body cap screw to 20 ft-lbs (27

Nm) (2.7 kgm) torque, and install gasket to be sure it is
correct. Remove gasket.
To complete pump repair, proceed to step 7, on

page 50-25-6.

CLUTCH PACK
Assembly and Repair
H 22619N
1Gasket 9 Bushing (4240 only) 17Pump Body with Bushing

2Seating Ring (4 used) 10 Pump Housing 18Snap Ring
3 Special Cap Screw 11Cap Screw (2 used) 19Ball Bearing
4Ball (2 used) 12Cap Screw (8 used) 20 Retaining Ring
5Bushing (4240 onfy) 13 Pump Drive Gear 21Thrust Washer
6Clutch Oil Manifold 14Pump Internal Gear 22 Bushing
7Gasket 15 Packing 23Clutch Drive Shaft
8Cap Screw 16Oil Seal
Fig. 1 1 -Clutch Oif Pump and Manifold (4240 Shown)
NOTE: 4040 Tractor uses two sealing rings (not

shown) at dutch drive shaft rather than bushings (5
and 9, Fig. 1 1).
1. To replace dutch shaft bearing (19, Fig.
11) t
remove snap ring retaining bearing on shaft and press

bearing from shaft.
2. If thrust washer (21) is replaced, be sure the
bevel on the I.D. of the washer istoward the large end
of the clutch shaft.
3. Press new bearing on shaft until it bottoms and
replace snap ring (18).
4. If replacing bushing (22) in end of clutch shaft,
use OTC driver No. 27487.
a) On 4040 Tractor, use disk No, 27497 (7/8 in.)
and 27498 (15/16 in.).
b) On 4240 Tractor, use disk No. 27499 (1 in.)

and 27501 (1-1/8 in.).
Install until bushing is flush with recessed end of

shaft,
Fig. 12-Ciutch Shaft Snap Ring
5. Install clutch shaft in oil pump manifold (6), and
replace retaining ring (20) that holds shaft in place. (Be
6. Install snap ring on clutch shaft splined area
sure bevel side of ring faces away from bearing.
nearest bearing (Fig. 12).

.
50-25-6 Power Shfft Transmission Power Train Repair
Fig. 15-lnstatting Manifold (with steel balls and seal

protector in place)
Fig. 13-JDT-13 Seat Protector in Place

9. Place the two steel balls in manifold (Fig. 15),
1. install plastic oil seal protector JDT-13 on clutch place transmission oil pump housing on manifold and
drive shaft (Fig. 13) and coat seal and protector with oil torque manifold-to-body cap screws to 20 ft-lbs (27
before installing oil pump housing with pump on shaft. Nm) (27 kgm).
10. To remove clutch pistons and seals, use JDT-
24 compression tool to remove snap ring retaining
spring washers.
1 1 Invert pump and insert smaller O.D. end of shaft

in bench hole or fixture.
NOTE: Coat ail mating parts with John Deere Hy-

Gard Transmission and Hydraulic Oil to prevent un-
necessary wear and to ease assembly.
12. If bushing in rear clutch drum is replaced, drive

bushing flush with either end.
a) On 4040
Tractor, use driver disk No. 27517
(2-1/8 and pilot disk No. 27515 (2 in.).
in.)
b) On 4240 Tractor, use driver disk No. 27521

(2-3/8 in.) and pilot disk No. 27519 (2-1/4 in.).
Fig. 14-Ttghten Pump Body Screw
8. Tighten pump crescent cap screw (Fig, 14) to 20

(27 Nm) (2.7'kgm) and replace manifold-to-pump
ft-lbs
housing gasket.

13. Inspect dutch pack components for the following 4240 Disks and Drive Plates New Part Thickness
specifications:
C-1
CLUTCH PACK WEAR AND ASSEMBLY SPECIFICATIONS 3 bronze disks
(yellow* stripe on O.D.) 0.127-0.133 in.
Pistons I.D. CD. (3.22-3.38 mm)
3 plates (flat next to piston)
4040 3.125-3.126 in. 6.600-6.610 in.
(79.37-79.40 mm) {167.64-167.89 mm) 2 wavy (notched tab) 0.118-0.122 in.
4240 3.974-3.978 in. 7.377-7.387 in. (3.00-3.10 mm)

{100.95-101.05 mm) (187.38-187.63 mm) 1 flat (no notch) 0.118-0.122 in.
(3.00-3.10 mm)
Piston Return No. Minimum Free Height
C-2
Spring Washers Used of One Spring
4240 5 bronze disks
(yellow* stripe on O.D.) 0.127-0.133 in.
C-1 5 0.126 in. (3.2 mm)
C-2 7 0.126 in. (3.2 mm) (3.22-3.38 mm)
PTO 5 0.126 in. (3.2 mm) 5 plates (flat next to piston)
4040
4 wavy (notched tab) 0.118-0.122 in.
C-1 0.120 in. (3.0 mm) (3.00-3.10 mm)

Piston Return (C2/PTO) Working Load 1 flat (no notch) 0.118-0.122 in.
Spring Free (3.00-3.10 mm)

Length PTO
2.8 in. 1.12 in. at 247- 3 paper disks 0.02 in. (0.5 mm) 0.127-0.133 in.
302 lbs.
min. facing (3.22-3,38 mm)
(71 mm) (28 mm at 1100- groove depth
1345 N) 3 plates (flat next to piston)
4040 Disks and Drive Plates New Part Thickness

(3.00-3.10 mm)
C-1
1 flat (no notch) 0.118-0.122 in.
3 bronze disks 0.112-0.118 in.

(3.00-3.10 mm)
(2.84-3.00 mm)
3 plates (flat next to piston)
14. Install C1 piston with seals and spring washers.
(3.00-3.10 mm) IMPORTANT: All wavy clutch plates (with a

1 ffat (no notch) 0.115-0.125 in.
notched tab) should be stacked out of phase to
(2.92-3.18 mm) prevent excessive leakage. Be sure high side of
plate is opposite the high side of the preceding
C-2 wavy plate (so the high side faces alternately
5 bronze disks 0.112-0.118 in. toward and away from the piston).
(2.84-3.00 mm)
Later wavy plates have a center punch mark on
5 plates (flat next to piston) the high side of the notched tab for identification.
4 wavy (notched tab) 0.118-0.122 in. Install so punch-marked side of plates are stacked
(3.00-3.10 mm) alternately toward and away from piston.

1 flat (no notch) 0.115-0.125 in.
(2.92-3.18 mm) *White stripe on later models (identifies harder ma-

PTO terial).
3 paper disks 0.02 in. (0.5 mm) 0.112-0.118 in.
min. facing (2.84-3.00 mm)

groove depth
3 plates (flat next to piston) 0.085-0.095 in.
(2.16-2.41 mm)
(2.84-3.00 mm)
) 1 flat (no notch) 0.115-0.125 in.
(2.92-3.18 mm)
CLUTCH PACK ASSEMBLY Continued 16. Slide C1 drum (A, Fig. 17) over four clutch oil
NOTE: When assembling spring washers over manifold sealing rings and clutch drive shaft, and install
dutch pistons, washers should alternately face one second snap ring on drive shaft (C),
another. if an odd number of spring washers is speci-

fied, install odd one first with its dished (concave) side
toward piston.
Ar-C1 Plates DC2-PTO Drum GClutch Separator

A^-C1 Drum B-^JDT-24 Tool C Snap Ring BC1 Disk EC2 Hub Plate
CBonded Thrust FC2 Plates HCI Hub
Ftg r 16-lnstalling C1 Piston Springs(4240) Washer
15. Compress spring washers or coil spring in C1
Fig. 18-Ctutch Assembly
drum (A, Fig, 16) using JDT-24 compression tool (B),
and install snap ring (C).
17. Install Cl hub (H, Fig. 18) (smallest I.D. hub)
over springs.
18. Install plates (A) and disks (B) alternately over

C1 hub. Note that the un-notched flat plate should be
placed next to the piston.
19. Install the PTO piston, seal and springs in the

smaller (PTO) side of the C2-PTO drum (D). Install
snap ring using JDT-24 tool.
20. Install C2 piston and seals (same as C1 parts) in

larger side of C2-PTO drum. Install snap ring using
JDT-24 tool.
21. Install second largest I.D. (C2) hub (E) over C2

spring washers.
22. Install C2 plates (F) and disks alternately over

C2 hub. Place un-notched flat plate against piston.
AC1 Drum BManifold CSnap Ring

Fig. 17-lnstaUing dutch Shaft Snap Ring

.
23. Place C1-C2 clutch separator plate (G) on C2 NOTE: Planetary is removed easiest as instructed
drum and, while holding plate and pack together, invert in the following sequence. If PTO gear train must be
the assembly placing C2-PTO drum on C1 drum. Be repaired; dutch housing should be removed and steps
sure to align dowel pins with holes. 3 and 4 can be omitted.
If clutch housing is to be removed, first remove cap
screws (D, Fig. 20).
AC1-C2 Shafts CSnap Ring

BPTO Clutch Gear DCap Screws
20-Ctutch Hou$ing-to-Transmi$sion Case Cap Screws
AClutch Backing Plate DC2 Plates
Fig,
B PTO Disk E PTO Plates

3. Remove C1-C2 shafts (A, Fig. 20) from PTO
C PTO Hub F^C1 Plates
clutch gear shaft (B).
Fig. 19-lnstalling PTO Clutch 4. Remove snap ring (C) and pull PTO clutch shaft
gear with bearing from housing. A small shaft or large
24. Install largest (PTO) hub (C, Fig. 19} over PTO nail can be inserted in holes in PTO shaft to pull
piston and springs. assembly using a slide hammer with hook.
25. Install PTO plates and disks alternately over

hub. The plate against the piston should be flat (un-
notched) on the 4240 only.
26. Install clutch backing plate and torque six long

cap screws to 20 ft-ibs(27 Nm) torque (2.7 kgm).
27. Install C1-C2 shafts. C2 has one snap ring at

planetary end.
28. Torque dutch pack-to-clutch housing cap

screws to 50 ft-lbs (66 Nm) (6.8 kgm). Note that two of
these cap screws are shorter.
PLANETARY PACK
Removal
1 Separate clutch housing from engine and remove
the rockshaft housing. (See Section 10, Group 20, for
instructions.)
ALoad Control Arm C Bearing Retainer
2. Remove clutch pack as instructed previously in B C3 Ofi Pipe DAir Bleed Ball Passage
this Group.
Fig. 21 -Reduction Gear Shaft Bearing Retainer
and Load Control Arm
5. Loosen load control arm (A, Fig. 21) mounting
screws to remove C3 oil pipe (B), rear bearing retainer

(C) and shims.

PLANETARY PACKContinued Disassembly
NOTE: See Figs. 21 26, 28 29 and 30 for exploded views.

Inspect bearing retainer. Be
sure air bleed
, t
passage (D, Fig. 21) is open and bleed check ball is 1.Place planetary pack on bench (B1 housing
free to move. down) and remove five hex. screws securing B4
housing to planetary.
6. Use a long brass drift to drive bearing cup and
2. Lift B4 housing off while holding separator plate
reduction gear shaft through planetary pack to the rear.
next to piston to keep piston from dropping from bore.
3. Lift C3 housing from pack and remove six cap

screws holding unit together to separate C3 and B4
parts.
4. Lift B3 housing from carrier while holding separa-

tor plate tangs.
5. Remove B3 ring gear and B2 housing while

holding separator plate against piston.
6. After removing B2 brake housing, the planetary

unit can be removed from B1 brake housing.
PLANETARY CARRIER DISASSEMBLY

7. Place planetary on bench with rear of unit up.
8. Remove rear retainer-to-carrier cap screws and

pry retainer (C, Fig. 23) off carrier.
9. Push planet pinion shafts (F) out of end plate (E)

catching shaft retainer balls (D), Be careful not to lose
Fig. 22-Removing Planetary Pack needle bearings (K) in planet pinion gears.
7. Lift planetary pack at 9/16-inch tapped holes on

B3 housing using a chain hoist.
R 29380N
ACap Screw (3 used) I 4th Planet Pinion --Carrier U Cap Screw (3 used)
B Lock Plate (3 used) J B3 Sun Pinion P Dowel Pin (3 used) V Bushing
C Rear Retainer KRoller (558 used) QSpacer (3 used) W Thrust Washer (4040 Only)
DSteel Ball (9 used) LSpacer (6 used) R1st and 2nd Planet X Front End Plate
ERear End Plate MThrust Washer Pinion (3 used) Y
C2-B1 Sun Pinion
FShaft (6 used) (18 used) S-tShaft (3 used) Z
C1-B2 Sun Pinion
GB4 Sun Pinion NHollow Dowel T Front Retainer AAThrust Washer
H3rd Planet Pinion (3 used)
Fig. 23-Planet Pinion Carrier Parts
TM-1181 (Fet>78) Litho in U.S.A. Tractors - 4040 and 4240

.
10. Turn carrier over and remove front retainer NOTE: Coat all mating parts with John Deere Hy-
screws to disassemble remaining parts. Gard Transmission and Hydraulic Oii Also, note that
there are 62 bearing rollers for each planet pinion.
Planetary Repair and Assembly
6. Install B1 ring gear to mesh with planet pinions.
1 . Inspect bushing (V) in front end plate bore. l.D. of
7. Position thrust washer (AA, Fig. 23) on C1 sun
4040 bushing is 2.130 to 2 J 32 in. (54.10-54.15 mm).
pinion.
ID. of 4240 bushing is 2.366 to 2.368 in. (60.09-60.15
mm). 8. Install carrier (O) inserting dowel pins into holes
in end plate.
a) Install new bushing with notched end of
bushing toward bottom of bore. 9. Turn assembly over and install front retainer (T)
and torque cap screws (U) to 35 ft-lbs (47 Nm) (4.7
4040 bushing using OTC No. 27519
b) Drive
kgm).
(2-1/4 and 27517 (2-1/8 in.) driver disks. Drive
in.)
4240 bushing using OTC No. 27523 (2-1/2 in.) and

27520 (2-5/16 in.) driver disks.
c) Bushing should be flush to 0.02 in. (0.5 mm)

below front face of end plate.
Fig. 25-Third and Fourth Planetary Assembly
10. Position planet pinion shafts with steel balls in

Fig. 24-First and Second Ptan&tary Assembly
rear end plate and insert in plate.
2. Install planet pinion shafts in front end plate with 1 1 Install fourth planet pinions with bearing rollers,
retaining balls. spacers and thrust washers.
3. Place the C2 sun pinion in position on the end 12. Install third planet pinions with bearing rollers,
plate. Be sure to install thrust washer (W, Fig. 23) on spacers, and thrust washers.
4040 Tractor.
13. Install B3 sun pinion.
4. Place the C1 sun pinion in position on larger C2
14. Invert carrier with front end plate and position
sun pinion.
over pinion shafts.
5. Install and second planet pinions with
the first
15. Invert entire assembly, install rear retainer (C,
roller bearings 23) spacers (Q) and thrust
(K, Fig.
Fig. 23), lock plates (B), and torque cap screws (A) to
washers (M). Align "V" mark on planet pinions with
35 ft-ibs (47 Nm) (4.7 kgm). Bend over lock plates.
pinion tooth on C1 sun pinion which is in full contact
with planet pinion.
IMPORTANT: Failure to time the planetary pin-

ions will result in early failure of the planetary
I assembly.

50-25*12 Power Shift Transmission Power Train Repair
Planetary Brake Pack Repair NOTE: Guide screws are used to align parts during
and Assembly assembly. Screws should be 10 in. (254 mm) long and
have heads cut off.
3, Install brake piston (5, Fig. 26) with inner and

^-
:
outer seals. Note that first and third brake pistons are
. n^-iis ljlllllllil.
the same and have a smaller ID than the other pistons
?:iii?i?i:;ii-;l;p;!!!^?ii^t
:: (on the 4240 Tractor).
it"
^H- 4L- .
:
!l
^*"* -,..
f-. îs? -" --. ;r!:.;r v.: ill
-iMitT~:.
j|i||pg:|l||||| K~4 ^M |4L|
:
B-1
COMPONENT USED
No.
SPECIFICATION
J^3fKl^3~-H|
i : i
SgL
1|S
:i:;ii4iiiiiaiiiS!l!lBB
y^::ii:;; ;
E
j :
;
i J:
"%: " 1* :*.
^JSaff gf^!;, ;.^w;
;:
fc
:
ill
1 1?
^JL Piston Re- 8 0.83 0.625 23-29
;: .:rr.f :::;
2-i H fill
"' ' *rr~*r *""
- Hfp E 5;.::\'! :
t
; *'
:;
t- .':
turn Springs (21 mm)

in.
(16
in. at
mm at 102-130 N)
lbs.
= ...
Thickness
.
;! jr
1 bjH KHii^K Lijj|jij::|j
Piston Re- 1 0.118-0.122 in.
m
HjiS
aHas
|;fc: turn Plate
Separator 1
(3-00-3-10
0.118-0.122
mm)
in.
HslM SS|5 lljîi Imp*. :
Rate (3.00-3.10 mm)

Minimum Facing
mBE^
Brake Disks Thickness Groove Depth
:;: ti mû;j;^
km.::::::
gygSft; K3r :::ai HHSt::::: :9
^ \"a|P l^:igggr: :i;s M L~ Iflll iif liili!;^

2 0.117-0.123 in.
(2,97-3.13 mm)
0.020
(0.5 mm)
in.
iSili^HiS :ffj:
Hits'
Piston 1
ID OD
:liilS llllSlil
i;:;
4040 9.258-9.262 in. 11.596-11.604 in.
(235.1 5-235.25 mm) (294.54-294.65 mm)

AB1 Housing
C Guide Screws 4240 8.856-8.860 in. 11,596-11.604 in.

B Dowels (224.95-225.05 mm) (294.54-294.74 mm)
Fig. 26-Brake Pack Assembly NOTE: Coat ail mating parts with John Deere Hy-
Gard Transmission and Hydraulic Oil to ease assembly
1. Place the four dowels (B) in the B1 housing and to minimize initial wear.
untapped holes. Install four guide screws (C) in tapped 4.Place planetary carrier assembly in B1 housing
holes. (A, Fig.26) wrth B1 ring gear. Planetary is installed
bushing-end downward.
2, Inspect B1 parts (Fig. 27) before installation.
lT
1Planetary Assembly 6Brake Piston 10B1 Brake Housing

2B1 Ring Gear 7Outer Seal 11Dowel Pin (2 used)
3Separator Plate 8Inner Seal 12 Pin (4 used)
4Brake Disk used) (2 9High-Strength Cap Screw (2 used) 13 Spring (8 used)
5 Brake Piston Return Plate
(
Rg. 27-B1 Planetary Brake Paris

.
8. Inspect B2 parts before assembly.
B2 NO.
COMPONENT USED SPECIFICATION

Piston Re- 8 0.83 in. 0.625 in. at 23-29 lbs.
turn Springs (21 mm) {16 mm at 102-130 N)
Thickness
Piston Re- 1 0.118-0.122 In.
turn Plate (3.00-3. 10 mm)

Separator Thickness
Plates 1 0.118*0.122 in.
(3.00-3.10 mm)
Minimum Facing
Brake Disks Thickness Groove Depth
2 O.117-0.123 in. 0.020 in.
(2,97-3.13 mm} (05 mm)

ID OD
Piston 1 9.258-9.262 in. 11.596-11.604 in.
(235.15-
235.16 mm) (194.54-294.74 mm)
9. brake backing plate (11, Fig. 29) on B1

Install
A Return Plate D Separator Plate housing. Be sure

oil holes are aligned as plate is
BReturn Springs EBrake Disk installed over guide pins.
C B1 Ring Gear
10. Install largest I.D. ring gear (B2) over B1 ring
Fig. 28-B1 Brake Assembly
gear.
5. Install brake piston return plate (A, Fig, 28) then
1 1 Install B2 disks and separator plate in B1 hous-
eight springs (B) over guide screws and dowels.
ing alternately over backing plate (disk against backing
6. Install B4 planetary sun gear in rear of planetary.
plate).
7. Install disk, separator plate and second disk,
alternately. 12. Install shorter spring (7) over each guide pin
and screw.
13. Install larger I.D. B2 piston (common with B4

piston) with seals in B2 housing.
1 B2 Brake Housing 5Brake Piston 9 Separator Plate

2O-Ring 6 Brake Piston Return Plate 10B2 Ring Gear
3 Inner Seal 7Spring (8 used) 1 1 Brake Backing Plate
4 Outer Seal 8 Brake Disk (2 used)
Fig. 29-Ptanetary Brake Parts

Brake Pack Repair Continued
R13T&
1 High-Strength Cap Screw, 5Bushing 10Brake Piston Return Plate

6Dowel Pin (2 used) 11 Spring {8 used)
3/8" x 1-1/2" (2 used)
2DoweT Pin (4 used) 7Third Planet Inner 12Brake Disk, with Facing (3 used)
3O-Ring Brake Piston Seal 13Separator Plate (2 used)

4Third Planet Brake Piston eOuter Brake Piston Seal 14Third Planet Ring Gear
Housing, with Bushings 9Third Planet Brake Piston
and Pins
Fig. 30-B3 Planetary Brake Parts
14. Holding piston in B2 housing with brake return 17. Install B3 ring gear (14) over planet pinions and
plate, place B2 housing assembly on B1 housing over B2 housing,
B2 disks and guide pins.
18. Install B3 disks and separator plates alternately
1 5. Inspect B3 parts prior to assembly.
over B3 ring gear. (Disk must be against B2 housing.)
B-3 NO. 1 9. Install eight longer springs (11) over guides and
COMPONENT USED SPECIFICATION screws.
Free Length Working Load 20. Install smaller inside diameter B3 piston (9) with
8 1.22 1.0 at 22-28 lbs
Piston Re- in. in.
seals in B3 housing.
turn Springs (30.9 mm) (25.4 mm at 100-
123 N) 21. Install piston return plate (10) over B3 piston,
and; holding the assembly together, install the B3
Thickness
Piston Re- 1 0.118-0.122 in. housing on B2 housing (piston goes downward).
turn Plate (3.00-3.10 mm)
22. Use JDT-24 compression tool or a press to
Separator compress C3 piston return spring enough to remove or
Plates 2 0.118-0.122 in.
install snap ring.
(3.00-3.10 mm)
Minimum Facing 23. Inspect clutch housing bushings. LD. of front
Thickness Groove Depth
bushing is 1.691 to 1.692 in. (42.95-42.98 mm). Rear
Brake Disks 3 0.117-0.123 in. 0.020 in.
bushing I.D. is 1.753 to 1.754 in. (44.52-44.55 mm).
(2.97-3.13 mm) (0.05 mm)
ID OD bushing using 1 -1 1 /1 6 in. pilot and
a) Install front
Piston 1 8.656-6.660 in. 11.596-11.604 in.
(224.95-225.05 mm) (294.54-294.74 mm) 1-3/4 in. driver disk (OTC No. 27510 and 17511).
Install bushing 3/16 in. deep (5 mm).
16. B3 housing bushing (5, Fig. 30) is replaced, and

If
b) Install rear bushing using 1-3/4 in. pilot
align cutout in bushing with cutout in housing. Bushing (OTC No. 27511 and 17513).
1-7/8 in. driver disk
inside diameter is 3.7550 to 3.7575 in. (95.38-95.44
Install with large chamfer on I.D. facing the outside.
mm).
a) bushing using 4-5/16 in. (110 mm)
Install
driver disk and 3-3/4 in. (95 mm) pilot (OTC No. 27552
and 27543).
b) Install bushing flush with surface of piston side
of housing.

1Hex. Bolt (5 used) 9Brake Disk (2 used) 17Outer Seal

2-B4 Brake Housing 10 Separator Plate 18Clutch Piston
3O-Ring (2 used) 11Special Cap Screw (6 used) 19Spring
4Inner Seal 12Bushing 20 Retainer
5Outer Seal 13Bushing 21 Snap Ring
6Brake Piston 14 Dowel Pin 22Clutch Hub
7Brake Piston Return Plate 15C3 Clutch Piston Housing 23Clutch Drive Plate (3 used)
8 Spring (8 used) 16Seal 24 Clutch Drive Disk (3 used)
25 C3 Clutch Drum
Fig. 31-B4 Brake and C3 Ctutch Parts
24. inspect C3 dutch parts. 26. Install C3 hub (22) outer spline toward piston
into C3 drum and install disks and separator plates
C-3 NO. (disk first) over the hub.
COMPONENT USED SPECIFICATION
Working Load
27. Torque clutch-piston housing-to-drum cap
Free Length
Piston Re- 2.79 in. 1.12 in. at 247-303 lbs. screws to 20 ft-lbs. (27 Nm) (2.7 kgm).
turn Spring (71 mm) (28.5 mm at 1100-
1346 N} 28. Inspect B4 components.
Thickness
Drive Plates 0.118-0.122 in.
B-4 No.
(3.00-3.10 mm) Component Used Specification
Minimum Facing
Thickness Groove Depth
Drive Disks 0.112-0.116 in. 0.02 in.
Piston He- 0.83 in. 0.625 in. at 23-29 lbs.
(2.84-3.00 mm) (0.5 mm) turn Springs mm) (16 mm at 102-130 N)
(21
ID OD
Piston 3.125-3.126 in. 6.600-6.610 in. Thickness
(7937-79-40 mm) (187.64-167.90 mm) Piston Re- 0.118-0.122 in.
turn Rate (3.00-3.10 mm)

25. Install C3 piston with seals and assemble spring Separator 0.118-0.122 in.
(19, Fig. 31) over piston (18) using JDT-24. Plate (3.00-3.10 mm)
Minimum Facing
NOTE: Be sure the C3 piston retainer plug is sealed Thickness Groove Depth
in the drum and that the bait is working property. These Brake Disks 0.117-0.123 in. 0.020 in.
parts are available for service, install bait in piston side (2.97-3.13 mm) (0.5 mm)
of drum (15), then retainer with its cupped side toward ID OD
drum. Piston 9-258-9-262 in. 11 .596-1 1 .604 in.
(235.15-235.25 mm) (294.63-294.65 mm)

Back Pack Repair Continued
mrmm 1 B1 Test Point and Plates 3B3 Test Point and Plates
2B2 Test Point and Plates 4B4 Test Point and Plates
AC3 Clutch EB4 Return Springs
BB3 Housing FSeparator Plate Ftg. 33-Air-Testing Planetary Pack
0-B4 Piston Gr-B4 Housing
D Return Plate H Backing Plate 34. Test brake operation with air. As air pressure is
applied at each piston housing inlet passage, the cor-
Fig. 32-B4 Brake Assembly
responding brake should be activated.
29. C3 assembly on B3 housing

A
Install (A, Fig. 32)
CAUTION: To avoid personal injury, use
(B) with screw heads up T
only 50-80 psi (3.5-5.5 bar) (3.5-5.5 kg/cm 2)

air pressure.
30. Install B4 brake piston (C), seals and brake
return plate (D) in B4 housing.
Installation
31. Install B4 springs (E), two disks and separator 1. Install new O-ring seals in brake control oil pas-
plate (F) over B3 housing. sages in bottom of transmission case.
32, Instaii B4 housing (G) with piston and return

plate on B3 housing.
33. Replace each of the four guide screws with long

hex. bolts. Torque five hex. screws to 35 ft-!bs (47 Nm)
(4.7 kgm).

REDUCTION GEAR TRAIN,

DIFFERENTIAL DRIVE SHAFT,
PARK PAWL, AND TOW DISCONNECT
Removal
1. Remove rockshaft housing as instructed in Sec-
tion 10, Group 20.
Fig. 34-lnstalIing Planetary Pack
2. Install brake pack in case (Fig. 34) using care not

to move O-rings.
3. Torque planetary hold-down screws to 55 ft-lbs

(75 Nm) (7.5 kgm),
4. Reverse planetary pack removal steps in this A Load Control Arm CBearing Retainer
group to complete reassembly. BC3 Oil Pipe D Bleed Passage
Fig. 35-Reduction Gear Shaft Bearing Retainer

Torque 3/4 inch clutch housing-to-transmission
5.
case cap screws to 300 ft-ibs (407 Nm) (40.7 kgm).

2. Disconnect C3 oil pipe (A, Fig. 35) at bearing
Torque 5/8 inch clutch housing-to-transmission case
retainer.
cap screws to 170 ft-lbs (230 Nm) (23 kgm).
3. Remove reduction shaft rear bearing retainer

with shims (C).
4. Proceed to the appropriate heading for removal

of a particular component.

.
Reduction Gear Shaft Removal Differential Drive Shaft Removal
IMPORTANT: If the differential drive shaft is re-

placed, the differential ring gear must also be re-
placed (since they are a matched set). (See Group
35 of this Section for service of the differential.)
AC3 OH Pipe D Bearing

BDrive Sleeve E Reduction Gear Shaft
CShims F 1/2 in. Blind Hole
Puller A Bearing Quill GJDG-19 Link
B Lock Line Oil HLock Fitting
Ftg. 36~Removing Reduction Gear Shaft 0-C3 Elbow I Differential
(Load Control Arm Not Shown) D Reduction Shaft J Dm Shaft
E Retainer and Shims K-C3 Inlet
1 . Remove reduction gear shaft assembly using a

FChain Hoist L Disconnect Shifter
1/2 in. blind hole puller (F, Fig, 36). Be sure end of Fig. 37-Removing Differentia} Housing
puller is inserted in the smaller i.D. of (OTC
the shaft. (Load Control Arm Not Shown)
No. 33859)
1 Remove planetary pack as instructed on page 9.
NOTE: Shaft can be removed by hand after the
bearing cup and cone (D) are removed. Also note that 2. Remove final drives as instructed in Group 40.
the reduction gear shaft can be driven to the rear from
the front of the planetary pack if the dutch housing has 3. Remove differential lock oil line (B, Fig. 37) from
been removed, left hand quill (A) and fitting (H).
2. Remove reduction gear drive sleeve (B). 4. Install a JDG-19 link (G) on differential housing-
to-ring gear cap screw.
5. Wrap a chain around differential housing and

through link (G).
6. Remove both rear bearing quills with shims (A)

and carefully raise differential from transmission case.
7. Remove differential drive shaft.

I
TM-1181 (Sep-77) Utho in USA Tractors - 4040 and 4240

Power Train Repair Power Shiift Transmission 50-25-19
Park Pawl and Tow Disconnect Removal
R27 75
A Disconnect Stop E Reduction Shaft Bearings I Shifter Yoke MThrust Bearing Q Lock Pawl
B Disconnect Shifter Lever F Disconnect Shifter Collar J Yoke Shaft (RH) N Lock Cam Shaft
C Shaft Retainer G Reduction Gear Shaft KYoke Shoe (2 used) O Lock Arm R Shims
D~ Disconnect Yoke Shaft (LH) H Reduction Gear L Drive Sleeve P Lock Pawl
Fig. 38~Reduction Shaft, Park Pawl andt Tow Disconnect (Not exactly a$ shown)
NOTE: If lock pawl shaft (Q, Fig. 38) is to be re- c) Remove right-hand yoke shaft (J) and remove
moved, differential or brake pack must also be re- yoke with shoes (K).
moved. (See the preceding page for instructions.) d) Remove disconnect shifter collar (F), drive
1. Complete Steps 1-4 under Removal on page 17. sleeve (L) 7 reduction gear (H), and front bearing.
2. To remove park pawl:
a) Remove lock arm spring pin and remove arm Reduction Gear Shaft
with spring (0). Repair, Assembly, and Adjustment
b) Remove shaft retaining pin (not illustrated).
1. Inspect bushing in the front end of the reduction
c) Disconnect lock pawj spring (P) and remove
gear shaft. Bushing I.D. is 0.752-0.754 in. (19.10-
pawl shaft (Q).
19.15 mm).
d) Remove lock pawl and lock cam (N)>
a) Bushing should be installed 0.06-0.10 in.
3. To remove tow disconnect:
(1.5-2.5 mm) flush with bottom of chamfer in end of
a) Remove tow disconnect cap screws and
bore.
spring pin to remove disconnect stop (A), and shifter
Jever (B).
b) Drive new bushing using 1-1/8 in. (29 mm)
b) Remove retainer (C) and remove left-hand
driver disk and 3/4 in. (19 mm) pilot (OTC No. 27501
shaft.
and 27495).

.
/L CAUTION: Oil fumes or oil can ignite

* above 380T (193C). Use a thermometer
flame or heating element to be in direct contact
with the oil. Heat the oil in a well-ventilated area.
Plan a safe handling procedure to avoid burns.
2. Install rear bearing cup with shim pack in trans-

mission case. Be sure bearing cup is properly seated.
3, Heat rear bearing cone to 300F (15CTC) and

install on differential drive shaft. Be sure cone is tight
against shaft pinion.
Rolling Drag Torque Adjustment

IMPORTANT: Use a spring scale as directed to
obtain the specified rolling drag torque. The spring
scale reading required to obtain the specified roll-
ing drag torque is provided.
R34436 Clean
1 differential drive shaft and its parts from all
A Reduction Gear Shaft C Rear Cone nicks and burrs. Lightly oil the front and rear bearings.
B Rear Cup
Fig. 38a~Rear Bearing Installed 2. Install front bearing cup into case. Be sure cups
2. reduction gear shaft (A, Fig. 38a) with

Install are properly seated against case shoulder as follows:
bearing cones and cups in the transmission case to
establish bearing preload. Make sure rear cup (B) and
cone (C) are installed as shown in Fig. 38a. Do not
install reduction gear at this time,
IMPORTANT: Gear on shaft is a slip fit. There-
foredo not attempt to measure end play on gear or
by moving gear. If planetary brake pack has been
removed, end play can be measured at front end of
shaft.
a) Install rear bearing retainer with enough
shims to establish shaft end play.
b) Install a rocker-type dial indicator so point
rests on shoulder of shaft or in gear oiling hole.
c) Measure shaft end ptay and remove shaft.
d) Remove shims from front of bearing re-
tainer to equal end play plus preload of 0.001 to
0.002 in. (0.02-0.05 mm). Shims are available in
sizes of 0.003, 0.005 and 0.010 in. thicknesses
(0.08, 0.13 and 0.25 mm).
3. Reverse the removal steps to install the reduction
gear shaft.
4. Torque reduction gear shaft retainer cap screws
to 55 ft-lbs (75 N-m) (7.5 kgm}.
Differential Drive Shaft

1. If the rear bearing cup, cone, or differentia! drive
shaft is replaced, determine proper shim pack for the
rear bearing cup as follows:
A Differential Drive Shaft B Holding Tool
Subtract the number etched on the pinion end
a)
of the differential drive shaft from 8.330 in. Fig. 38b~Drive Shaft Holding Tool Installation
b) The the correct shim pack to use
difference is
(4840 Shown)
in front of the rear bearing cup.

.
Power Train Repair Power Shift Transmission 50-25-20a
a) Install differential drive shaft with rear bearing 4. Install front spacer with enough front shims to
cone and rear thrust washer through case wall and provide a measurable amount of end play.
drive shaft gear.
5. Heat and install front bearing cone on shaft
b) install holding tool (B, Fig. 38b) as shown and
against shims far enough to install old Jock nut.
tighten nuts on
so screw holds shaft forward.
tool
c) Heat front bearing cone to 300F (150C)
maximum and install on shaft. Shims should not be
installed at this time.
Use a brass drift to drive bearing cone onto
d)
shaft far enough to start all the old lock nut threads and
torque lock nut to 300 ft-lbs (406 N-m) (40.6 kgm).
NOTE: Use a wedge against the drive gear to
tighten the lock nut Use of a D-Q5124ST Torque
Multiplier with the JDT-44 socket eases nut installation.
e) Strike end of the shaft with a lead hammer.
f) Retorque the lock nut to 300 ft-lbs (406 N-m)
(40.6 kgm) and repeat Step e three times.
A Dial Indicator C Lock Nut

B Differential DAlignment Marks
Drive Shaft E Front Bearing Cone
Fig. 38d-Checking Differential Drive Shaft End Pfay
(4840 Shown)
6. Torque lock nut (C, Fig. 38d) to 400 ft-lbs (542

N-m) {54.2 kgm). Do not stake at this time.
7. Mount a dial indicator (A) so the pointer rests on

a smooth portion of the differentia! drive shaft (B).
8. Mark the lock nut and the case wall (D) so end
play can be checked at the same point on the drive
shaft.
Grasp the pinion end of the drive shaft and

9. rotate
it each direction several times while pushing
in it for-
ward to seat the rear bearing rollers.
ADrive Gear B Hydraulic Jack 10. Align the mark on the nut with the mark on the
C Differential Drive Shaft case (D) and while holding the shaft forward, zero the
dial indicator,
Fig. 38c-Removing Differential Drive Shaft (4840 Shown)
3. Remove lock nut and press drive shaft through

1 1 Rotate the shaft several times in each direction
front bearing cone using a hydraulic jack as shown in

while pulling it rearward to seat the front bearing
rollers.
Fig. 38c.
IMPORTANT: A hydraulic jack Is the safest way 12. Align the mark on the nut with the mark on the
to remove the drive shaft without damaging bear- case (D) and while holding the shaft rearward, read the
ing or shaft. If a jack Is not available use a brass dial indicator. Note end play.
drift.
13. If end play is greater than 0.0000 but less than
0.0005 in. (0.013 mm), check drag torque as described
in Steps 17 through 20.

50-25-20b Power Shift Transmission Power Train Repair
Rolling Drag Torque Adjustment 19. Attach a JDT-42 spring scale (or its equivalent)
Continued (A) to the end Be sure the spring scale is
of the string.
zeroed.
14. Remove lock nut (C)and drive shaft rearward
IMPORTANT: The reduction gear shaft re-
through the front bearing cone (E).
duction gear must be removed while checking
IMPORTANT: Do not lose any of the front bear- rolling drag torque.
ing shims. 20. Pull the spring scale up rotating the shaft a
maximum of one revolution per second while reading
15. Remove enough front shims to obtain 0.0005 in. the spring scale. Repeat several times for an accurate
(0.013 0.0015 in. (0.038 mm) preload.
mm) end play to reading.
IMPORTANT: Measure shims individually using a) If spring scale reading is not to within 2-1/2
a micrometer. Shim thicknesses may vary. to 7-1/2 lbs. (1.13 to 3.40 kg), repeat the entire ad-
justment. Be sure shaft components have no nicks,
16. Install shim pack determined in Step 15 and
burrs or brass shavings.
install front cone. Repeat Steps 5 through 12.
NOTE: The 2-1/2 to 7-1/2 lbs. (1J3 to 3.40 kg)
a) If end play is greater than 0.0005 in. (0.013 scale reading provides the specified rolling drag torque
mm), repeat Steps 14 through 16. of 5 to 15 in-lbs (2.3 to 6.8 kg),
b) If rolling drag torque is within the specifica-
end play is less than 0.0005 in. (0.013
b) If
tion, stake the lock nut in two places and reverse the
mm), continue on through the following steps to check
steps of removal to assemble the tractor.
rolling drag torque.
Park Pawl and Tow Disconnect
A Spring Scale C Differential Drive

B String Shaft Bevel Pinion
D Drive Shaft Gear
Fig. 38e-Measuring Roiling Drag Torque (4840 Shown)

A Differential Drive Shaft D^ Pawl Shaft Retaining Pin
17. Tie a string (approximately 6 ft. [2 m] long) & Pawl Shaft E Pawl
tightly around differential drive shaft bevel pinion at flat
C Cam F Reduction Gear
area as close to rear bearing as possible (B, Fig. 38e). Hg. 39-Park Pawl and Reduction Gear
18. Rotate the shaft (C) to wrap the string around 1. Install spring with closed end in slot on pawl (E,
the shaft. Fig. 39) and open side of hook toward the roller. Insert
spring pin.
.
Park Pawl and Tow OIL PRESSURE REGULATING

Disconnect Continued VALVE AND PEDAL VALVE
Removal
2. Install park pawl and tow disconnect parts in the
reverse sequence of Removal,
3, Fully engage the disconnect shifter collar with the

reduction gear (F),
A Shifter Yoke Shaft CDisconnect Lever

BCap Screws D Adjusting Mark
Fig. 40-Tow Disconnect Lever Stop Adjustment
4. Assemble the shifter yoke to the splined shaft so

the hole the shaft (A, Fig. 40)
in is 10 down from
horizontal toward rear of tractor. AReturn Spring FTo Main Pump
BMetering Pump Hose GClutch Valve Rod
5. With cap screws (B) loose, rotate disconnect CReturn Line HA/C Line
shifter lever (C) forward out of detent until lever stops.
DBypass Line 1 Pedal Vatve-to-Housing
E Sender Wire Screws
6. Align adjustment mark on stop (D) with rear edge Fig. 41-Pressure Regulating Valve and Pedal Valve
of lever (C), and tighten cap screws (A). (Early Model)*
7. Return lever to the engaged detented position on 1 Remove clutch valve operating arm return spring
stop and hook up spring, (A, Fig. 41) from left-hand side of clutch housing.
8. To complete the assembly, reverse the steps of 2. Remove steering metering pump return hose (B)
Removal. and its connector.
*NOTE: Later models may have a low pressure

warning switch located in the pedal valve housing.

Pressure Regulating Valve Continued 8. Slide pedal valve out to remove.
NOTE: If only the pedal valve is to be removed Pedal Valve Repair and Assembly
proceed to step 4,
1. Use Fig. 43 as a reference to assembly and
3. If pressure regulating valve is to be removed; disassembly.
a) Remove oil pressure regulating valve-to-

2. Install new clutch control shaft (B) oil seal in
transmission case return pipe (C).
housing metal side out Use a 1 -1/4-in. (32 mm) driver
b) Disconnect lubrication bypass line (D) from disk and 11/16 in. (17 mm} pilot (OTC No. 27503 and
regulating valve. 27494 disks), install seal flush with finished face of
housing.
c) Disconnect temperature sender wire (E).
d) Remove pressure reguiating valve-to-hy- 3. Replace O-rings and inspect valves and bores
draulic pump line (F) from regulating valve housing. for chips and wear.
e) Remove seven screws from regulating valve

housing and remove the housing.
4. Remove cotter pin and pin from clutch valve

operating rod (G). Pull rod up and out of way. Note that
long end of pin is installed toward the tractor,
5. Remove inner air conditioner pipe (H) from

bracket and push up and out of way.
6. Remove seven pedal valve-to- ho using screws

(1).
!:n
^Si^^B^HW^â^^| 2
it:::'! :?:
:!!li35Ja::5::5::iJiii:!
AClutch Valve Housing I Inner Clutch Spring

BClutch Valve Arm Shaft J Lower Clutch Spring
CSpecial Pins KClutch Valve
D Link LSpecial Plug
EClutch Valve Shaft MPTO Clutch Vatve
BMetering Pump House FTo Main Pump F Spring Pin NPTO Spring
O Bypass Line GClutch Valve Rod GShim OPTO Clutch Valve Shaft
E Sender Wire HA/C Pipe H Upper Clutch Spring PPTO Arm Shaft
Fig. 42-Pedal Valve and Regulating Vaive - Removed
Fig. 43-Pedat Valve Assembly
7. Remove 1/4 in. nut from PTO valve arm on

inside of valve housing (can be seen by removing
(
foot-rest panel).

.
Power Tram Repair Power Shift Transmission 50-25-23
4. Inspect springs (H, l

T J, N, Fig. 43):
) VALVE FREE WORKING

SPRING KEY LENGTH LOAD
Clutch H 0,5 in. 0.34 in. at 3.3-4.1 lbs.

(13 mm} (87 mm at 15-19 N)
Clutch [ 2.0 in. 1.4 in. at 11.7-14.3 lbs.

(51 mm) (357 mm at 52-64 N)
Clutch J 1.3 in. 1.1 in. at 15.1-16.3 lbs.
(33 mm) (27.8 mm at 68-81 N)
PTO N 1.8 in. 1.4 in. at 16.6-20.4 lbs.

(45 mm) (34.9 mm at 74-91 N)
5. When re-installing clutch pedal valve housing,

reverse the steps of removal. Be sure to install gaskets
on each side of plate.
6. Torque valve housing cap screws to 45 ft-!bs (61

Nm) (6.1 kgm).
Pressure Regulating Valve Repair

and Assembly
1 Refer to Fig. 44 for disassembly and assembly of
pressure regulating valve.
2. inspect valves and bores for wear or chips. Note

that valve housing has a guide forassembly of each
valve over each valve bore.
liSlSteSSl
3. Replace O-rings and coat all parts with John
Deere Hy-Gard Transmission and Hydraulic Oil for

assembly.
4. Inspect springs for the following specifications. AValve Housing I Pressure Regulating
Replace any spring that is distorted or pitted. BCooler Relief Valve Spring
CCooler Relief Valve JShim
VALVE (FIG, 44) FREE WORKING Spring K Plug
SPRING KEY LENGTH LOAD DPlug and Washer L Plug
E Check Valve Spring MLube Relief Spring
Oil Cooler 4.6 in. 3.53 in. at 357-437 ibs. FCheck Valve N Filter Bypass Spring
Relief (115.5 mm) (897 mm at 159-194 N) GCheck Valve Plug OLube Relief Valve
H Pressure Regulating Valve P Filter Bypass Valve
Check 2.31 in. 0.75 in. at 10.8-13.2 Ibs.
Fig. 44-Pressure Regulating Valve Housing
(58.5 mm) (19.0 mm at 48-59 N)
Pressure 5.09 in. 4.44 in. at 53.5-71.5 Ibs. 5. Reverse pressure regulating valve removal steps
(129.3 mm) (112.8 mm at 260-319 N) for installation procedure.
Transmission M 2.83 in. 2.13 in. at 11.7-14.3 Ibs.

6. Torque pressure regulating vaive-to-housing cap
Lube Oil (72.0 mm) (54.0 mm at 52-64 N)
screws to 45 ft-lbs (61 Nm) (6.1 kgm).
Fiher 371 in. 2.6 in. at 24.3-29.7 lbs.
Bypass (94.0 mm) (66.3 mm at 108-132 N)
TM-1181 (Sep-77) Lrtho in USA. Tractors - 4040 and 4240

TRANSMISSION CONTROL VALVE 2. Remove start safety switch wire (C).

AND SHIFT VALVE Remove eight control
3. valve-to-transmission case
Removal cap screws
(
(D, Fig. 45), and remove control valve.
Shift Valve Repair and Assembly

1. Remove six shift valve-to-control valve housing
cap screws and remove shift valve housing from rear of
control valve housing.
2. Use Fig. 47 as a reference for disassembly and

repair of shift valve.
3. Inspect valves (B and G) and bores for chips and

wear.
NOTE: Shift vaives and related vaive parts (F, G t

H,
/, and J) are identical.
Replace O-rings on all four shift valves and coat

4.
all Deere Hy-Gard Transmission and
parts with John
'
'iii^s^.irsiissy^
Hydraulic Oif prior to assembly.
s
:::t;; j::::::::;::;; r: r;t; :;:,:;;::;.. :;:;:k::::::::::::::::::: r:::;;:;:;;
:::::;;::::::::;:::tr;:: :t- :*;.:;:!:;;;::::::::::;:;:::;;:;;;::;;;;: r
::::::::;::::::::::::::::::::::..:::: ::Ka:!:::;ii:::;;;;:::::::::::-
SS"
. ~
--::
: Is":: 1 :-":.-": :
"*
*::.&.
'I: ?
1
,.
:
:
'.
IMPORTANT: Install dump valve (B) and shift
!r
;:
"it:?::;::::
;;**'
:. . V: ...;:*;:::::?;&;:
valves with drilled end of valves outward.
:; : '
" ' " :r-;;Si;.*t;a:;:r .. .:: .
;:;;HH:Ht' :;.:
AYoke Pin (Speed) CSafety Switch Wire

BYoke Pin (Direction)
on) DCap Screws
/vg. 45-Controt Valve
1 , Disconnect control valve cable at yoke pin (A,

Fig. 45) and direction valve cable at yoke pin (B).
AShift Valve Cover O-Rings

and Gasket GShift Valve (4 used)
B Dump Valve HShift Valve Spring
(open end up) (4 used)
ASpeed Control Yoke CStart Safety C Dump Valve Spring I 4 Special Washers
B Direction Control Yoke Switch Wire D Special Screw J 4 Retaining Rings i
EShift Valve Housing
Fig. 46-Control Valve Removal
Fig. 47-Shtft Valve Housing Assembly

5. Inspect springs. If physical appearance is in

doubt, replace.
)
VALVE (FIG. 48) FREE WORKING
Dump C 1.12 in. 0,84 In. at 31.5-38.5 lbs.

(28.5 mm) (21.3 mm at 144-174 N)
Shift H 1.39 in. 0.81 In. at 6.8-8.4 lbs.

(4 used) (35.3 mm) (20.5 mm at 30-37 N)
6. Stake the dump valve special screw (D) in two

places.
7. Tighten shift valve housing-to-control valve

housing cap screws to 20 ft-lbs (27 Nm) (2.7 kgm)
torque. Be sure gasket is in place on cover and that
control valve gaskets are properly positioned.
Control Valve Repair and Assembly

1. Use Fig. 48 as a reference during disassembly
and assembly.
2. Do not lose detents (A and C) when gasket plate

(F) is removed.
3. To remove control valve (H) and direction valve ACone Detent (Speed) JArm Cover
(l) T remove operating arm cover (J). BCone Spring KDirection Operating
C Detent (Reverse)
Bail Arm
D Spring
Ball L Control Operating Arm
4. Inspect valves, pistons and bores for chips and E Plate and 2 Different MControl Valve Arm
wear. Gaskets NControl Link
F Control Valve Housing 0Accumulator Cover
5. Inspect springs. Accumulator pistons, orifices
and Cover Gasket P Accumulator Pistons
and springs are identical.
G Start-Safety Switch QOuter Springs
HControl Valve and RShim Washer
FREE
Spring Pin S Inner Springs
(FIG. 48) WORKING I Reverse Valve and TOrifices
SPRING KEY LENGTH LOAD Spring Pin
Speed De- B 1.16 in. 0.83 in. at 5.85-7.15 lbs. Fig. 48-Control Valve Paris
tent cone (29.5 mm) (21.1 mm at 27-32 N)
Rev, De- D 1.12 in. 0.80 in. at 14,4-17.6 lbs. 6. Coat all parts with John Deere Hy-Gard Trans-
tent half (28.5 mm) (20.3 mm at 65-79 N) mission and Hydraulic Oil prior to assembly.
Accumulator Springs
Outer ^ Q 4.09 in. 2.91 in. at 185-225 lbs. 7. ff operating arms (K and L) are disassembled,
(2 used) (104 mm) (74 mm at 822-1000 N) replace shaft oil seals. Use 1-1/8 in. (28 mm) driver
and
3.76 in. at 52-65 lbs.
disk and 9/16 in. (14 mm) pilot (OTC No. 27501 and
(95.5 mm at 233-286 N) 27492). Install with metal side of seal out.
Inner S 3.78 in. 2.91 fa at 100*122 lbs.

NOTE: When installing control and reverse valve
(2 used) (96 mm) (74 mm at 445-543 N)
arms, align slots on inner spring pin with slot on outer
spring pin.
8. Install speed valve detent cone (A), then spring.
) 9. Install reverse valve detent ball (C), then spring.

. .
Control Valve Repair and Assembly 4. Remove screw on outside of fender to loosen
Continued outer support (A, Fig, 49).
(
10. Install control valve gasket, plate, then shift 5. Remove speed selector cable at pivot (C).
valve gasket. Be sure not to interchange gaskets.
6. Remove reverse cable at reverse bellcrank (G).
1 1 Torque shift valve-to-control valve housing to
20 ft-lbs (27 Nm) (2.7 kgm). 7. Remove throttle rod (F) at throttle lever and re-
12.Assemble B3-B4-C3 (left-hand) accumulator move throttle lever.
piston over springs and large washer. B1-B2 piston is
8. Remove lock cable (K) from bellcrank at swivel
installed open end out, then springs.
and at lower support (L).
13. Torque accumulator cover (O) cap screws to
control valve housing to 35 ft-lbs (47 Nm) (4.7 kgm). 9. Remove four cap screws retaining outer support
14. Reverse steps of removal for installation of to body and remove shift assembly as a unit through
control valve. the lever guide.
10. Use the following illustrations under Repair and

SPEED SELECTOR Assembly as a reference for disassembly.
Removal and Disassembly
Repair and Assembly
1 Remove three cap screws on outside of fender to
loosen lever guide, 1 . Check control cables for free operation. Lubricate
or replace as necessary.
2. Remove six cap screws retaining console cover.
3. Remove load control knob and pull off console

cover.
A Lock Lever DLock Bellcrank, with

B Lock Link Cap Screw and Washers
C Lever Bushing EOuter Support
AOuter Support E Speed Control I inner Support Fig, 50-Lever Outer Support
BLock Lever Lever J Swivel
CControl Lever FThrottle Rod KLock Cable 2. Press bushing and dowel pins into transmission
Pivot G Reverse Bellcrank L Lower Support lock lever (A, Fig. 50) flush with surfaces opposite
D Selector Cable H Bellcrank chamfer. i
Fig. 49-Speed Selector Lever Assembly
3. Install lever lock (A), link (B), and bellcrank (D) on
outer support (E).
TM-1181 ($ep-77) Litho in U.S.A. Tractors - 4040 and 4240

7. Torque inner support-to-outer support screw (D)

to 21 ft-lbs (28 Nm) (2.8 kgm).
*.::
JBl;
:"!rH!%_" **;^
8. Install iever guide plate (E).
9. Adjust end play of the pivot and lever assembly to

0.005-0.024 in. (0,13-0.61 mm) by adding or deducting
shims between the control lever pivot and the spacer.
10. Use 53 and 54 as a reference when in-

Fig.
stalling the speed selector assembly. Reverse the
steps of Removal for a step-by-step installation pro-
cedure to follow.
A Lever Pivot CControl Lever

B Lever Spring D Lever Pin
Fig. 51 -installing Control Lever and Pivot
4. Press transmission control lever pivot bushings

into pivot 0.06 in. (1.5 mm) below ends of bores.
5. Assemble tever pivot (A, Fig. 51) and control

lever (C), and install on outer support.
ASpeed Control Rod C Reverse Cable

B Lock Cable DControl Valve Cable
Fig. 53-Speed Selector AssemblyRemoved
AInner Support DSpacer and Cap Screw

B Reverse Beltcrank E Lever Guide Plate
CSpacer
Fig. 52-$peed Selector Assembly
6. Assemble reverse beNcrank (B, Fig. 52), spacer

(C) with shims, and support spacer (D).
ASpeed Control Rod C Reverse Cable
I BLock Cable DControl Valve Cable
Fig. 54-lnstalfing Speed Selector Assembly

.
ADJUSTMENTS Pedal Valve Adjustment

Oil Pressure Regulating Valve Adjustment
NOTE:Adjust oil pressure regulating valve after
testing. (See page 250-20-31 Pressure regulating
valve should maintain 175-185 psi (12.07-1276 bar)
(1232-13.02 kg/cm2).
Ftg. 56-PedaI Return Spring
Fig. 55-Adjushng Pressure Regulating Vafve

1. Disconnect clutch pedal return spring.
1 If oil pressure is high, remove one or more shims
under the pressure regulating spring to obtain proper

oil pressure.
2. If oil pressure is low, add one or more shims

under the pressure regulating valve spring to obtain
proper oil pressure.
NOTE: See Group 30 of this Section for instructions

on adjustment of the PTO clutch operating rod.
AClutch Valve Operating Arm B Stop Pin
Ftg. 57-Adjusting Peda! Vaive Stop Screw
2. Rotate clutch valve operating arm (A, Fig. 57)

counterclockwise until valve travel stops.
3. Adjust stop screw until screw head contacts stop

pin (B).
(
4. Back out stop screw one-half turn and lock jam
nut. Connect return spring.

Pedal Height Adjustment 3. Rotate adapter to a new position to give proper

pedal height. The lowest part of the clutch pedal should
1. Remove left-hand cowl.
|
be 5-1/4 to 5-3/4 in. (133-146 mm) above the footrest.
Speed Selector Adjustment
R 27349N
/
Fig. 60-Transmission Control Lever in "N-Reverse"
; 1. Place transmission control lever in the "N-
REVERSE" position in the guide plate.
A PTO Rod B Hex. Adapter CClutch Rod

Fig. 58-Pedal HeightLH. Cowl Removed
IMPORTANT: Be sure clutch valve operating

arm is rotated downward against lower stop by
its
connecting return spring on valve housing. See

Fig. 56.
R 27850H
Fig. 61 -Valve Operating Arm Positions
2.Rotate the reverse valve operating arm to its
lower (reverse) detent position.
3. Adjust cable yoke until pin holes in yoke align

Fig. 59-Adjusting Pedal Height
with pin hole in reverse valve operating arm. Then
2. Remove cotter pin in operating rod and slide hex. install headed pin and cotter pin, DO NOT tighten yoke
adapter (Fig. 59) out of clutch pedal. nut.

N
Speed Selector Adjustment Continued
A Direction Selector Arm C Speed Selector Arm E Lock Cable

G Lock Cam Arm
BDirection Cable Yoke DSpeed Cable Yoke FClamp Stud HDisconnect Shaft End
Fig. 62-Transmission Control Valve Linkage
4. Place transmission control lever in "N-N" posi-

tion.
r\
a) Lever should be centered over the park slot in
the guide plate.
r\
^7
R 27851
Fig. 63-Transmissron Control Lever in "N-N"

R 27852N
Fig. 64-VaIve Operating Arm Positions

A Swivel B^-Bellcrank
Fig, 65-Speed Selector Assembly

b) The reverse valve operating arm should be in
the middle detent position (neutral).
9. Rotate transmission lock cam arm clockwise tight
against disconnect shifter yoke shaft end, and adjust
5. If step 4 is true, tighten reverse valve cable yoke lock cable swivel (A, Fig. 65) until swivel pin aligns with
nut; if not, readjust yoke until lever is centered over
hole in belJcrank (B). Install swivel so it is at its upper
park slot and tighten yoke nut,
limit.
6. With control lever held in "NT position in lever

10. Move control lever to "Park" and return the
guide plate, place transmission control valve operating
lever to its neutral position. The lock cam arm should
arm in its uppermost detent position (park) and adjust
be tight or within 0.08 in. (2 mm) of touching disconnect
cable yoke until pin holes in yoke align with pin hole in
shifter yoke shaft end.
operating arm. Install headed pin and cotter pin, and
tighten yoke nut. 11. If arm is not in proper position, rotate swivel up
two turns and repeat step 10.
7. Install transmission lock cable above clamp stud
12. Install retaining ring.
in transmission case and parallel with top edge of case
in the clamped area (See Fig. 62). 13. Check detented neutral position with slot in
guide.
8. With lock cable secured at lower end, place
14. Check park lock for proper operation.
transmission control lever in neutral position.
15. Operate tractor in each gear checking for ex-
cessive noise.

50-25*32 Power Shift Transmission Power Train Repair

/
Power Train Repair PTO 50-30-1
Group 30
PTO
PERMA-CLUTCH PTO
NOTE: See Group 25 for repair information for the
Power Shift Transmission PTO dutch. See page 30-5
for repair of the Power Shift PTO gear train. For repair
and adjustment of the Perma-Clutch PTO clutch, see
Group 5.
REMOVAL
Rear Bearing Quill and
Dual-Speed PTO Assembly
Fig. 3-Remove Dual PTO Drive Shaft
3. Compress large snap ring and pull drive shaft

rearward out of case.
AStub Shaft BBearing Quill
Fig. 1 -Removing Stub Shaft and Rear Bearing Quill
1. Remove stub shaft (A, Fig. 1) and rear bearing

quill (B) from transmission case.
A Idler Shaft B Idler Gear

Fig. 2-Remova 540 rpm Drive Gear Fig. 4-Removing Duat-PTO Reduction idler
4, Pull idler shaft (A, Fig. 4) with snap ring from

2. Remove 540 rpm drive gear.
case.
5. Remove idler (B) with bearing rollers and bearing
spacer from case.

50-30-2 PTO Power Train Repair
REMOVALContinued
PTO Drive Gear
1. Separate tractor between clutch housing and
engine (See Section 10, Group 20 for instructions}.
2. Remove clutch operating assembly from clutch

housing (See Group 5 of this Section for instructions).
3. Remove PTO drive shaft as instructed on the

preceding page.
4. Remove PTO drive gear.
Fig. 5-PTO Drive Gear with Oil Shield
REPAIR AND ASSEMBLY

Rear Bearing Quill Drive and Dual-Speed PTO Assembly
1Snap Ring (2 used) 10Spring Pin (2 used) 19Spacer

2540 RPM Stub Shaft 11 Rear Bearing Quilt 20Idler Gear
3Bearing Race 12-Gasket 21540 RPM Drive Gear
4O-Ring used)
(2 13 Stud (2 used) 22Spring Washer
51000 RPM Stub Shaft 14Snap Ring 23Snap Ring
6PTO Pilot 15Wler Shaft 24Snap Ring
7Nut {2 used) 16O-Ring 25Bearing
8 Lock Washer (2 used) 17Thrust Washer (2 used) 26Oil Seal
9 Drive Screw (2 used) 18 Bearing Roller (48 used) 27High-Strength Cap Screw
(4 used)
Fig, 6-Reductbn Gear Assembly

1. To replace oil seal (26, Fig. 6) in rear bearing

quill, install with sealing lips away from bottom of bore.
a) Install using 3-3/4 in. (95 mm) driver and

2-7/8 in. (73 mm) pilot (OTC No. 27543 and 27529).
b) Before installing seal, coat sealing lips with

oil.
2. PTO pilot (6) and bearing (25) may be pressed

out and reinstalled using PTO stub shaft (2 or 5).
3. Install snap ring (14) on idler shaft (15).
4. Inspect idler shaft bearing rollers (18). Roller

O.D. is 0,2186 to 0.2188 in. (5.55-5.56 mm). Length is
1,50 in. (38 mm).
5. Load bearing rollers and spacer (19) in idler shaft

ASnap Ring B Sleeve C Powershaft Front Bearing
gear with grease. Also grease thrust washer (17) to
each end of shaft gear (20} and place in position in Fig. 7-PTO Powersoft Front Bearing
case.
through openings in clutch housing. If replacement is
required, separate the clutch housing from the trans-
6. Install idler shaft (with snap ring to rear) in shaft
mission case to gain access to the snap ring (A),
bore. Align protruding half of shaft end up and to the sleeve (B) and bearing (C).
right.
8. Press front bearing onto grooved end of sleeve
Check bearing (C, (6, Fig. 8) with loading grooves on bearing facing
7. front Fig. 7) by reaching
press.
4
5
R 29472
1Oil Shield, Rear Half 5 Dowel Pin 10Bushing 14Snap Ring

2OH Shield, Front Half 6Sleeve 11Snap Ring 15 Drive Shaft with Gear
I 3 Drive Gear with Oil Shield 7 Snap Ring used) (2 12Snap Ring 16 Bearing Race and Roller Assembly
4Brake Piston 8Snap Ring (2 used) 13Ball Bearing 17Snap Ring
9 Ball Bearing
Fig. 8-540 and 1000 RPM PTO Shaft and Drive Gear
TM-1181 (Sep-77) Litho in US. A. Tractors - 4040 and 4240

REPAIR AND ASSEMBLY Continued PTO Clutch Lever Adjustment

9. A new drive gear is supplied with the oil shield
installed. If only the oil shield is to be replaced, remove
by separating front and rear portions at the welds.
10. Install new oil shield on gear and tack weld in

five locations,
11. Install large PTO drive gear in dutch housing

using care not to drop the gear damaging the oil shield.
12. Install rear powershaft snap rings so tangs on

snap rings are on flat of shaft and install shaft.
NOTE: targe drive gear fell off sleeve in clutch

If
housing, can be property positioned by removing

it
pressure regulating valve housing and relocating gear

on sleeve.
13. Install 540 rpm drive gear (21 , Fig. 6).
14. Install quill gasket and tighten rear quill (11) to

85 ft-ibs (115 Nm) (11.5 kgm) torque.
15. Install stub shaft.
A^-PTO Valve Rod CPTO Lever

BClutch Valve Rod OHex. Adapter
Fig, 9-LH. Cowl Removed
1. Remove left-hand cowl from control station and

check to be sure PTO operating rod is in rear (upper) of
the three PTO lever holes. Also be sure lever return
spring is in place.
2. Move PTO lever to 3/4 inch (19 mm) from rear of

lever slot.
3. Rotate PTO clutch valve operating arm clockwise

against stop on pressure regulating valve housing.
4. Adjust PTO rod to align pin with upper hole in

lever.

POWER SHIFT TRANSMISSION PTO

REMOVAL
Rear Bearing Quill and Dual-Speed PTO
Assembly
AStub Shaft B^Bearing Quilt

AIdler Shaft BIdler Gear
Fig. 10-Duaf-Speed Stub Shaft and Quill
Fig. 12~Dua!-PTO idler and Shaft

1. Remove stub shaft (A, Fig, 10) and rear bearing
quill (B) from rear of transmission case. 3. Pul! idler shaft with snap ring (A, Fig. 12) from
case.
4, Remove idler (B) with bearing rollers and spacer

from case.
Fig. 1 1 -Removing 540 rpm Drive Gear
2. Remove 540 rpm drive gear.

REMOVAL- -Continued
PTO Drive Removal
1. Separate the clutch housing from engine and
remove the transmission clutch pack as instructed in
;
tSs'5is!Ria.s iHiS.6*
s
5|Hi|iia;jSi aft.
A-C1-C2 Shafts CSnap Ring

B PTO Clutch Gear DCap Screws
Fig. 13-PTO dutch Gear Shaft
NOTE: If only the dutch gear is to be serviced, A Drive Gear Shaft GSnap Ring
remove the C1-C2 dutch and snap
shafts (A, Fig. 13) Bearing H Lower Idler Gear
ring; then pull clutch gear shaft as instructed on page
B Upper Idler Gear Shaft
50-20-9.
C Upper Idler Bearing IDrive Gear
D Upper Idler Gear J Special Cap Screw
2. Remove the two cap screws (D) inside the clutch

Shaft K Retaining Washer
housing and separate the clutch housing from the
E Lower Idler Gear L Oil Baffle
F Lower Idler Bearing MCap Screw
transmission case.
Fig. 15-PTO Drive Train
3. If has not already been re-
rear bearing quill
moved, complete removai steps as instructed on page

5. Remove cap screw (J, Fig. 15) and retaining
5.
washer (K) and use a puller to remove drive gear (I).
6. Carefully drive PTO drive shaft rearward out of

case.
IMPORTANT: Be sure snap ring (Fig. 14) is free

from groove in case before driving PTO shaft.
7. Remove PTO upper idler (B) and lower idler (E)

gear assemblies.
Fig r 14-Removing Dual PTO Drh/e Shaft (
4. Compress snap ring retaining power shaft in rear

of case,

Power Train Repair
PTO 50-30-7
REPAIR AND ASSEMBLY

NOTE: See pages 2 through 4 (steps 1-6 and 12-
15) for information on repair and assembly of the rear
bearing quill and dual-speed PTO reduction assembly.
PTO Drive Train

1. Install snap ring (A, Fig, 17) in front of transmis-
sion case.
2. Install ball bearing (B) over power shaft. Bearing

shield should face clutch housing.
3. Install drive gear (C).
4. Install special cap screw (E) with retaining

washer (D), Torque special cap screw to shaft to 120
ft-lbs (163 Nm) (16.3 kgm).
5. Install oil baffle (L, Fig. 15). Torque three special

cap screws (M) to 21 It-lbs (28 Nm) (2.8 kgm).
6. Press brake shoe guide pins (D, Fig, 16) into ^lii
clutch housing until pins project 0.75 inch (1 9 mm) from
finished face of brake piston bore.
7. Coat brake piston packing (I, Fig. 17) with oil and
install with shoe (F) in clutch housing.
AUpper Idler Shaft Bore C Lower Idler Shaft Bore

B PTO Gear Shaft Bearing D Guide Pins
Cup Bore EBrake Shoe
Fig. 16-Rear of Clutch Housing
R 29006N
ASnap Ring E Special Cap Screw I O-Ring M Ball Bearing

B Ball Bearing F Brake Shoe J Bushing NSnap Ring
C Drive Gear G Pin (3 used) KSnap Ring O Drive Shaft with Gear
D Retaining Washer H Brake Piston L Snap Ring P Bearing Race and Roller Assembly
QSnap Ring
Fig. 17-PTO Drive Shaft and Brake

.
REPAIR AND ASSEMBLYContinued CAUTION: Be sure to replace all safety

and guards after servicing the PTO.
shields
PTO Clutch Lever Adjustment

.. Ili-xliii! 7-"
^^KfcitfiftiBSin
Mi , ;
;
v ;
'
R 23397F |lll|fc :? :
; ;:
1 Ranged Bearing Cup 10 Snap Ring PSjHjIjKijj
2 Bearing Cone 11 Upper Idler Gear

3 PTO Drive Gear Shaft 12 Snap Ring A PTO Valve Operating Rod C Rod Yoke
4 Front Bearing Cone 13 Upper Idler Shaft B PTO Lever D Lever Return Spring
5 Front Bearing Cup Retainer
6 Retaining Ring 14Snap Ring Fig, 19-Adjusting PTO Lever
7 Upper Idler Gear 15 Bearing Cone
Shaft 16 Bearing Cup
8 Bearing Cone 17 Lower Idler Gear 1 Hold clutch valve operating rod (A, Fig. 19) down
9 Bearing Cup 18 Snap Ring until itbottoms.
19 Lower Idler Gear Shaft
Fig, 18-PTO Helical Drive Train .
2. Push PTO lever (B) forward until front edge of
lever is 3/16 inch (5 mm) from front end of lever slot.
8. Press upper idler gear shaft oi! retainer (13, Fig.
18) into shaft (7) with smaller diameter hole away from 3. Adjust PTO rod yoke (C) until yoke hole aligns
shaft. with front (lower) lever hole.
9. Assemble upper idler shaft with bearings (8),

cups (9), gear (11) and snap ring (10). Install the
4. Install yoke pin, washer and cotter pin.
thickest snap ring (12) which will fit into the groove.
5. Lock yoke jam nut and replace cowl.
10. Install upper idler assembly in front of trans-
mission case. 6. Make sure PTO lever return spring (D) is in place.
11. Assemble lower idler gear shaft (19) with gear
and bearing assemblies. Install thickest snap ring (14)
which will fit into groove and install in transmission
case.
12. Replace the packings which seal the oil pas-

sages between the clutch housing and transmission
case. Hold in place with a light, clean grease.
13. Slide rear bearing cup (1) into the transmission

case.
14. With drive gear shaft assembly in place, rotate

gear train as clutch housing and transmission case are
joined to aid alignment.
15. Install front bearing cup (5) and install thickest

snap ring (6) which will fit into groove in clutch housing.
TM-1181 (Jun-80) Litho in U.SA, Tractors - 4040 and 4240

.
Power Train Repair Differential 50-35-1
Group 35
DIFFERENTIAL
REMOVAL
PERMA-CLUTCH Differential Removal
Fig. 1 -Removing Hex. Shaft A Load Control Arm

1 Remove the hex. drive shaft that extends through Fig. 2-Perma-Cfutch Differential Case
the transmission pump, from the engine crankshaft, to
the rear of the case. Protect the machined end a/id 6. Remove differential lock oil line and fitting, if
remove with a pliers. equipped.
2. Remove operator station and rockshaft assem- 7. Remove clamp retaining oil lines and remove
bly. (See Section 10, Group transmission oil pump pressure oii pipe.
20.)
3. Remove both final drive units as instructed in 8. Remove drive shaft lube oil line with bracket from
Group 40, this Section. pump and remove line from transmission case. Note
that line is fastened on inner left-hand side of trans-
4. Remove brake backing plate, sun pinion and disk mission case.
from each side of case.
9. Remove pump manifold retaining screws and
5. Remove transmission case cover. remove manifold,
10. Remove differential shaft lube oil line from dif-

ferential drive shaft bevel pinion.
11. Remove transmission oil pump body.
12. Remove one differential ring gear-to-housing

cap screw (for installation of lift link).

50-35-2 Differential Power Train Repair
PERMA-CLUTCH Differential Removal-

Continued
A Right-Hand Bearing Quill B Lock Oil Line Inlet Fitting
Fig. 3-Removing Differential (Load Control Arm Not Shown)
13. Install JDG-19 Lift Link Bracket with ring gear A Load Control Arm
cap screw,
Fig. 4-Power Shift Differential Case
14. Secure a chain around differential housing and
through lift bracket (to balance housing), and raise 4. Remove differential lock oil line, retaining as-
differential housing enough to relieve the weight on the sembly, and quill inlet connector (if equipped).
bearing quills (A, Fig. 3).
15. Remove six cap screws from each bearing quill

5. Remove C3 oil line and bearing retainer.
and remove quills.

6. Remove one differential ring gear-to-housing cap
IMPORTANT: Be sure to keep quill shims with screw (for installation of lift link bracket).
their respective bearing quills.
16. Remove load control arm.

7. Remove three cap screws which secure load
control arm lower support to case.
17. Remove differential housing assembly from
case using a chain hoist. Use care to balance assem- 8. Install a JDG-19 Link Bracket on differential
bly on chain so bearing are not damaged during re- housing-to-ring gear cap screw.
moval.
9. Secure a chain around differential housing and
Power Shift Differential Removal through link bracket.
1. Remove operator station and rockshaft assem-
bly. (See Section 10, Group 20.) 10. Remove both bearing quills with shims and
carefully raise differential with load control arm (A) from
2. Remove both final drive units as instructed in transmission case.
Group 40, this Section.
3. Remove brake backing plate, sun pinion, and IMPORTANT: Be sure to keep quill shims with
disk from each side of case.
their respective bearing quilts.
TM-1181 (Jun-80) Utho in U,SA. Tractors - 4040 and 4240

Disassembly 3. Invert housing so ring gear is up and use com-

pressed air toblow the piston out Note oil pressure
4040 Tractors {Serial No. -6406)
4240 Tractors {Serial No.
inlet (A, Fig. 6) between sealing rings (B),
-15150)
4. Remove retaining cap screw (C) from differential
housing and remove bevel pinion shaft and bevel
pinions.
Disassembly
4040 Tractors (Serial No. 6407- )
4240 Tractors (Serial No. 15151- )
1. Complete Steps 1-3 of the preceding procedure.
2. Remove retaining cap screw (C) from differential

housing.
A Cover C Bevel Lock Gear

B Return Springs D Disks (3 used)
E Plates (2 used)
Fig. 5-Differential Housing Cover
1. Remove differential cover cap screws and lift
housing cover (A, Fig. 5) off differential housing. Be

careful not to lose the three small springs (B) which are
mounted in the inner side of the differential cover.
2. Remove splined differential bevel lock gear (C) A Bearing Retainer C Pinion Shaft
with three clutch disks (D) and plates (E).

BTang
Fig. 7-Removing Shaft
3. Bend up bearing retainer tang (B, Fig. 7).
4, Remove bevel pinion shaft, bevel pinions with

bearings, bevel pinion thrust washers and needle
bearing thrust washers.
Inspection
1. Check sealing rings (B, Fig. 6).
2. Check bore in right-hand (Power Shift, left-hand)

bearing quilL Replace quill if sealing ring
differential
bearing surface is scored or damaged.
3. Examine bevel gears. If damaged, differential

housing bores may also be damaged.
$80$7X 4. If bevel pinions or bevel pinion shaft are worn or
A Pressure Inlet C Pinion Shaft Retaining damaged, replace all parts.
BSealing Rings Cap Screw
D- Pinion Shaft
5. On 4040 Tractors (6407- ) and 4240 Trac-
tors (15151- ), inspect needle bearings and bevel
Fig. $-DifferentiaI Housing
pinion thrust washers for wear.

Inspection Continued 5. Install remaining bevel pinion, bearings and

thrust washer.
Check roller bearing cones on differential hous-
6.
ingand housing cover. pitted or worn, remove and

If 6. Torque differential housing-to-bevel pinion inner
press new parts onto hubs. shaft special screw to 85 ft-lbs (115 N-m) (11.5 kgm).
7. inspect bearing quill cups. If worn or scored,
7. Coat clutch piston mating surface and new
press out and press new cups into place.
packings for piston I.D. and O.D. with John Deere
8. inspect differential plates and disks. a disk is If
HY-GARD Transmission and Hydraulic Oil. Install pis-
less than 0.100 inch (2.5 mm) thick, replace.
ton and packings.
Assembly
IMPORTANT: If the ring gear is replaced, the
differential drive shaft must also be replaced. Refer
to the transmission groups for instructions.
NOTE: If repair is being done on a no-iock dif-
disregard any references to differentia! lock

ferentia!,
components during the foilowing assembly and ad-
justment procedures.
1. Install thrust washer and bevel gear in bottom of
housing.
NOTE; Coat all mating parts with John Deere HY-
GARD Transmission and Hydraulic Oil prior to assem-

bly.
2. Install bevel pinions (B) on gear aligning pinion
bores with bore for shaft in housing.
3. On early model tractors* install bevel pinion shaft

through housing and two pinions.
R 28059N
ARing Gear Cap D Bevel Lock Gear

Screws (12 used) E Springs and Pins
B Clutch Disks F Housing Cover
C Separator Plates
Fig. 9-Differentiai Lock dutch Assembly
8. install bevel lock gear (D, Fig. 9) (with thrust

washer).
9. Install 12-tang clutch backing plate, paper disks

and 9-tang separator plates (C) alternately.
A Bevel Pinion Thrust Washer
C Pinion Shaft
(B, Fig. 9}
BNeedle Bearing Thrust Washer

D Tangs (There are three disks and two 9 -tang plates in as-
sembly.)
Fig, 8-lnstaIting Pinion Shaft
NOTE: This arrangement allows the piston return

4. On model tractors** install pinion shaft
later
springs be placed on the backing plate when the
to
through bevel pinion thrust washer (A, Fig. 8) and
housing cover is installed.
needle bearing thrust washer (B). Make sure hole in
outer end of pinion shaft is on same side of differential 10. Install three springs (E) over spring pins in
housing as hole for pinion shaft retaining cap screw. housing cover with light clean grease.
NOTE; Make sure tangs (D) on bevel pinion thrust
11. Torque housing cover (F) retaining cap screws
washer are in groove in housing.
to 85ft-ibs (115 N-m) (1 1.5 kgm) on tractor without lock
*4Q40 Tractors ( -6406)
or 55 ft-lbs (75 N-m) (7.5 kgm) with lock.
4240 Tractors ( -15150)
**4040 Tractors (6407- )
4240 Tractors (15151- )

1 2. If ring gear was replaced, heat to 300F (1 50C) 3. Torque bearing quill cap screws (B) to 85 ft-lbs
before assembly. (115 N*m) (11.5 kgm).
A
*
CAUTION: If hot oil Is used to heat parts,
Backlash Adjustment
remember that oil fumes orcan ignite
oil
above 380F (193C). Use a thermometer and do not NOTE: Make this adjustment after preload adjust-
exceed 360T (182X). Do not allow a flame or ment only.
heating element to be in direct contact with the oil.
Heat the oil in a well -ventilated area. Plan a safe 1 . Mount a dial indicator to check backlash between
handling procedure to avoid burns. differential ring gear and drive shaft pinion.
Torque housing-to-ring gear cap screws to 85

13.
(115 N-m) (11.5 kgm). Note that washers are
ft-lbs
used on screw holes in housing without spot faces.
Adjustments
Preload Adjustment
1. Check for a measurable amount of backlash

between the differential ring gear and drive shaft pin-
ion.
irM ""..
A
Fig. 1 1 -Checking Backlash
NOTE; If backlash ischecked at only two points on

ring gear, they should be 180 apart,
2. If backlash is not within 0.0075-0.0155 inch

(0.178-0.396 mm); adjust as follows:
"
NOTE: Since the Power Shift ring gear is "flopped,
the following steps (a and b) should be shimmed in the
opposite directions.
a) If backlash is low, transfer shims from the

right to the left-hand quill.
b) If backlash is high, transfer shims from the left
to the right-hand quill,
IMPORTANT: The same shims must be added to

A Bearing Qui I! C Shims
one quill as removed from the other to maintain
B Cap Screws D Differential Housing proper ring gear bearing preload.
Fig, 10-Adjusting Bearing Preload

3. Reverse removal steps for installation procedure.
2. Check differential endpfay using a dial indicator.
If necessary;
a) Add shims (C Fig. 10) under bearing

t until a
measurable amount of endplay is obtained.
b) Set quill bearings with 0,002-0.005 in. (0.05-

0.13 mm) preload by removing shims from either
bearing quid.

DIFFERENTIAL LOCK VALVE

Removal
1. Relieve hydraulic brake accumufator pressure.
AMetering Pump Fitting EInlet Tee

B Lock Valve Mount F Differential Lock Vaive
C Brake Valve Tee G Lock Valve Arm
D Inlet Fitting HOperating Rod
Fig. 13-Lock Valve Removal

Fig. 12-Differentiai Lock Vaive (R.H. Cowl Removed)
9. Remove the differential lock valve (H).
2. Remove right-hand cowl (Fig. 12).
3. Remove differential lock pressure line cfamp and

remove line from tee on valve and from bottom fitting
(D, Fig. 13).
4. Remove outer front eibow from valve (not illus-
trated).
5. Remove differential lock return line from fitting
and from brake valve fitting (C).
6. Remove two differentia! lock valve mounting

screws.
7. Disconnect valve operating arm (G) from rod and

remove arm screw.
8. Remove pressure return pipe between lock valve

and steering metering pump.

.
R19066F
1 Plunger 7 O-Rtng 13Tee (pressure oil)
20- Ring S Differential Lock Valve Housing 14O-Ring

3 Spring 9 Pressure Control Valve 15Spring
4Shim (use as required) 10 Spring 16 Steel Ball
5Spacer (2 used) 11 O-Ring 17Pin
G Elbow (return oil) 12 Bbow (lock pressure oil) 18Cap Screw
19 Cap Screw
Fig. 14-Differentiai Lock Valve Parts
1 Use Fig. 1 4 as a reference. Note that the tee (13) 3. Press lock pedal bushings into pedal flush to 0.02
must be removed to release detent pin (1 7) before the in, (0.5 mm) below ends of bushing bore.
valve can be removed,
4. Reverse removal steps for installation.
2. Inspect valve bore, valve and springs.
FREE WORKING
Control (10) 2.56 in. 1.31 in. at 9.5-11.5 lbs.

Valve (65 mm) (33.3 mm at 42-52 N)
Plunger (3) 2.28 in. 1.92 in. at 10.3-12,5 lbs.
(58 mm) (48.8 mm at 458-556 N)

Release Bar Adjustment 1. With the brake pedals released, place the dif-
the "ON" position.
ferential lock pedal (B, Fig. 15) in
2. Adjust differential lock adjusting screws to obtain

0.010-0.030 inch (0.3-0.8 mm} clearance between ad*
justing screws and rod release bar (C).
3. Check to be sure rod will release with slight brake

pedal pressure.
4. Retest valve pressure as instructed on Section

250,
A Brake Pedal C Release Bar

B Lock Pedal D Feeler Gauge
Fig. 15-Feefer Gauge To Check Proper Clearance

.
Power Train Repair Final Drive 50-40-1
Group 40
FINAL DRIVE
NOTE: Repair of Hi-Crop final drive begins on page
40-5.
REMOVAL
1. Drain transmission oil.
2. Raise tractor and place support stands under

drawbar support.
3. Remove axie snap rings from end of axle and

remove rear wheels.
i "... .Jtr.r:
NOTE: Final drive assemblies can be removed "..U f;rj

%
without removing rear wheels,
4. Loosen cab mounting bolts and rear mounting

1* It
vV -'%%:" :
cap screws from axle housings.
A Differential Lock Oil Line C Axle Housing

5. Remove differential Jock line (A, Fig. 2) from BSun Pinion Drive Shaft D Planetary Carrier
transmission case when removing right-hand final
drive. Fig. 2-Remov'mg Final Drive (4840 Shown)
A Planetary Carrier
B Special Cap Screw
Fig. 3-Removing Planetary Assembly
Fig. 1-Attaching D-05007ST Support Stand with
D-05149ST to Axle Housing (4840 Shown)
1 Slightly loosen special cap screw (B, Fig, 3) and
remove lock plate (C) from special cap screw.
6. Attach Support Stand (Fig. 1) to axle housing
and remove axle housing-to-transmission case cap
2. Remove cap screw and remove planet pinion
screws.
carrier assembly (A) from axle housing.
7. Remove axie housing.

50-40-2 Final Drive Power Train Repair
Disassembly and Repair Continued
R 29369N
A Snap Ring I Cap Screws PThrust Washer T Thrust Washer

BAxle Shaft J Axte Housing (6 used) U Snap Ring
C Bearing Spacer and Gear Q Roller Bearing V Planet Pinion Carrier
DOil Seal K Gasket (99 used) WWasher
E Oil Seal Cup LOil Seal R Planet Pinion X Cap Screw
F Bearing Cone MBearing Cup (3 used) Y Lock Plate
G Bearing Cup N Bearing Cone S Planet Pinion Shaft Z Final Drive Shaft
H Pipe Plug O Dowel Pins (3 used) and Sun Pinion
Fig. 4-Finaf Drive Parts
3. Remove thrust washer (T, Fig. 4) from axle

housing.
4. Expand large snap ring (U) on carrier enough to

remove each planet pinion shaft (S). Do not lose
rollers.
5. Examine the sun pinion shaft (Z) for wear and

damage using the following procedure to determine
what repair action is required.
a) Place a piece of 5/8 in. (16 mm) ground pin

which is straight and smooth, between two gear teeth
as shown in Fig. 5.
NOTE: On some sun pinions, the gear teeth area is

"Fmi-Sheared". These pinions can be identified by a
slight shoutder (B) near the center of the gear tooth.
When positioning rod between gear teeth on these
pinions, make sure it is located as close as possible to
shoulder (B) without coming in contact with shoulder
A Ground Pin B^Shoulder
Fig. 5-Measuring Wear

b. While holding the ground pin firmly in place,

insert a feeler gauge between gear tooth and rod to
determine amount of wear. Check at three different
locations around the gear. This amount of wear along
with tooth condition (pitting) is used to determine repair
required (see Final Drive Service Condition Chart).
y-i ^ppyp^^g^^ y^-
Fig. 7-Moderate Pitting
d. Moderate pitting (Fig. 7) usually is -concentrated

around the "pitch line" but may also extend to other
parts of the tooth. If pitting is moderate and wear is less
than 0.008 in. (0.20 mm), the final drive assemblies
should be reversed.
Fig. 6-Light Pitting a 'Pitch Line"
c. shows pitting which would be described as

Fig, 6
"light."Depending on the use and the number of hours
on the tractor, it is not uncommon to see a line of small
pits thatextend across the tooth approximately halfway
down. This pitting occurs at what is known as the "pitch
line" or the main contact point between the mating
gears. If pitting is light and wear is less than 0.008 in.
(0.20 mm), the final drive assemblies should be re-
versed.
Fig. 8-Heaving Pitting
e. Heavy pitting (Fig, 8) is a condition where the

area of all the pits is approximately equal to 1/3 of the
tooth contact surface. If heavy pitting is present, it is
not necessary to measure wear because the sun pin-

ton must be replaced.

FINAL DRIVE SERVICE CONDITION CHART 1 0* If wheel is still on axle, use jacking tool as shown
to pull axle housing from axle. Attach a hoist to axle

Condition Repair housing and remove from axle.
(Pitting) Wear Required
11. If wheel was removed from axle, place axle in

None Under 0,003 in. Reinstall a press, and press axle from bearing.
{0.08 mm) Parts
Light or Under 0-008 in. Reverse

Moderate {0.20 mm) Parts
Heavy or Over 0.008 in. Replace

Chipping (0.20 mm) Parts
6. Inspect pinion shafts for wear and scoring. Shaft

O.D. is2.0838-2.0844 in. (52.928-52.944 mm).
7. Inspect planet pinions. I.D. is 2.5226-2.5240 in.
(64.07-64.11 mm).
8. Inspect roller bearings for wear or damage. O.D.

is 0.2186-0.2188 in. (5.552-5.558 mm). Replace bear-
ings as a set.
R80112H1
A^-O-01267AA Bearing Pulling C^-D01311AA Push Puller

Attachment DOuter Bearing
BT>0124aAA Legs
Fig. 10Removing Bearing

12. If wheel is still on axle, assemble pulling tools
as shown in Fig. 10 to remove outer bearing cone (D,
Fig. 10), spacer and oil seal.
13. Inspect bearing cones and axle shaft at cone

diameter for scoring or wear.
a) Inner cone I.D. is 3.2813 in. (83.345 mm).
ASupport Tool D^-Hydraulic Jack

BAxle Shaft ESupport Too! Screws b) Outer cone I.D. is 3.3750 in. (85.728 mm).
CInner Bearing FJacking Tool
c) Axle O.D. at inner cone is 3.2828 to 3.2838 in.
Fig.
9 Removing Axfe (83.383 to 83.409 mm).
If wheel is not on axle, remove axle shaft (B, Fig.

9. d) Axle O.D. at outer cone is 3.3787 to 3.3797 in.
9) by pressing shaft through inner bearing (C) and (85.819 to 85.844 mm).
housing. Use jacking tool (F) as shown or install an old
cap screw in end of shaft (bottom screw in hole) and 14. If outer bearing on axle shaft is loose on shaft,
drive shaft out using a hammer on the end of the screw. the shaft may be modified using the following
(
directions.
TM-1181 (Mar-83) Litho in USA. Tractors - 4040 and 4240

Power Train Repair Final Drive 50-40-4A
MODIFYING 86 mm AXLE SHAFT FOR

UNDERSIZE BEARINGS
1. Grind the axle (A, Fig. 10A) as shown. 2. Use a punch to mark the outer end of the shaft
as shown (E) for identification.
NOTE: Use a crankshaft grinder capable of a 48 in.
(1219 mm) length.
17.640 in.
{446.10 mm)
3.3497 in. 0.0005 in. ,

(85.062 mm 0j013 mm)*
AAxle Shaft BGrind Concentric With C-Concentricity Diameter EIdentification Mark

Diameter (C) Within DDo Nat Grind
0.005 in. (0.125 mm) T1R
Fig. 10AModifying Bearing Journals For Undersize Bearing Cones (86 mm Axles Only)

50-40-4B Final Drive Power Train Repair
Assembly
1. Coat I.D. of planet pinions with a thin layer of
grease and assemble roller bearings in pinion.
2. Position planet pinion shaft thrust washers (D, Fig.

11) on both sides of the planet pinion. Dip shaft in oil
and bore through planet pinion. Note

install in carrier
that snap ring groove on shaft should face center of
carrier.
NOTE: two of the three pinions In carrier. Seat

Install
snap groove and be sure it is posi-
ring in
tioned to hold shaft
ADriving Disks CDriver Handle

BBearing Cup
Ftg. 12Installing inner Oil Seat
3. Install the washer (W, Fig. 4) in the center of the

planetary carrier with the depressed side of washer
facing away from the axle. Install remaining planet
pinion and shaft.
HHSbTS*
4. Install inner bearing cup (B, Fig, 1 2) and outer cup
in housing tight against shoulders.
APlanet Pinion DThrust Washers

B Roller Bearings ECarrier 5. Install inner oil seal in axle housing. Drive with
CPlanet Pinion Shaft F Snap Ring sealing lip spring facing driver. Use OTC Driving Handle
No. 27489 and OTC disks No. 27535 (3-1/4 in.) and
Fig. 11Assembling Planetary Carrier
27547 (4 in.). Drive seal into housing 0.27 in. (7 mm)
below shoulder that locates inner bearing cup.
TM-1181 (Mar-83) Litho in U.S.A. Tractors - 4040 and 4240

. .
Power Train Repair Final Drive 50-40-4C
6. Coat inner oil seal lip with grease before installing 1 2. Install shaft with bearing, spacer, and seal in the
axle. axle housing. Install thrust washer (T, Fig. 4) in housing.
7. Install and bottom outer oil seal cup in housing. 13. Assemble special cap screw (X, Fig. 4) through
washer (W) in planetary.
CAUTION: Plan a safe handling procedure
to avoid burns when heating parts. 14. Heat inner bearing cone (N) to 300T (150*C)
and on shaft. Install planetary carrier assembly
install
8. Heat axle bearing spacer (C, Fig. 4) to 460F in housing and torque special cap screw to 170 Ib-ft
C
(237 C) and drop onto shaft Drive on shaft shoulder (230 N m) (23 kgm).
until cook
15. Rotate axle in housing three revolutions and
retorque special cap screw to 170 Ib-ft (230 N-m) (23
kgm).
16. Repeat step 15.
cap screw. If plate will not

17. Install lock plate over
fit by turning over, tighten cap screw 8 maximum.
18. Fill outer bearing compartment with SAE multi-

purpose grease.
Installation
1 Reverse the removal procedure to install the final

drive. Also note the following special installation
instructions.
2. When installing final drive assembly, install sun

gear in differential, install brake disk and backing plate
on sun gear.
3. Torque rear axle housing-to-transmission case
AOuter Oil seal BOuter Bearing Cone Driving Surface cap screws to 170 Ib-ft (230 N-m) (23 kgm).
Fig. 13inner End of Axle Shaft
9. Install outer bearing oil seal (A, Fig. 13) with metal
side of seal facing driver. Coat seal with SAE multi-
purpose grease.
10. Heat outer bearing cone (B) to 300T (150C)

and install on shaft.
1 1 Drive or press cone and spacer, after cool, to

reseat assembly against shoulder
Utho in USA, Tractors - 4040 and 4240

50-40-4D Final Drive Power Train Repair
TM-1181 (Mar-83) Litho in U.S.A. Tractors - 4040 and 4240

HI-CROP FINAL DRIVE

(4240 Only)
REMOVAL 3. Remove two closure plugs from flange of drive
shaft housing (C) and insert 3/4 in. jack screws in the
1. Remove drawbar or 3-point hitch (as equipped).
plug hofes.
4. Alternately tighten jack screws to remove final

drive gear housing (D).
5. Remove drive shaft housing (C).
DISASSEMBLY
Final Drive Gear Housing
1. Drain housing of gear lubricant and remove
housing bottom cover (00, Fig. 15).
2. Remove inner bearing cover (GG).
3. Remove cotter pin from axle shaft (KK), and

remove slotted nut (FF) and spacer (EE).
4. Remove inner gear retaining snap ring (BB) and

drive axle shaft out for disassembly.
R 2S197& 5. Use a slide-hammer and puller to remove drive

gear housing outer bearing quill (O) and seal.
A Cap Screws C Drive Shaft Housing
a Stud Nut Drive Gear Housing 6. Remove drive shaft outer pinion (S) and remove
Fig, U-Removing Final Drive Housings
large final drive gear (NN).
2. Remove seven stud nuts and washers (B, Fig.

14) which hold the two housings together.

DISASSEMBLYContinued
R 31095
A Differential Output Shaft I Dowel Pins P Oil Seal X Drive Gear Housing GG--Inner Cover
BCap Screw and Washers JDrive Shaft Q Bearing Cup Y Backing Washer HH--Spacer
C Inner Quill Housing and Gasket R Bearing Cone Z Oil Seal II --Seal Cup
0 Quill Shirns-0.002, 0.005, K Cap Screws SOuter Drive AA Bearing Cup JJ --Oil Seal
0.010 in. (0.05, 0.13, 0.25 mm) L Closure Plugs Shaft Pinion
BB Snap Rings KK--Axle Shaft
E Bearing Cups M Final Drive Shaft T Hex Nuts CCBacking Snap Ring LL--Snap Ring
F Bearing Cones NShim-0.003, 0.005, 0.010 in. U Gasket DD Bearing Cone MM--Grease Fitting
G Differential Output Gear (0.08, 0.13, 0.25 mm) V Studs EEWasher NN--Final Drive
(27 teeth) OOuter Quill WPlug FFSlotted Nut OO--Bottom Cover
H Inner Drive Shaft Pinion
(23 teeth) {
Fig. 15-Hi-Crvp Final Drive

Drive Shaft Housing
1 . Remove final drive shaft (M, Fig. 1 5) and differen-

tial output shaft (A).
2. Remove inner quill (C).
3. Remove differential output shaft gear (G) and

drive shaft inner pinion (H).
Inspect Axle Shaft
1 . If outer bearing on axle shaft is loose on shaft,

the shaft may be modified using the following
directions.
MODIFYING AXLE SHAFT FOR UNDER-

SIZE BEARINGS
1 . Grind the axle (A, Fig. 1 5A) as shown. 2. Use a punch to mark the outer end of the shaft
as shown (E) for identification.
NOTE: Use a crankshaft grinder capable of a 48 in. 3. Install oil seal, spacer, and undersize bearing as
(1219 mm) length. instructed.
91.478 mm 0.013 mm
(3.6015 In. * 0.0005 In.)
AAxle Shaft BGrind Concentric With CConcentricity Diameter EIdentification Mark

Diameter (C) Within DDo Not Grind
0.005 in. (0.125 mm) TIR
Fig. 15AModifying Bearing Journal and Drive Splines For Under Size Bearing Cone
TM-1181 (Mar-83) Utho in USA. Tractors - 4040 and 4240

.
50-40-7A Final Drive Power Train Repair
REPAIR AND ASSEMBLY 3.Heat the rear axle outer bearing cone (C, Fig. 16)
to 300F (150'C) and install on axle. Retain until cool.
Axle Shaft and Final Drive Gear Housing
4. Coat oil seal lips with grease.
CAUTION: fumes or oil can ignite above
Oil
3TF (193C). Use a thermometer and do 5. install drive gear outer retaining snap ring (D, Fig.
not exceed 360F (182C). Do not allow a
16) on axle shaft.
flame or heating element to be in direct
contact with the oil. Heat the oil in a
well-ventilated area. Plan a safe handling
procedure to avoid burns.
ASeal Driver CInner Seal

B-Ôuter Seal Cup DSnap Ring
Fig. 17Installing Gt Seal
6. Install inner cup backing snap ring (D, Fig. 17) in

A^Spacer CBearing Cone
B-Sea! DSnap Ring gear housing and press inner cup against snap ring.
Fig. 16Axle Assembly 7. Instail backing washer in gear housing.
1. Heat outer bearing spacer (A, Fig. 16) to 300*F 8. Install axle bearing inner oil seal (C) against
(15CTC) and install on axle (larger O.D. out). Retain on backing washer. Use 4-5/8 in, driver disk and 3-9/16
axle shoulder until cool. in. pilot (JDT-32 and OTC 27540) with OTC 27489
Handle. Install with spring side of seal facing driver.

2. After spacer Is cool, install outer bearing seal (B)
over spacer. Drive on the case of the seal. 9. Install outer bearing cup against housing
shoulder.
10. Instail outer oil seal cup (B).
1 1 Assemble outer drive shaft gear (S, Fig. 1 5) with

bearing cones. Note that outer drive shaft gear has
sixteen teeth.
12. Press outer drive shaft gear bearing cup into

gear housing tight against shoulder.
TM-1181 (Mar-83) Litho in USA, Tractors - 4040 and 4240
Power Train Repair Final Drive 50-407B
REPAIR AND ASSEMBLYContinued

13. Press drive shaft outer oil seal (P, Fig. 15) into
gear housing quill (O) with spring side facing driver. Use
3-5/8 in. driver disk and 2-5/8 in. pilot (OTC No. 27541
and 27525).
14. Install outer drive shaft gear inner bearing cup

in qurll.
ADrive Gear DSlotted Nut GFinal Drive Shaft

BBar EJDT29 Wrench HInner Cover
CAxle Shaft F^-Torque Wrench ICotter Pin
Fig. 19 Tightening Axle Shaft Nut

20. install large final drive gear in housing so it
properly meshes with the outer drive shaft gear.
21. Insert axle shaft (C, Fig. 19) through gear

housing and final drive gear. Avoid damaging oil seal.
Install inner gear retaining snap ring on axle shaft.
22. Install bearing cone and spacer washer on shaft.
23. Using JDT-29 Lock Nut Wrench (and formula

AHousing Gasket D-^3/8 in. Cap Screws
BFeeler Gauge EAdjustment Tool given on page 00-1 8), torque slotted nut (D) to 200 Ib-ft
COuter Quill FHex Nuts (271 N-m) (27 kgm) while rotating axle at least three
times.
Fig. 18Adjusting Outer Drive Shaft Gear Bearings
24. Loosen slotted nut (D) and retorque to 50 Ib-ft
15. Install gear in housing and install quill (C, Fig. (68 N-m) (6,8 kgm).
18).
25. Loosen slotted nut to next castellation and insert
16. Install drive gear housing gasket (A) and Adjust- cotter pin (I).
ment Toof (E). See Group 00 to construct the tool.

26. Install gear housing oil filler plug with washer so
17. Torque hex nuts (F) to 250 Ib-ft (339 N-m) (34 raised center of washer contacts head of plug.
kgm).
27. Install gasket and quill shims before installing
18. While turning outer drive shaft gear (using drive gear housing on final drive shaft housing.
shaft), alternately tighten 3/8 in. cap screws (D) to
achieve a final torque of 25 in-lbs (2.825 N-m). 28. RII final drive gear housing with 2-1/4 qt (2 L)
John Deere SAE 90 Gear Lubricant or its equivalent.
1 9. Measure the distance between Too! (E) and quill Fill outer bearing compartment with multipurpose
using a feeler gauge (B). grease.
a) Remove Adjustment Tool (E).
I b) Install shims equal to the measurement 29. Torque drive shaft housing to final drive gear
housing to 445 Ib-ft (603 N-m) (60.3 kgm).
Drive Shaft Housing
1. Install inner oil seal (P, Fig. 15) in housing with

spring side facing driver. Use a 3-5/8 in. driver disk and
2-5/8 in. pilot (OTC No. 27541 and 27525).
2. Press differential output gear and drive shaft

pinion bearing cups into drive shaft housing and inner
quill tight against shoulders.
3. Install bearing cones on gears.
A^-Gear Ends BInner Quill

Fig, 21Checking Drive Shaft Housing End P/ay
5. Torque drive shaft housing quill-to-drive shaft

housing cap screws to 55 Ib-ft (75 N-m) (7.45 kgm).
6. Using a dial indicator at ends of pinion and gear

through the 21 ), measure drive shaft pinion
quill (A, Fig.
and differential drive shaft gear bearing end play.
7. Remove inner quill (B) and bearing cups in quill.
ADrive Shaft Housing CInner Drive Shaft Pinion 8. Install shims to provide 0.000 to 0.004
B Differential Output Gear (0.00-0.10 mm) end
in quill
DO NOT
in.
play. install too many

shims (creating bearing preload).
Fig, 20Drive Shaft Housing Gears
9. Install bearing cups in quill over shims and install
quill.
4. Install gear (B, Fig. 20) (27
differential output
teeth) in upper position in the drive shaft housing.
10. Torque drive shaft housing quill-to-drive shaft
IMPORTANT: Differential output pinion and inner housing cap screws to 55 Ib-ft (75 N-m) (7.5 kgm).
drive shaft gear use common bear^
ings. Be sure smaller O.D. gear is
11. Recheck end play using the dial Indicator.
placed the lower position in the
in
drive shaft housing. 1 2. Torque drive shaft housing-to-transmission case
cap screws to 170 Ib-ft (230 N-m) (23 kgm).
TM-1181 (Mar-83) Litho in USA, Tractors - 4040 and 4240

A
INSTALLATION
1. Reverse the removal procedure for installation.
h1P!
AHex. Nut and Washer B^Cap Screws CFiller Plug

Fig. 22 View of Hi-Crop From Front of Tractor
2. Torque drive shaft housing-to-final drive gear

housing hex. nuts (A, Fig. 22) 445 ib-ft (603 N-m) (60.3
kgm).
3. Torque drive shaft housing-to-transmission case

cap screws to 170 Ib-ft (230 N-m) (23 kgm).
4. Grease outer axle fitting and fill each gear housing

(C) with 2-1/4 qt (2 L) John Deere SAE 90 Gear
Lubricant or its equivalent
TM-1181 (Mar-83) Utho in US. Tractors - 4040 and 4240

Litho in US.A.
.
Power Train Repair Power Front-Wheel Drive 50-45-1
Group 40
REMOVAL
Control Valve Removal
A CAUTION: Escaping fluid under pressure

can have sufficient force to penetrate the
skin, causing serious personal injury. Before dis-
connecting lines, be sure to relieve all pressure.
Before applying pressure to system, be sure all
connections are tight and that lines, pipes and
hoses are not damaged. Fluid escaping from a very
small hole can almost be invisible. Use card board
or wood, rather than hands, to search for suspect-
ed leaks.
If Injured by escaping fluid, see a doctor at once.

medical treatment is not administered immediate- Fig. 2-PFWD Control Valve (From RR Side)
ly-
6. Remove pump pressure pipe from elbow.
7. Remove pump pressure pipe from Tee at control

valve inlet.
8. Disconnect electrical connector which leads to

solenoids.
9. Remove right-hand oil lines from control valve as

described in step 1
10. Remove right-hand oil drain line from manifold.
11. Remove cap screws securing control valve

housing to bracket and remove control va}ve housing.
Fig. 1-PFWD Control Valve (From L.H. Side)
1. Remove outer left-hand oil line from its tee, and

remove the tee for inner oil iine removal. Remove inner
oil fine from fts adjustable elbow.
NOTE: Control valve housing is marked "A, B, C,

D" at each hose connection. "A" - Left Lower
"B" - Left Upper
"C" - Right Upper
"D" - Right Lower
2. Remove bleed valve-to-drain line manifold hose
from control valve,
AOil Drain Lines F Bleed Valve Hose
3. Remove pump return-to-control valve Tee oil BOil Drain Pipe GPump Pressure Pipe
line. C^Bracket HSolenoid Connector
D Pump Pressure Pipe I Wheel Oil Lines
4. Remove pump return oil pipe from Tee. E Pump Return Pipe JOH Line Guard
5. Remove left-hand oil drain iine from manifold. Fig. 3-PFWD Con trol Valve Removal

.
50-45-2 Power Front-Wheel Drive Power Train Repair
REMOVALContinued Wheel Manifold and Motor Removal

Planetary Removal
1 Place tractor splitting stand on tractor frame and
raise tractor for ample tire clearance.
NOTE: if control valve is also to be removed, spirt-
ting stand should be installed as near as possible to

tractor step.
2. Remove tire and rim if wheel housing is to be

removed.
3. Remove plug from outside of wheel housing and

drain oil.
A Relief Valve
C Cap Screws
B R.K Steering DOil Manifold
Arm
Fig. 5-Wheet Motor Oil Manifold Removal
1. Remove tie rod at steering arm (B, Fig. 5) and

turn wheel for manifold removal.
2. Remove relief valve (A) from manifold.

A First Planetary CSecond Sun Pinion
B First Sun Pinion 3. Remove manifold cap screws (C) and lift oil
manifold (D) off dowel pins.

Fig. 4-Removing Outer Planetary
4. Remove outer wheel cover and remove planetary

(A, Fig. 4).
5. Remove first sun pinion stub shaft (B) and sec-

ond planetary sun pinion (C).
6. Remove eight cap screws securing planetary

housing to the wheel hub.
7. Remove planetary housing and second planetary

as a unit exposing brake and brake piston housing.

. ,
Ft&!&'" ^'^''^" "~HjSiMiiW*^^

J
\.'r\.'"''. . '".'.".'"..' ''.'\".' ' ' \s* f:$X
if
^v.
v^. ;-.; .-.^.vt'W.'^ "*a -

'''-'"".:' ,..-..:..
) ^vy^ ' ;: ': ' , ". ui .;. ._. . .

.....,;. .

Fig. 7-Removing Oil Sea! from Motor Housing
4. To remove oil seal and its spacer* from motor

housing, pry behind sea) on opposite sides. Be careful
not to score motor housing surface.
A Dowel Pin C Inner Roller Bearing REPAIR

BBearing Plate D Motor Housing
Control Valve
Fig. 6-Motor Housing (Manifold Removed)
IMPORTANT: The wheel motor bearing plate (B,

Fig. 6) have lapped surfaces. Do
and valve plate
not drop these plates as manifold is removed.
4. Remove motor from housing carefully to avoid

damage to lapped inner face of motor housing. Swash
plate is located on a dowei pin,
IMPORTANT: Do not turn motor across swash

pfateany more than necessary without lubrication.
Piston slippers could score surface of swash plate.
3??S!*
Brake Housing and Wheel Hub Removal A 2 O-rings and 1 Backup G O-Ring
Ring HBackup Ring
Remove twelve special screws that secure brake
1
piston housing and remove housing with pistons from

B Retaining Ring I O-Ring
C Sleeve JTube
motor housing. D Valve KSolenoid Coils
E Plunger LTube and Valve
2. Grab outer edge of front whee! hub and pivot F Spring and Washer Assembled
against housing to remove outer bearing from motor
Fig. 8-Soienoid Vaive Assembly
housing,
1. Remove nut from each solenoid that secures coil

3. Remove hub and inner bearing.
(K t Fig. 8) to tube and remove tube (J),
"4040 (Serial No. -6478) 2, To disassemble solenoid pilot valves, remove

> 4240 (Serial No. -15148) retaining ring (B) from tube and pull sleeve, valve and
plunger assembly.

CONTROL VALVE REPAIRContinued

NOTE: Ail three valve, sleeve and plunger assem- (
blies are the same. Assemble valves in the bores they
were removed from.
illifylli!
3. Replace al! O-rings and packings.
NOTE: Pressure-control valve, direction vafve and t
torque valve are not supplied as parts. If they are

replaced, the entire housing must be replaced.
i|i:gp |:igi|jy^ s
:giÊ:;r: ?!?!
4. Inspect springs for pitting, distortion and proper
est-" :
::= :: :' :
specifications. .
Valve Free
Spring Length Working Load
A Direction Valve Springs C Direction Valve
BSpecial Washers DRear of Control Valve
Solenoid 0.65 in. 0.50 in. at 5.5-6.0 lbs.
(17 mm) (13 mm at 24-27 N) Fig. 9-lnstaIling Direction Valve
Pressure 6.49 in. 4.85 in. at 73-90 lbs. 3. Install direction valve (C, Fig. 9) with washer (B),
Control (165 mm) (123 mm at 325-400 N) and spring (A) over each end.
Direction 1.68 in. 1.38 in. at 15-19 lbs.

(2 used) (43 mm) (35 mm at 67-84 N)
Torque 3.06 in. 2.25 in. at 11-15 lbs.

(78 mm) (57 mm at 48-67 N)
Relief 1.31 in. 1.11 in. at 130-150 lbs.

(33 mm) (28 mm at 577-668 N)
Check 1 .25 in. 0.88 in. at 0.3-0.5 lbs.

(32 mm) (22 mm at 1.3-2.2 N)
Control Valve Assembly
NOTE: Oil all parts prior to assembly,
1. Assemble pilot valves using Fig. 8 as a refer-

ence.
2. Install two backup rings with an O-ring in the

center at "TRQ" side of housing, and direction valve R27$S$N
plug with O-ring in the center (direction valve) bore. AConnectors ESpring I Ball
B Plug FValve Seat JSpring
C Special Plug GCheck Valve Bore KGuide
D Bleed Valve Ball HSpecial Seat L Elbow
Fig. 10-tnstaiiing Neutral Bleed Valve and
Regenerative Check Valve
4. Install direction valve plug with O-ring (B, Fig.

10), special plug (C), bail (D), spring (E), and seat (F).
(
5. Assemble regenerative check valve assembly (H
through L) and install in bore (G).

A Priority Plug and Shims D Plug

B Spring
Priority ETorque Vafve Spring
CPressure Control Valve FTorque Valve 1^1
Fig. 11 -installing Pressure Control and Torque Valves
AAdjustable Tee DRelief Vafve Housing

1. Install pressure-control valve (C, Fig. 11) with BSolenoid Tube ERelief Valve
orifice installed in valve at side of housing marked C Adjustable Tee F Bypass Pipe
"FWD".
Fig. 13*Rellef Vaive and Bear Oil Lines
2. install spring (B) in bore from "TRQ" side, seat-

7. Assemble relief valve (E, Fig. 13) with O-rings,
ing the orifice.
spring, and shims and install in housing (D).
3. Install same number of shims as were removed 8. Assemble oil lines, pipes, and fittings as shown in
from plug and install plug with O-ring (A). Fig. 13 and 14.
4. Install torque valve (F) in bottom valve bore (long

land toward "FWD")-
5. Install spring (E) and plug with O-ring (D).
R 28705N
ATee CReturn Check Vafve E Snap Ring

BSpring DO-Ring ARelief Valve DRegenerative Check Valve
BAdjustable Tee E Return Tee
Fig. 12-Return Flow Check Valve C-Check Valve Oil Line F Special Adjustable
Elbows
6. Assemble spring, O-ring, and snap ring in ad-
Fig. 14-Controf Valve Housing - Ready for Installation
justable tee (A, Fig. 12).
>
9. Reverse the steps of Removal to install the con-
trol valve housing*
TM-1181 (Feb-79) Utho in USA. Tractors - 4040 and 4240

50-45-6 Power Front- Wheel Drive Power Train Repair
Pivot Pin and Bushing Repair Motor Housing Assembly
<
A Upper Pivot Pin D Inner Bearing A Drain Line EMotor Housing

B Axle Knee E Motor Housing B Upper Oil Line FThrust Washer
CSeal and Spacer F Upper Cap and Tube C Pivot Pin G Lower Cap
D Axle Knee HLower Oil Line
Fig. 15-Removing Upper Pivot Pin
Fig, 16-Axte Knee and Motor Housing
1. Loosen brake bleed line from fitting and remove
return tube with cap (F, Fig. 15). 1. Place wheel motor housing (E, Fig. 16) in axle
knee (D).
2. Install two cap screws into tapped holes in pivot
pin to press pivot pin (A) from housing. 2. Position thrust washer (F) on top and bottom
between axle knee and motor housing.
3. To replace housing bushing, remove old bushing
and press new one into housing flush with edge of bore 3. Install pivot pins (C) into axle knee with holes in
and with grease holes aligned. pivot pins aligned with holes in axle knee. Remove cap
screws used for pulling pivot pins.
NOTE: 4040 Tractors (3609- ) and 4240 Trac-
tors (8339- ) use a wiper seal below the housing 4. Install caps (G) with oil tubes into pivot pins.
bushing.
5. Torque pivot pin cap screws to 35 ft-lbs (47 Nm)
4. If knee was removed, torque axle-to-knee (4.7 kgm).
screws and nuts to 350 ft-lbs (475 Nm) (47 kgm).

6. If bleed oil tube was removed from cap, install 3. Bolt two pieces of strap iron approximately 6 in.
and tighten securely as follows: (150 mm) Jong, to the front of the motor housing (A,
Fig. 17).
Turn jam nut counterclockwise away from
a)
backup washer, Place a washer (B) under each strap end so they
4.
b) Push backup washer toward jam nut to the contact the edge of the bearing. Washers should not
edge of the O-ring groove. contact motor housing.
c) Place backup ring against backup washer and
the O-ring against the backup ring. 5. Tighten both strap bolts so washers are lightly
d) elbow and tube assembly into cap.
Install held.
e) Tighten elbow until washer contacts the fin-
ished surface on the cap. 6. Bolt a 3-lb. (1 .36 kg) weight (C) at the 2 o'clock
f) Align elbow with bleed line by turning the position on the outer edge of the front wheel hub.
elbow. Jam nut may have to be backed off.
g) Tighten jam nut securely. Release the weight from its 2 o'clock position.
7.
one cap screw until weight fails to

Slightly tighten only
7. Connect upper oil lines to caps and torque tie rod turn wheel hub.
to steering arm nuts to 100 ft-lb (136 Nm) (14 kgm).
8. Mark the cap screw and back off 1/2 turn.
8. Grease front axle pivot pins.
9. Release the weight again from its 2 o'clock posi-

INSTALLATION AND ADJUSTMENT tion. Slightly tighten second cap screw until weight fails
to move the hub.
Wheel Bearing Adjustment
1 0. Retighten the first cap screw the same amount it
1. Install inner wheel bearing over motor housing.
was backed off-
NOTE: Do not install oil sea! until after bearing

adjustment
2. Install front wheel hub and outer bearing.
A End Play BPreload

Fig. 18-Using Feeler Gauge to Measure
End Pfay or Preload
Lay a straight-edge across motor housing and

11.
F.262BSu
outer bearing.Use a feeler gauge to measure between
AStrap Iron BWashers C Weight straight-edge and outer bearing to determine end play
> (A) or preload (B, Fig. 18).
Fig. 17-Measuring for Shim Requirement

.
Wheel Bearing Adjustment Continued

(
&Z?3$?.
A Motor Housing C Oil Seal

B Spacer* DJDT-34 Driver
RZ787SH
Fig. 20-fnstalfing Oil Seal and Spacer
A End Play Shims Required C Strap iron

B Preload Shims Required D Motor Housing 14. Install spacer* (B, Fig. 20) on motor housing I
(A).
Fig. 19-Adjusting Front Bearings
15. Fill lips of oil seal with grease and press oil seal
(C) onto housing (spring-side facing driver).
12. Vary the number of shims behind the outer
bearing cup in the front wheel hub until the bearing is 16. Press oil seal on until it bottoms against the
adjusted to 0.004 in. preload-0.004 in. end play (0.10 spacer*. Use OTC Driver No. JDT-34. On later model
mm preload-0.10 mm end play), tractors, press on oil seal until it bottoms against
housing.
13. Remove hub and bearings to install oil seal.
17. Coat l.D. of seal cup with grease and O.D. with
sealant. Press cup into wheel hub until it bottoms.
18. install inner bearing about 1 in. (25 mm) onto

motor housing.
19. Install inner bearing cup in wheel hub.

20. Install wheel hub over inner bearing and using
the bearing as a guide, slide hub in until outer bearing
can be installed.
21 Slide assembly oil seal. Use care

carefully over
not to tift the wheel hub damaging the motor housing.
*4Q40 (Serial No. -6478)
4240 (Serial No. -J 5148)
(
TM-1181 (Jun-80) Litho in U.S. A Tractors - 4040 and 4240

Brake Piston Housing Repair and Assembly
>
teJrm
R 27876N
A Cylinder Block J Spacer S Front Wheel Hub

B Swash Plate K Oil Seal T Shim
C Pipe Plug LOil Seal Cup U Packing Ring
DGrease Fitting M Motor Shaft V Plug and O-Ring
E Dowel Pin N Bearing Cone W Planet Brake Piston Housing
F Motor Housing 0 Bearing Cup X Special Screw (12 used)*
G O-Ring P Bearing Cone (2 used) (13 used)**
H Dowel Pin (2 used) Q Bearing Cup (2 used) YQuad Ring Packing (9 used)
I Snap Ring RHigh-Strength Cap Screw and Z Backup Ring (9 used)
Washer (8 used) AA planet Brake Piston (9 used)
Fig. 21 -Wheel Motor Housing and Hub
1. Remove brake pistons from housing by inserting
a 5/16-inch cap screw in the threaded hole in end of

each piston. Pulf piston out of its bore.
2. Install brake piston housing (A, Fig. 22) on wheel

motor housing. Be sure "UP" marked on housing is at
top. Torque cap screws (C) to 45 ft-lbs (61 N-m) (6
kgm) on eariy model tractors* or 81 ft-lbs (110 N*m)
(11 kgm) on later model tractors.*"
3. Install pistons (B) in bores. They may be inter-

changed with other bores.
*4040 (Serial No. -6478)

4240 (Serial No. -15148)
**4040 (Serial No. 6479- )
4240 (Serial No. 15149- )
A Piston Housing B Brake Piston C Special Screw

Fig. 22~fn$taffing Piston Housing

50-45-10 Power Front- Wheel Drive Power Train Repair
Planetary Repair and Assembly
i.&Ovwifp
A Pin at Shaft B Pinion Retainer
Rg. 23-First Planetary Assembly
1. To remove first planet pinions, insert a drift at
each shaft (A, Fig. 23) and push out pinion retainer (B)
and dowels which hold pinion shafts in place.
2. Inspect 17 roller bearings in each pinion for wear. A Brake Backing Plate B Second Ring Gear
3. Check carrier and pinions for breaks or chips.
Fig. 24-instaIling Brake Backing Plate
4. Check outer planetary ring gear for damage.
5. Remove six inner (second) planetary cap screws 9. Check return springs for proper strength and
from housing. appearance. Springs should be 1.69 in. long at 70-86
6. Inspect 22 roller bearings in each planet pinion lbs. load (43 mm at 312-383 N).
for wear. 10. Install second planet ring gear (B), planet brake
7. Inspect second planet ring gear. Its surface pressure plate (grooved side toward gear), and
should be free of chips and scoring since it is also used springs.
as a brake for gear reduction. 11. Tighten cap screws to 35 fHbs (47 N-m) (4.7
8. Inspect backing plate (A, Fig. 24) and pressure kgm) torque.
plate (1, Fig. 25) for wear or scoring. 12. When installing second planet pinion retainer
(8 T Fig. 25) on fater model tractors*, make sure
chamfer on I.D. of retainer faces away from planet
pinions.
*4040 (Serial No. 6479- )
4240 (Serial No, 15149- )
B1B822H
1 Planet Brake Pressure Plate 7 High-Strength Cap Screw (6 used) 13 Second Planet Pinion (3 used)
2Spring (B used) 8Planet Pinion Retainer 14 Dowel Pin (3 used)
^Second Planet Ring Gear 9Thrust Washer (6 used) 15Planetary Housing wrth Gear
APlanet Brake Backing Plate 10 Steel Sail (6 used) 16O -Ring
5Washer (18 used) 11 Second Planet Pfntdn Shaft (3 used) 17 Plug
6 High-Strength Cap Screw (18 used) 12Bearing Roller (66 used) (
Fig. 25-PFanetary Housing, Brake Plates and Second Planet Pinion
m-1181 (Jun-80) Litho in U.S.A. Tractors - 4040 and 4240

Oil Manifold Repair Wheel Motor Disassembly

1. Remember that valve plate and bearing plate 1. If the bearing plate remained with the cylinder
I surfaces are lapped. Do not damage. block, remove with a brass hook at one of the drain
grooves in the plate.
2. if valve plate remained with oif manifold, use a
smafl brass hook under retaining pin groove to break IMPORTANT: Pry only at drain grooves.
oil seal, and remove valve plate. Grooves are on the cylinder block side of the plate.
A dowel pin locates the plate and oil causes the
IMPORTANT: If any place but retaining pin plate to adhere to the block.
groove is used as a pry point, surface may be
damaged. 2. Remove dowei pin from end of block.
3. Remove top plug and examine check valve body. 3. To remove inner bearing from motor shaft:
a) Place outer bearing end (larger bearing) down

on bench.
b) Protect lapped surface on top.
c) Carefully push down on cylinder block housing

while inserting a knife-edge bearing puller behind
bearing.
d) Remove bearing taking care not to drop parts

that are released upon removal.
.CT^^::vv.../i%-v-:';..
:
R.
ARelief Valve Body EOil Manifold

B Spring Retainer FCheck Valve
CRelief Valve G Plug with O-ring
DSpring
Fig. 26-Motor Oil Manifold Valves
4. Disassemble relief valve and inspect. Spring (D,

Fig. 26) free length is 2.4 in. (60 mm). With 20-25 lbs.
(90-1 10 N) compressive force applied, spring length is
1-1/8 in. (29 mm).
5. Inspect check valve (F). Its steel ball should be

free to move.
6. Carefully scrub parts and coat with oil
7. Assemble relief valve and install retainer ring on

valve stem (C).
8. Install shims and bearing cup in manifold (Ef re-

moved).
valve plate so dowel on manifold

> 9. Install steel
aligns with plate slot.

Wheel Motor Disassembly Continued Motor Repair and Assembly

1- Clean all parts and coat with dean oil. Also
protect face of cylinder block when installing parts into
(
Z^j:;.Ê;^^?v^?fl
the block.
2. Install spring seat (C, Fig. 29) in cylinder block

llSShllipPllS' (bevel side first).
3. Install spring (B) and spring retainer using same

"bolt and washer press" method to seat the retaining
ring as for removal of the
9p9 ring.
| 4. Remove the bolt-press tool.
5. Install springs (I) and retainer guide (E) so

springs not slide out.
jM^HCL^ will
6. Install slipper pistons (H) with piston retainer.

.-Tins^j^BB^BM^MSlMlM^BKnwwnMrfBSiBEJEjSEj"::;:::::
::::::::::
Retainer (F) is installed bevel side toward the pistons.
7. Install shaft (A) (with larger bearing in place)
II M ;^^^^^^W^
]:
:
'
l
through swash plate so splines align with guide splines
(E)-
8. Carefully press on smaller bearing.
AWasher BBo*t C Retaining Ring Wheel Motor and Oil Manifold Installation and Ad-
justment
Fig. 27-Removing Cylinder Block Parts
4. If spring retainer (A, Fig, 28), block spring (B),

and seat are to be removed for replacement, or the if
block needs a more thorough cleaning; remove as

follows:
a) Insert a 3/8 in. x 5 in. bolt with nut through the

block I.D.
b) Place a large washer on the neck of the block

and another over spring retainer at (A, Fig. 27).
c) Insert the bolt (B) through the washers and

start the nut.
d) As the nut is tightened (compressing the block

spring), the retaining ring (C) is freed for removal.
e) Hook the ring with a machinists scribe and

pull the ring out of its groove.
IMPORTANT: Do not pry on the KD. of the cylin-

der block to remove ring. A burr created on this KD.
will cause leakage between the bearing plate and
cylinder block.
5. If the front (larger) bearing is replaced, remove

inner race using a bearing puller. Protect drive shaft
with a washer between the shaft and puller arm. A Dial Indicator CR28781 Bushing
B Motor Shaft DAR52254 Screw
6. Inspect springs; free length is 1.86 in. (47 mm)
and spring should be 1.67 in. long at 34-46 lbs. load Fig. 28-Measuring Wheel Motor Shaft End Play
(42 mm at 151-200 N). \
TM-1181 (Sep-77) Litho in U.S.A.

.
Power Train Repair Power Front- Wheel Drive 50-45-13
R Z63d7
ASpring Retainer E Retainer Guide I Cylinder Block with 6 Springs

B Spring F Retainer J Dowel Pin
CSpring Seat G Sw3*h riate K Bearing Plate
DMotor Shaft and Bearing Hbiipper Piston L Spring Guide
MPilot
Fig. 29-Motor Assembly
1. Install wheel motor in housing. Be sure thick part 8. an AR52254 adjusting screw (D) in bush-
Install
of swash ramp (on both
plate sides) is positioned ing bore and drive motor shaft at splined end toward
toward steering arm with dowel pin in groove. manifold using a brass drift,
2. Install manifold on inside of wheel motor housing. NOTE: These parts or simitar parts from a main
hydraulicpump adjusting screw are used to push
3. Tighten cap screws to 35 ft-lbs (47 Nnn) (4.7 kgnn) motor shaft outward to check shaft bearings. Remove
torque. washer from adjusting screw before installing in bush-
ing.
Adjusting Shaft End Play
9. Set dial indicator at zero.
4. Place a dial indicator (A, Fig. 28) on outside of
planetary housing.
1 0. Turn in adjusting screw until dial indicator stops.
5. Set indicator needle on end of motor shaft (B).

1 1 Read shaft end play.
6. Remove relief valve from rear of manifold.

12. Adjust end play to 0.003-0,006 in, (0.076-0.152
7. install an R28781 adjusting screw bushing
mm) by adding or removing shims behind inside bear-
(C) in
I ing cup in oil manifold.
the relief valve bore.
TM-1181 (Sep-77) LHho in U.S.A. Tractors - 4040 and 4240

Installation Continued 13. Remove adjusting screw and replace relief

valve in oil manifold housing.
14. Place one gallon (4 I) of John Deere Hy-Gard

Transmission and Hydraulic Oil in the planetary hous-
ing and replace wheel cover.
15. Test and adjust control valve as instructed in
Group 250.
Fig, 30-Left-Hand Wheel (Front View)

1
Steering/Brakes Repair Specifications and Special Tools 60-00-1
Section 60
STEERING/BRAKES REPAIR
GROUP 00 - SPECIFICATIONS AND Steering Motor Repair
SPECIAL TOOLS Steering Motor Access 60-05-8
Specifications Disassembly 60-05-9
Power Steering 60-00-1 Inspection 60-05-1
Power Brakes 60-00-2 Assembly 60-05-12
Special Too!s 60-00-3
GROUP 10 - POWER BRAKES
GROUP 05 - POWER STEERING Pistons, Plates, and Disks
Steering Column and Metering Pump Removal 60-10-1
Removal 60-05-1 Repair 60-1 0-1
Disassembly and Inspection 60-05-3 Assembly and Installation 60-10-2
Steering Column 60-05-3 Brake Valve
Metering Pump 60-05-4 Removal 60-10-2
Steering Pump and Column Assembly 60-05-4 Disassembly 60-10-3
Steering Valve Repair 50-05-6 Inspection 60-10-3
Removal 60-05-7 Assembly 60-10-4
Disassembly and inspection 60-05-7 Installation and Adjustment 60-10-5
Assembly 60-05-7 Brake Accumulator 60-10-6
Group 00
SPECIFICATIONS
Power Steering
Friction spring Free length 0,735 in. (18.67 mm)
Compressed 0.52 in. at 81 to 99 lbs.
(13.2 mm at 360 to 440 N)
Steering motor piston O.D 2.621 to 2.623 in. (66.70 to 6675 mm)
Steering motor piston sleeve ID 2.625 to 2.626 in. (66.79 to 66.81 mm)
Feedback piston pin
Len 9 th 2.58 in. mm)
(65.6
00 0.7357 to 0.7363 in. (18.719 to 18.734 mm)
Feedback piston pin bore I.D 0.7365 to 0.7375 in. (18739 to 18765 mm)
Feedback piston pin spring
Free length 1.16 in. (29.464 mm)
Compressed 074 in. at 45 to 55 lbs.
(18.8 mm at 200 to 244 N)
Feedback piston O.D 1.499 to 1.500 in. (38.14 to 38.17 mm)
Feedback piston bushing
LD 1 .501 to 1 .506 in. (38.27 to 38.32 mm)
- D 1.8515 to 1.8525 in. (47.110 to 47.135 mm)
>

60*00-2 Specifications and Special Tools Steering/Brakes Repair
SPECIFICATIONS AND SPECIAL TOOLSContinued

Torques (
Metering pump cap screws 35 ft-lbs (47 N-m) (5 kgm)
Manual steering valve seats 25 ft-!bs (34 N-m) (4 kgm)
Steering motor spindle arm 300 ft-lbs (407 N-m) (43 kgm)
Tractor side frames 275 ft-ibs (373 N-m) (40 kgm)
Power Brakes
Rem Measurement Part Dimension
Brake facing Thickness 1/8 in. (3 mm)

Facing rivet head Depth 1/16 in. (1.6 mm)
Disk Flat to within 0.004 in. per in. of disk O.D.
(0.1 mm per 25 mm of disk O.D.)
Piston
4040 and 4240 O.D 2.2495-2.2505 in. (57.14-57.16 mm)
Bore I.D 2.2530-2.2560 in. (57.22-57.30 mm)
Brake valve
Plunger O.D 0.5595-0.5605 in. (1 4.2 1-1 4.24 mm)
Plunger bore I.D 0.5610-0.5630 in. (14.25-14.30 mm)
Manual piston O.D 0.9330-0.9350 in. (23.70-23.75 mm)
Manual piston bore I.D 0.9365-0.9375 in. (23.70-23.80 mm)
Plunger return spring Working load 1.7 in. at 39-47 lbs. (43 mm at 173-209 N)
Brake inlet valve assembly Torque 40 ft-lbs (54 N*m) (5.4 kgm)
Brake pedal Height 5-3/4 to 5-7/8 in. (146-149 mm)
Brake accumulator Capacity 5 pedal applications after engine is off at least 15

minutes
Accumulator piston O.D 2.9930-2.9960 in. (76.00-76.10 mm)
Bore I.D 2.998-3.001 in. (76 .1 -76.2 mm)
Accumulator inlet check valve spring
Inner Working load 0.84 in. at 5.8-7.2 lbs. (21 mm at 26-32 N)
Outer Working load 1.0 in. at 37.8-46.2 lbs. (25 mm at 168-206 N)
Accumulator charge. Pressure 475-525 psi (29.3-36.2 bar)

(29.9-36.9 kg/cm 2 )

SPECIAL TOOLS
Power Steering
A-ÎDG-17 Steering Wheel Used for steering wheel re-

Puller movaL
&-JDH-42-2 Pump Align- Used for assembling metering
merit Dowels pump.
*iîij-i~n":inj5i
Fig. USteenng Wheel Puffer and

Pump Alignment Dowels
A D-01O45AA Bushing and Used for installing oil seals.

Seal Driver Set
n%B$$7$- : ".*
Fig. 2-Bushing and Seat Drivers

60-00-4 Specifications and Special Tools Steering/Brakes Repair

A-^jDH-42-1 Piston Used for piston removal
Turning Tool
B D-01061 AA Blind Hole Used for feedback piston bush-
Puller Set ing removal.
C D-01045AA Bushing Used for sleeve removal.
Driver
Fig. 3-Piston Turning Tool and Bfind

Hole Puffer
JDH-52 Steering Piston Used to aid in steering piston

Installation Toof installation.
R 2S571N1
Fig. 4-Steering Piston installation Tool
A^D-05007ST Used to remove front support

Splitting Stand
&-D-05149ST Used with splitting stand.
Adaptors
trip
R 2S0S6N
Ftg, 5-$p!itting Stand and Adaptors

(

TOOL NUMBER USE
Used with regulator and charging kit to

precharge brake accumulator. Obtain
from local nitrogen supplier.
R79058BI
Fig. 6-Nitrogen Cylinder
Used with nitrogen and charging kit to

R730S3KI
Fig. 7~Pre$sure Regulator

60-00-6 Specifications and Special Tools Steering/Brakes Repair

TOOL NUMBER USE (
*JDG-85 Nitrogen Used with nitrogen and pressure reguia-
Charging Kit tor to precharge brake accumulator. In-
4t ih^H î cludes adapter assembly

9.
*A~1337 High Pressure Hose

shown in Fig.
*B 23$4Adapter Assembly
*C877 O-Ring Washer
*LV-6577Tru-SealNut
R3473S
Rg. 8-Nitrogen Accumulator Charging Kit
*D-15019NU Adapter kit for charging accumulator.

Supplement
Adapter Kit
*A-2364 Adapter Assembly

*B-6877 O-Ring Washers
RSOOSOKp* W W ^ *C-6577 Tru-Seal Nut
Fifr 9-D-15019NU Supplemental Adapter Kit
* Order from:
Service Tools
Box 314
Owatonna MN 55060

Steering/Brakes Repair Power Steering 60-05-1
Group 05
I
POWER STEERING
IMPORTANT: Perform all service repairs on the 4. Telescope steering column and install JDG-17
metering pump and steering valve in a clean, iso- Remove steering wheel and also
Puller (A, Fig. 1).
lated work area, preferably a separate, well-lighted cowls (B C) and cover (D).
?
room. Use extreme care to keep work benches,

tools, and test equipment clean. Use the proper
tools, cleaning materials, and lubricants. i
f
-~&M$vti!$^Mi i ;)sl^
While the steering motor can be repaired on the

make every effort to maintain a clean envi-
tractor,
ronment for this service as well.
STEERING COLUMN AND

METERING PUMP
Removal
R26Z7Z&
1. Disconnect battery ground cables.

A Snap Ring &Steering Column
2. Relieve hydraulic system pressure.
Fig. 2-Steering Column Sleeve Removal
3. Remove wheel emblem, release knob,
steering
jam nuts, and washer from top of steering wheel. 5. Remove snap ring (A, Fig. 2) and sleeve (B) from
steering column.
%ze$*%$
A-JDG-17 Puller C L.H. Cowl

B R.H. Cowl D Rear Control
Support Cover
Fig. 1-Meterfng Pump Access

60-05-2 Power Steering Steering/Brakes Repair
Removal Continued
R 2soj;:i?;?;:;
Fig. 4-Removing Metering Pump Assembfy
NOTE; Control support removed from tractor for

AHydraulic Lines D Steering Column photographic purposes only.
B Spring and Support
CCap Screws E Metering Pump
steering column up
9. Tilt in dash slot and remove
Fig. 3-Disconnecting Metering Pump metering pump assembly out the rear of the control
support, ^
6. Disconnect hydraulic lines (A, Fig. 3) from me-

tering pump Use a clean container
cover. to catch
1 0. Remove the four cap screws holding the tube to
leaking oil. Cap and plug lines and fittings. the metering pump and slide tube off the steering shaft.
7. Disconnect spring (B).

IMPORTANT: Before disassembling the steering
metering pump, perform the steering metering
8. While bracing metering pump assembly, remove pump leakage test on page 260-05-15.
the two cap screws (C) holding the tube assembly.

Disassembly and Inspection
R 23014N
Fig. 5-Cut-Away Steering Column (Legend-Fig. 6)
.^j^^^Si ^j 1
32* 07 $3?
AÔil Seal F Retaining Ring KThrust Washer P Plastic Bushing

B Bushing G Upper Steering Shaft L Coupling RSnap Ring
C Steering Column Tube H Release Rod M Lower Steering Shaft S Plate
DSleeve I Thrust Washer N Washer T Washer
E Retaining Ring J Needle Bearing 0Snap Ring U Oil Seal
V Metering Pump
Fig. 6-Steenng Column Assembly
Steering Column Examine bushing (B) for wear, install new bushing if
necessary using Disks No. 27495 and 27500 from
Remove four cap screws holding tube (C, Fig. 6) to
Bushing Driver Set. Drive bushing into tube (C) until
|
metering pump (V), not already removed.
if
disk bottoms on tube.
) Check oil seal (A) for damage.

Inspection Continued Remove the two remaining cap screws to separate

Check threads, and bushing contact area of
splines,
pump assembly.
upper shaft (G) for wear or damage. Examine threads (
and splines on release rod (H) and internal spline of NOTE: The friction spring (C, Fig. 7) is compressed.
steering shaft coupling (L) for damage. Replace parts Loosen the cap screws gradually.
as necessary.
Examine pump base (A), body with gears (B) and
Examine thrust washers (I, K, Fig. 6) and needle
cover (E) for wear, scoring or damage. Malfunctions
could be caused by an improperly installed shim (l)
bearing (J). Be sure that needle bearing moves freely. :
contaminated oil, or excessive leakage.

Inspect spfined ends of lower steering shaft (M).
NOTE: Pump body and gears (B) are a matched
Damage assembly and must be replaced.
to the smaller splined end could indicate
damage to the metering pump (V) drive gear.
Check 0.0005 inch (0.013 mm) shims (I) for damage
Check or improper installation that could cause wear, leakage
plastic bushing (P) and oil seal (U) for dam-
age and excessive wear. or damage to other parts. New shims MUST be in-
stalled whenever the pump is disassembled.
Metering Pump
Check friction spring (C) for damage or incorrect
compression rate. Spring should compress to 0.52 inch
^^L^' ^ -
at 81 to 99 lbs. (13.2 mm at 360 to 440 N).
Examine return oil check valve (H) for ieaking or

<elSh damage. Replace valve fitting if necessary.
'.^ts&jF, ASSEMBLY
Metering Pump and Steering Column
iSO Use new o-rings, oil seal, and shims. Clean, dry
1.
^ with compressed air, and dip all parts (except shims) in
clean John Deere Hy-Gard Transmission and Hydrau-
& lic Oil just before assembly. Use special care to keep
all parts clean.
2. Place pump parts on a clean work surface.
1*< 3. Install special fittings (F, G, and H, Fig. 7) in I
pump cover (E). Be sure fittings are in correct bores.

Tighten fitting jam nuts.
APump Base G Special Fitting

4. four cap screws in each corner of the
Install
B Pump Body with Gears H Special Return Oil
C Friction Spring Check Valve Fitting
pump cover. Place cover on blocks to hold cap screws
D Friction Plate (2 used) I 0.0005 in, (0.013 mm) in place.
E Pump Cover Shim (2 used)
F Special Fitting
Fig. 7-Metering Pump

A Identification Marks F Pump Cover ANut ERetaining Ring

B Friction Plate (2 used) GDrive Gear B-Washer F Plate
C Friction Spring HIdler Gear C Retaining Ring GWasher
DJDH-42-2 Alignment Dowels I Shim DPlastic Bushing HOil Seal
EShim
Fig. 9-Oii Seal and Lower Shaft Installation
Fig. 8-Pump Assembly
12. Install washer (B), retaining ring (C), plastic
5. Insert JDH-42-2 Alignment Dowels (D, Fig. 8) in bushing (D) and retaining ring (E) on upper end of the |
the two center cap screw holes. lower steering shaft. Place plate (F), washer (G), and
oil seal (H) over end of shaft. Install shaft in metering
6. CAREFULLY install shim (E) on cover (F). pump.
7. Install pump gears (G, H) in body. Make sure the 13. Press oil seal (H) into pump base with fingers.
identification marks (A) are up and that the idler gear
(H) is in the lower bore of the body. Carefully install 14. Assemble steering column, using Fig. 6 as a
body and gears on cover (F). guide.
8. Install friction spring (C) and plates (B) in idler 15. Install the center two cap screws through the
gear (H). metering pump. Install steering column on pump and
tighten the four cap screws holding the column to the
9. CAREFULLY install shim (I) on pump body. pump to 35 ft-lbs (47 N-m) (5 kgm).
10. Place pump base, (not illustrated) on body, 16. Rotate steering shaft to be sure that shaft and
again making sure that shim (I) is not wrinkled or pump gears turn freely.
damaged.
1 7. To install metering pump and steering column in
11. Install nuts (A, Fig. 9) on the two bottom cap tractor control support, reverse removal procedures,
screws and tighten to 35 ft-lbs (47 N-m). Remove page 05-1.
alignment dowels.
IMPORTANT: Perform the Steering Metering

Pump Leakage Test on page 260-05-15 again, be-
I
fore installing column and metering pump in trac-
tor.

Assembly Continued ASleeve E Lock Nut

18. Connect hydraulic lines to fittings on pump
BRetaining Ring FRelease Knob
C Steering Wheel GNut
cover. On clamped hoses (return oif circuit) cut 1/2 DSpecial Lock H Emblem with O-ring
inch (12.7 mm) from end of hoses and install. Be sure Washer
that return hose to oil pressure regulating valve hous-
Legend for Figure 10
ing is connected to the special fitting on the bottom of
the pump cover.
19. Install steering column sleeve (A, Fig. 10) re-
taining ring (B), steering wheel (C), special lock washer
(D), lock nut (E), release knob (F), nut (G), and emblem
with O-ring (H).
20. Connect battery ground cables. Start engine

and cycle steering several times to bleed air from
system. Check metering pump, fittings, and steering
column for leaking oil or binding parts. Tilt and tele-
scope steering column to be sure of proper operation.
21. Install cowls and rear control support cover.
R28S74N
Fig. 10-Steering Wheel Installation
STEERING VALVE REPAIR
^^^^^m^^^mm jsb^
334775
AValve Plug (2 used) EControl Circuit I Spring MManual Steering R Plug (2 used)
BValve Housing used)
Fitting (2 JGuide Valve Ball (2 used) S Return Circuit
CControl Circuit F Pressure Inlet K Manual Steering N Spring Fitting
Orifice used)
(2 Fitting Valve Seat (2 used) O Make-Up Valve TMake-Up Valve
Control Circuit GPressure inlet L Steering Valve Ball (2 used) Seats (integral
Filter (2 used) Filter P Spring (2 used) with housing)
H^lnlet Check
Valve Baff
Fig. 1 USteering Valve Assembly

Removal While valve is out, remove manual steering valve

seats (K) and check seats for damage. Check balls (M)
and spring, replace if damaged.
2. Disconnect battery ground cables.
Check valve housing (B) oil passages for plugged or
cracked conditions. Replace housing and valve, if
3. Remove tractor hood and parts to gain access to
necessary.
the steering valve assembly.
4. If necessary, clean around the steering valve

Assembly
area. 1. Replace all O-rings. Be sure all parts are clean;
air dry. Dip all parts in clean John Deere Hy-Gard
5. Disconnect hydraulic lines and immediately cap Transmission and Hydraulic Oil.
and plug all lines and fittings. Identify lines for aid in
reassembly. 2. Use Figure 11 as an aid in assembly.
Disassembly and Inspection 3. Install manual steering valve assembly (N, M,

and K) in steering valve (L). Tighten seats (K) to 25
IMPORTANT: Steering valve repair requires the ft-lbs (34 Nm) (3.4 kgm).
same clean environment as that required for repair
of the metering pump. 4. Carefully slide valve (L) into housing (B). Gently
rotate vaive to aid installation. Install valve plugs (A).
Check for obvious failures such as leaks or cracks in
fittings or housing (B, Fig. 11.) 5. Install inlet check valve assembly (H, I, J) and
pressure inlet fitting (F) with filter (G).
Remove control circuit fittings (E) and examine
filters (D) and orifices (C). Clean filters and orifices, 6. Install control circuit orifices, filters, and fittings
replace if damaged. (C, D, and E).
Remove and examine pressure inlet filter (G) for 7. Install make-up valve assemblies (O, P, and R).
plugged or damaged conditions. If filter is plugged or
damaged, check valve and valve housing for scoring or 8. Secure steering valve on tractor and connect
damage caused by contaminated oil. Replace or clean hydraulic lines. Be sure that lines are connected to the
filter as necessary. correct fittings.
Check pressure inlet fitting (F) and check valve

inlet 9. Start tractor engine and cycle steering several
assembly (H, I, J). The failure of this assembly could times to bleed air from the steering system. Check for
allow controf circuit oil to enter the pressure side of the leaks at fittings and plugs.
hydraulic system during a manual turn operation.
IMPORTANT: Be sure steering pressure line is
Inspect make-up valve balls (O), springs (P) and connected to the non-orrficed side of the tee in the
seats (T) (in housing). If seats (T) are damaged, attenuator.
housing and steering valve should be replaced.
CAREFULLY remove valve (L) from valve housing

(B). Examine valve and valve bore for scoring or dam-
age that could cause valve to stick or oil leakage past
the valve lands.
NOTE: Valve and valve housing are matched and

must be replaced as a unit.

.
STEERING MOTOR REPAIR
Fig. 12-Steering Motor Access
Steering Motor Access 7. Disconnect steering motor bleed line.
NOTE: Most steering motor repairs can be made by 8. Remove left- and right-hand frame plates and
sliding the front support out of the side frames to hydraulic oil reservoir. Attach the hydraulic reservoir to
expose steering motor pistons. the radiator tie rod clamp with rope or wire.
1 (Not Illustrated) Remove muffler, air stack, side 9. Disconnect lines at the steering motor, plug and
shields, grill screens, front weights and hood from cap fittings.
tractor.
NOTE: On tractors with convertible front axle, the
2. (Not Illustrated) Relieve hydraulic system pres- main pump stroke control valve adjusting screw must
sure and disconnect the battery ground cable. be removed.
3. Remove leak-off line and radiator tie rod from top 10. Raise front of tractor and attach D-05006ST or
of fuel tank. D-05151ST splitting stand to side frames.
4. Remove intake hose and restriction indicator 11. Attach D-05149ST adaptors and D-05007ST
wire. splitting stand (A, B Figure 13) to front of tractor.
5. Remove horns and fuel gauge sender wire. 12. (Not Illustrated) Remove lines to the PFWD
control valve if tractor is equipped. (See Section 50-45)
6. Shut off fuel at valve on bottom of tank and
disconnect fuel line. 13. Remove cap screws from side frames and (
carefully slide front support out of side frames.
Wt-1181 (Feb-78) Litho in U.S.A. Tractors - 4040 and 4240

3. To remove piston plugs, install a bridge (C, Fig.

14) and spacer (D) as shown. Tighten cap screws
holding bridge. The plug (A) is forced in against the
spring washer, allowing the snap ring to be removed.
11
Remove "bridge assembly, plugs, and spring wash-
ers.
4. Remove tie rods from steering motor spindle

arm. Center spindle timing mark and remove spindle
arm, quill (A, Fig. 15) and spindle (B).
Ar-D-05149ST Adaptors B D-05007ST Stand

AQuill BSpirtdfe
Fig. 13-Front End Separation
Fig. 15-Spfndie Removal
Disassembly
1. Disconnect steering motor hydraulic lines at
motor housing.
2. Remove steering motor piston plug caps.
A^-Piston Plug C"Bridge"

BSnap Ring DSpacer
Fig. 14-Steering Piston Removal

Steering Motor Disassembly Continued 5. Align feedback piston pin (A, Fig. 16) in front
steering motor piston with channel (B) in motor hous-
ing. Use JDH-42-1 piston turning tool (C) to rotate
piston until pin clears channel. Remove pin.
6, Remove steering motor piston from steering
motor.
A Feedback Piston Pin C^JDH-42-1 Piston

BHousing Channel Turning Tool
Ar^Snap Ring B Feedback Piston Plug
Fig. 16-Feedback Piston Pin Removal Fig. 17-Feedback Piston Removal

7. Remove snap ring (A, Fig. 17) and feedback
piston plug (B). Slide feedback piston from housing.
'
::'A
liiiiyi
A Piston Cap (2 used) FSpring Washer (2 used) KSpring PO-Ring (2 used)

BSnap Ring (2 used) GSleeve (2 used) L Piston Pin RBackup Ring (2 used)
CPlug (2 used) HSlipper Seal (2 used) M Feedback Piston SPlug (2 used)
DFiber Backup Ring I Packing (2 used) NO-Ring (2 used) TSnap Ring (2 used)
(4 used) J Piston O Bushing (2 used)
EO-Ring (4 used)
Fig. 18-Steering Motor and Feedback Piston Assembly

Inspection Examine feedback piston pin (L, Fig. 18), bore,

piston (J) and pin spring (K). Pin should not be burred
Check steering motor piston (J, Fig. 18) and sleeves
or scored and should move freely in pin bore. Use the
(G) for damage or scoring. Scoring could be caused by
following specifications as reference:
foreign material. Replace pistons, sleeves and spindle
if heavy scoring is evident. Use the following specifi-
item New Part Specifications
cations as reference:
Pin length 2.58 in. (65.6 mm)
Pin O.D. 0.7357 0.7363 in.
to
Item New Part Specification
(18.719 to 18.734 mm)
Piston O.D. 2.621 to 2.623 in. (66.70
Pin bore LD. 0.7365 to 0.7375 in.
to 66.75 mm)
(18.739 to 18.765 mm)
Sleeve LD. 2.625 to 2.626 in. (66.79
Spring compressed
to 66.81 mm)
to 0.74 in. (18.8 mm) 45 to 55 lbs (200 to 244
N)
If sleeve removal is necessary, use Disks 27524 and
27536 and extension handle (A and B, Fig. 19). The

Examine feedback piston (M), piston bushings (O)
disks must be assembled inside the piston bore
and O-ring grooves in piston bore and piston bushing
through the spindle cavity to remove the first sleeve
C).
for scoring damage or burrs. Replace bushing ONLY if
necessary. Use the following specifications as refer-

ence:
Item New Part Specifications

Piston O.D. 1.499 to 1,500 in. (38.14
to 38.17 mm)
Piston bushing LD. 1.501 to 1.506 in. (38.27
to38.32 mm)
Piston bushing O.D. 1.8515 to 1.8525 in.
(47.1 10 to 47.135 mm)
A Bushing Diver Disks CSleeve

B Extension Handle
Fig. 19-SIeeve Removal A Blind Hole Puller
Fig. 20~Feedback Piston Bushing Removal
To replace bushings, use blind-hole puller (A, Fig.

20) from D-01061AA Blind-Hole Puller Set. Use Disks
27505 and 27511 from Bushing Driver Set to install
bushings. Install O-ring (N, Fig. 18) in bushing and
carefully drive bushing in until it bottoms in bore.

Inspection Continued Assembly

1. Replace all O-rings, slipper seals and backup
rings. Dip all parts in clean John Deere Hy-Gard
(
Transmission and Hydraulic Oil before assembly.
2. Soak fiber backup rings (D and I, Fig. 23) in dean

hydraulic oil for 30 minutes prior to installation,
3. Install the internal set of O-rings and fiber backup

rings (H, I) in sleeve bore. Fiber backup ring is toward
the spindle (N) cavity.
4. Use Disks 27523 and 27535 from Bushing Driver

Set to install sleeves (L). Carefully drive sleeves until
R 28600N they bottom in bores.
ASteering Motor HOil Seal

Housing I Cap Screw 5. Carefully slide feedback piston (T) into bore.
B Bushing J Lock Plate Center piston so that pin groove is aligned with channel
CSpindle Bushing KWasher in spindle cavity.
D Spindte LSpindle Arm
E Bearing MQuill
FSnap Ring NPin
GO-Ring
Fig. 21 -Steering Spindte Assembly
Check spindle bushing (C, Fig. 21) (in spindle bore

in housing) and upper end of spindle (D) for excessive
wear or scoring. Damage could be caused by leakage
or inadequate lubrication. If necessary, install new
bushing. Use Disks 27518 and 27521 from Bushing
Driver Set. Drive bushing in until flush to 0.015 inch
(0.38 mm) below bushing bore.
Check spindle bearing (E) for damage. If necessary,

install new bearing with supplier's identification to the
outside. Install snap ring (F).
Check steering motor housing and housing oil pas- ASlipper Seal BPacking
sages for cracks, or plugged passages or damage.
Fig. 22-Stipper Seat and Packing
Repair or replace as necessary.
6. Install packings (B, Rg. 22) and slipper seals (A)

on steering motor piston.

.
R 28009N
ACap (2 used) FPlug (2 used) L Sleeve (2 used) R Bushing (2 used)

BSteering Motor GSpring Washer (2 used) MPiston
S O-Ring (2 used)
Housing HO-Ring (2 used) NSpindle TFeedback Piston
C Snap Ring (2 used) I
Fiber Washer (2 used) OSpring U O-Ring (2 used)
DFiber Washer (2 used) J Slipper Seal (2 used) P Feedback Piston V Backup Ring (2 used)
E O-Ring (2 used) K Packing (2 used) Pin WPlug (2used)
X Snap Ring (2 used)
Fig. 23-Steering Motor Assembly
7. Install the steering piston with the two counter- 9. Insert the steering motor piston into the JDH-52
sunk holes to the right side of the tractor. Piston Installation Tool (Fig. 24). Using one swift, con-
tinuous motion, insert the piston through the outer
sleeve and into the second.
IMPORTANT: Do not stop with the end of the

piston between the sleeves as the seal will expand
and cannot be started into the second sleeve
without damage.
10. Once installed rotate the piston to install the

feedback piston pin (P, Fig. 23) and spring (O). Use a
small amount of grease to hold pin in place.
1 1 Rotate steering motor piston with the JDH-42-1

Turning Tool to move the pin into the feedback piston
groove. Do not turn piston too far.
12. Install fiber backup ring (D) and O-ring (E) in

piston bores.
13. Install spring washers (G), piston plugs (F), and

snap rings (C). Use "bridge" and spacer as used in
removal to compress spring washer.
Fig, 24-Steehng Motor Piston Installation with

JDH-52 Piston Installation Tool
8. Dip each end of piston in John Deere Hy-Gard

I Transmission and Hydraulic Oil to lubricate the slipper
seals.

Assembly Continued 16. Install quill with dash marks (A, Fig. 25) toward
14. Use Disks 27521 and 27531 from Bushing
front of tractor. Rotate spindle to be sure timing mark
(C) aligns with dash marks (A and B) on quill and
Driver Set to install oil seal in spindle quill. With spring
support in each direction.
side of seal toward driver, carefully drive oil seal into
quill until oil seal bottoms.
1 7. Install feedback piston plugs and snap rings (W,
X, Fig. 23). Install steering motor piston caps (A).
15. Install spindle as follows: Hold the piston
against the right-hand plug. Install spindle so that
18. Install spindle arm on spindle with arm pointed
timing mark ("V") aligns with the right-hand dash mark
on center toward the rear of the tractor. Install washer,
on the front support. (See Fig. 25).
lock plate, and cap screw. Tighten cap screw to 300
ft-lbs (407 Nm) (41 kgm). Strike arm hub several times
with hammer and retighten to 300 ft-lbs (407 Nm) (41
kgm). Bend lock plate into hub recess. Attach tie-rod
ends to arm.
19. To re-install steering motor assembly (front

support) in tractor, reverse removal procedures as
given on page 7. Tighten side frame to front support
cap screws to 275 ft-lbs (373 Nm).
20. Fill spindle cavity with hydraulic oil. Start tractor

engine and cycle steering system several times to
bleed air from the system. Check for leaking connec-
tions.
AQuillDash Marks CSpindle riming

B Support Dash Marks Mark
Fig. 25-Steering Motor Timing Marks

Steering/Brakes Repair Power Brakes 60*10-1
Group 10
POWER BRAKES
PISTONS, PLATES, AND DISKS 2. Remove brake backing plate (E, Fig. 1), disk (A),
and sun pinion (F).
Removal
Remove 3. Remove the three pressure plates (C) and their
1 . the rear axle housing. See Section 50
pistons (D).
Group 40 for instructions.
Repair
1. Inspect final drive gasket and replace if neces-
sary.
2. Inspect backing plate and pressure plates for
missing rivets or worn or loose facings, and replace as

necessary.
a) New facings are 1/8 inch (3 mm) thick.
b) Facing rivet head depth is 1/16 inch (1.6

mm).
3. Inspect disks for wear or excessive play on sun

E 253U2N pinion. Disk should be flat within0.004 inch per inch
(0.1 mm per 25.4 mm) of disk O.D.
A Brake Disk DPiston
B Brake Cylinder E Backing Plate 4. Inspect piston bore O-rings and paper washer.
CPressure Plate FSun Pinion
Replace if damaged.
Fig. 1 -Pistons, Plates, and Disk

60-10-2 Power Brakes Steering/Brakes Repair
Repair Continued 5. Remove the two elbows (in front of firewall) con-
necting the brake valve pressure outlet lines to the
5. Inspect pistons and piston bores for pitting or
brake valve.
scoring.
a) New piston 0,D. is 2.2495-2.2505 inches

(57.14-57,16 mm}.
b) Bore I.D. is 2.2530-2.2560 inches (57.22-

57.30 mm).

1. Install pistons with pressure plates in cylinders.
Be sure Orings and paper washer are in place.
2. Install disk over, but not behind teeth of sun

pinion.
3. Install backing plate with facing toward disk.
4. Install rear axle housing. To install, reverse the

steps of removal.
5. Bleed the brakes (60-10-10).

A Lock Return Line ELock Operating Rod
BRAKE VALVE BBrake Valve Return FOperating Rod Extension
C Brake Valve Inlet G Special Pin
Removal 0 Lock Inlet Line HStrap
Discharge brake accumulator oil pressure by
1. Fig. 2-Brake Vatve Removal (R.H. Cowl Removed)
depressing the brake pedals with a brake bleed screw

open. 6. Remove brake valve return (B, Fig. 2) and pres-
sure inlet (C) lines.
2. Remove right-hand cowl.

7. Remove differential lock return (A) and pressure
3. Raise and block up tractor hood. inlet (D) lines (if equipped).
8. Remove strap (H) from brake pedal.

4. Remove differential lock pressure outlet line (if
equipped) from front of firewall. 9. Remove retaining rings from special pin (G), and
remove pin from pedal.
A CAUTION: Escaping
fluid under pressure
10. Remove operating rod extension (F) through
hole in pedal and slide right-hand pedal from pivot pin.
connecting lines, be sure to relieve all pressure. 11. Remove differential lock valve operating rod
Before applying pressure to system, be sure oil (E).
connections are tight and that lines, pipes and 12. Remove inner pedal, remove the two valve
hoses are not damaged. mounting screws, and remove the brake valve assem-
bly.
Fluid escaping from a very small hole
can almost
be invisible. Use a piece of cardboard or wood,
rather than hands, to search for suspected leaks.
If injured by escaping fluid, see a doctor at once.

ly.

Steering/Brakes Repair Power Brakes 60-10-3
2. Remove equalizing valve pins (A, Fig. 4) and

operating rod guides (B).
i
~=Si
-~ ; ~ti'M
AManual Brake Pistons B^Valve Plungers
Fig. 5-Piungers and Pistons
3. Remove manual brake pistons (A, Fig. 5); press

plungers (B), by hand, from the pistons.
4. Remove equalizing valve assemblies from their

A Lock Return Fitting DLock Inlet Fittings bores as a unit.
B Brake Return Fitting Operating Rod Link
C Brake Inlet Fittings Remove
5. equalizing valve ball and spring from
Fig. 3-Brake Valve (Removed)
each valve bore.
Disassembly Inspection
1 . Remove retainer, valve cover, and operating rod Inspect all parts for wear, scoring or damage; and
assemblies. replace as necessary.
Inspect operating rod stop retainer for a dished

surface and replace if necessary.
Check upper end of operating rod guide for corro-

sion or dirt build-up which may prevent complete re-
lease of guide.
NOTE: Failure to obtain complete guide release

can cause both brakes to be applied with one pedal
since both equalizing valves will be open.
p. 2smmm
i AEqualizing Valve Pins B^Rod Guides CValve Cover

Fig. 4-Brake Vafve Cover

60-10-4 Power Brakes Steering Brakes/Repair
Inspection Continued Inspect operating valve orifice. A restriction of the

0.040 in. (1 mm) orifice could cause brake pedal kick.
Use the following specifications when examining
brake valve parts:
Be sure valve assembly is operabfe. (
tern Measurement New Part

Inspect pedal bushings, pivot pin, operating rod
extensions, and special pins. Replace as necessary.
Brake Valve Plunger O.D. 0.5595-0.5605 in.
(14.21-14.24 mm) Clean inlet oil screen.

Brake Valve Plunger bore I.D. 0.5610-0.5630 in.
(14.25-14.30 mm)
Manual Brake Piston O.D. 0.9330-0.9350 in.
(25.70-2375 mm)
Manual Brake Piston bore I.D. 0.9365-0.9375 in.
(23.70-23.80 mm)
Brake Valve Plunger Return 1 .7 in. at39-47 lbs.
Spring Working Load (43 mm at 173-209 N)
p y
1S
~^ dT 25
fU 2
23
/i 1-33
1Shaft (2 used) 9Paper Washer (2 used) 17O-Ring (2 used) 26 Ball

2Sleeve (2 used) 10O-Ring (2 used) 18Pin (2 used) 27Spring
3Washer (2 used) 11 Piston (2 used) 19Connector 28O-Ring
4O-Ring (2 used) 12Plunger (2 used) 20O-Ring 29Screen
5O-Ring (2 used) 13Spring (2 used) 21 Ball 30O-Ring used)(3
&Equalizing Valve Shaft 14Inlet Valve 22Inlet Guide 31Plug
Guide (2 used) Nipple (2 used) 23Spring 32Check Valve Disk
7Ball (2 used) 15O-Ring (2 used) 24Washer used)
(2
8Spring (2 used) 16Backup Ring (2 used) 25 Housing 33Spring used)(2
34 Plug (2 used)
Fig. 6-Expioded View of Brake Valve
Assembly 4. Install brake operating valve assemblies and
IMPORTANT: Dip tighten nipple (14) to 40 ft-lbs (54 Nrri) (5.4 kgm)
all interna! parts in John
torque.
Deere Hy-Gard Transmission and Hydraulic Oil
prior to assembly. 5. Install equalizing valve springs, balls, guides,
1. Install new O-rings and washers. sleeves, and shafts with guides (6).
2. Install check valve disks (32, Fig, 6) and spring
6. Install plunger return springs. Push plunger (12)
(33) in housing.
manual brake piston
(
into (1 1) and place assembly over
3. Install check valve bail (26), spring (27), screen
spring.
(29) and plug.

8. Place boots, boot retainer, springs, stops, and

snap rings on operating rods (2, Fig. 8) and install
assembly in guides.
9. install retainer on valve cover and attach cover to

brake valve housing.

1. To install the brake valve, reverse the instruc-
tions on removal given on page 60-10-2.
2. Be sure all hydraulic lines are tight.
A O-Ring B Operating Rod Guide

Fig. 7-installing Guides
7. Install Orings (A, Fig. 7) and operating rod

guides (B) in valve cover.
1 Retainer 7 Snap Ring (2 used) 12Operating Rod 16 Brake Pedals

2Operating Rod (2 used) 8 Operating Rod Extension (2 used) 17 Retaining Rings (2 used)
3^Boot (2 used) Guide (2 used) 13 Pedal Bushing (2 used) 18Special Pin (2 used)
4 Boot Retainer (2 used) 9O-Ring (2 used) 14Pivot Pin 19 Bar
5Spring (2 used) 10 Valve Cover 15Deferential Lock 20 Leaf Spring
G Stop (2 used) 11Strap Valve Release Screw 21 Spring Pin
(2 used)
Fig. 8-ExpJoded View of Pedals

.
60-10*6 Power Brakes Steering/Brakes Repair
Adjustment Continued Removal

1 Open a brake bleed screw and depress the brake
pedal to relieve hydraulic oil pressure.
2. Remove the right-hand cowl.
A Lock Inlet Line D Pressure Line

B Lock Operating Rod EAccumulator Inlet
C Lock Pedal FAccumulator
Fig. 9-Brake Pedal Height
Fig. 10-Removing Accumulator
3. Adjust pedal height by adjusting operating rod

3. Remove the differential lock inlet line (A, Fig. 10)
jam nuts to obtain 5-3/4 to 5-7/8 inches (146-149
and its lower fitting.
mm}. Pedal height should be measured with the floor
mat removed. Measure at right angle from foot rest to
4. Remove the accumulator-to-brake valve pres-
pedal crown.
sure line (D).
4. Bleed the brakes as instructed on page 60-10-

5. Remove the differential lock operating rod (B)
10.
from the lock pedal (C) (if equipped).
BRAKE ACCUMULATOR 6. Remove the accumulator inlet line (E).
Testing
7. Remove the retaining clip retaining the accumu-
1.With the engine stopped for no less than 15 lator in the tractor and remove the accumulator (F).
minutes, apply the brakes five times at five second
intervals.
2. if there are no power brakes in five applications

or less, there is a malfunction in the accumulator.

Repair
1. Bleed the accumulator.
A CAUTION: Bleed nitrogen gas from accu-

mulator before attempting to disassemble.
Bleed by removing plug over charging valve and
pressing charging valve in until gas has escaped.
2. Remove retaining rings (3, Fig. 12) on accumu-

lator Remove caps (4 and
caps. 15) and accumulator
piston (14).
3. Inspect piston and piston bore for scoring or

damaged packings and O-rings.
a) O.D. of a new piston is 2.993 to 2.996 inch

(76.0-76.1 mm).
b) I.D. of the bore is 2.998 to 3.001 Inch (76.1-

76.2 mm).
4. Check thermal relief and inlet check valve

springs.
a) Inner inlet check valve spring working load is

0.84 in, at 5,8-7.2 lbs. (21 mm at 26-32 N).
b) Outer inlet check valve spring working load is
1 in. at 37.8-46.2 lbs. (25 mm at 168-206 N).
5. Inspect accumulator charging valve (10), spring,

ALock Inlet Fitting C Pressure Line Fittings valve guide and packing for damage. Replace parts as
BOperating Rod D Elbow
Inlet necessary.
E Accumulator Cylinder
Fig. 1 1-Brake Accumulator (Removed)
>

Repair Continued
1Plug
R 22862
^H
13 Backup Ring (2 used) 24Inner Spring (Thermal relief
2O-Ring 14 O-Ring (2 used) valve)
3 Retaining Ring (2 used) 15 Piston 25Outer Spring (Thermal relief
4Accumulator Cylinder End 16 Backup Ring valve)
5Backup Ring (2 used) 17Retaining Ring (Inlet check valve) 26O-Ring
6O-Ring (2 used) 18Special Washer (Inlet check valve) 27Special Plug (Thermal relief
7Cylinder 19Spring (Inlet check valve) valve)
8 Packing 20Inlet Guide (2 used) 28Cap Screw
9Special Washer 21 Ball (2 used) 29Clip
10Charging Valve 22 Accumulator Cap 30Hex Nut
11Spring 23Washer (2 used) (Thermal relief 31 Lock Washer
12Guide valve)
Fig. 12-Brake Accumulator
Assembly
NOTE: Dip O-rings, packings, and parts in clean 3. Install an O-ring and a backup ring on each cap.
John Deere Hy-Gard Transmission and Hydraulic Oil.
4. Install piston in cylinder.
1. Install charging valve, O-rings, packing, and
spring. 5. Secure caps in cylinder with retaining rings (3,
Fig. 12).
From closed end of piston to open end; install a
2.
backup ring, O-ring, single coil-backup ring,
single-coil
O-ring and a double-coil backup ring.

Pre-Charging Accumulator Continued 6. Turn depressing screw of gas cock (C, Fig. 13)
counterclockwise, install gas cock on adapter assem-
1. Crack nitrogen cylinder valve for an instant to
bly and secure hose to nitrogen regulator as shown in
remove any dirt that may have collected at the valve
Fig, 13.
outlet.
fi CAUTION: Use adequate eye protection
* and stand away from cylinder valve and
7.Turn cylinder regulator screw counterclockwise
Rotate gas cock screw (C) clockwise to open
until free.
regulator valve when opening valves to prevent
accumulator gas check valve.
persona! injury.
8. Slowly open cylinder shut-off valve. After cylinder

needle stops moving, fully open valve.
9.Turn cylinder regulator screw clockwise to get

475-525 psi (29.31-36.21 bar) (29.89-36.92 kg/cm 2 ).
Check all connections for leakage.
10. Close cylinder valve and turn regulator valve (D)

counterclockwise.
11. Close gas cock (C) (rotate counterclockwise).
12. Remove the high-pressure hose and tee from

the accumulator.
NOTE: If the accumulator is over-charged, remove

the hose from the gas cock and fitting. Using the gas
A Brake Accumulator D Pressure Regulator* cock, depress the charging valve in the accumulator to
B D-15019NU Adapter E Nitrogen Cylinder* allow excess gas to escape.
C 1330 Gas Cock F High Pressure Hose
Fig. 13-Chargfag Brake Accumulator
13. Install the charging valve hex. plug.
"From Local Distributor

Installation
2. Attach regulator (D, Fig. 13) to cylinder vafve and
1. To install the brake accumulator, reverse the
tighten securely.
steps of removal given on page 60-10-6.
3. Attach high pressure hose (F) to regulator outlet
and turn regulator pressure adjusting screw counter- Check be sure
2. to ail hydraulic lines are tight.
clockwise until it turns freely.
4. Remove plug from end of accumulator.
3. Bleed the brakes and test the accumulator.
. |f
RS0050K1
A Adapter Assembly (2364) C Tru-Seal Nut (6577)

B O-Ring Washers (6877)
Fig. 14-lnstaliing Adapter Assembly
5. Remove the Tru-Seal nut (C, Fig. 14) from

adapter assembly (A). Install two O-ring washers (B)
on adapter assembly. Install Tru-seal nut with Teflon
side towards accumulator. Install adapter assembly in
gas check valve port of brake accumulator.

.
Bleeding the Brakes Testing Accumulator

1. With the engine stopped for no less than 15
minutes, apply the brakes five times at five second

intervals.
2. If the brakes feel spongy after five pedal appli-

cations, bleed the brakes and retest accumulator.
3. If pedal feel is the same after bleeding, there is a

malfunction in the accumulator or brake system.
Fig. 15-Right-Hand Brake Bleed Screw
1 Loosen the brake bleed screw lock nuts on both

sides of the transmission case.
2. Turn the bleed screws out two turns and tighten

the lock nuts.
3. Start and run the engine at 1900 rpm to pres-

surize the hydraulic system,
4. Depress the brake pedals for 2 minutes. With the

pedals held down, loosen the lock nuts and tighten the
bleed screws.
5. Tighten the bleed screw lock nuts.

6
1
Hydraulic Repair Specifications and Special Tools 70-00-
Section 70
I
HYDRAULIC REPAIR
GROUP 00 - SPECIFICATIONS AND Seat Valve Housing 70-05-9
SPECIAL TOOLS Removal 70-05-9
Specifications 70-00-2 Disassembly 70-05-10
Special Tools 70-00-7 Inspection and Repair 70-05-10
Making Special Tools 70-00-14 Charging the Accumulator 70-05-1
Transmission-Hydraulic System
GROUP 05 - MISCELLANEOUS HYDRAULIC Cleanup Procedure 70-05-13
COMPONENTS
Charging Circuit Valves 70-05-1 GROUP 10 - HYDRAULIC PUMPS
QUAD-RANGE Transmission Equipped External Gear Pump (QUAD-RANGE
Tractors 70-05-1 Transmission) 70-10-1
Oil Pressure Regulating Valve Removal 70-1 0-1
Housing 70-05-1 Inspection and Repair 70-10-1
Removal 70-05-1 Assembly and Installation 70-10-2
Inspection 70-05-1 Internal Gear Pump (Power Shift
Assembly and Installation 70-05-2 Transmission) 70-1 0-2
Oil Filter Relief Valve Housing 70-05-2 Removal and Disassembly 70-10-2
Removal 70-05-2 Repair and Assembly 70-10-3
Inspection 70-05-2 Replacing Main Pump Shaft Oil Seal 70-10-5
Assembly and Installation 70-05-3 Removal 70-10-5
Power Shift Transmission Equipped Installation 70-1 0-5
Tractors 70-05-4 Main Hydraulic Pump 70-10-6
Oil Pressure Regulating Valve Removal 70-1 0-6
Housing 70-05-4 Repair 70-10-7
Removal 70-05-4 Assembly and Adjustments 70-10-11
Inspection 70-05-4 Installation and Adjustments 70-10-14
Function Return Oil Filter Relief Valve . . . 70-05-5 GROUP 15 - ROCKSHAFTAND
Removal 70-05-5 IMPLEMENT HITCHES
Inspection 70-05-5 Rockshaft Piston Cover 70-15-1
Assembly and installation 70-05-6 Rockshaft Housing 70-15-3
Oil Cooler Check Valve 70-05-6 Control Valve Housing 70-15-7
Removal 70-05-6 Operating Linkage 70-15-10
Inspection 70-05-6 Load Control Arm 70-15-13
Installation 70-05-6 Console Linkage 70-15-16
Pressure Control Valve 70-05-7 Adjustments 70-1 5-1
Removal 70-05-7 Hitch 70-15-20
inspection and Repair 70-05-7 Lift Assist 70-15-21
Assembly and Installation 70-05-8 Power Weight Transfer Hitch 70-15-23
Directional Control Valve 70-05-8
Repair 70-05-8 GROUP 20 - SELECTIVE CONTROL VALVE, AND
Assembly and Installation 70-05-8 REMOTE CYLINDER
Hydraulic Oil Cooler 70-05-9 Breakaway Coupler 70-20-1
Repair 70-05-9 SCV Housing 70-20-3
Removal 70-05-9 SCV Adjustment 70-20-8
Inspection 70-05-9 Remote Cylinder 70-20-12
Installation 70-05-9

70-00-2 Specifications and Special Tools Hydraulic Repair
SPECIFICATIONSContinued
Miscellaneous Hydraulic Components I
QUAD-RANGE transmission valve springs

Oil cooler relief valve Free length 5.9 in. (150 mm)
Compressed 4.54 in. at 36.5 to 44.5 lbs.
(115.3 mm at 163-198 N)
Oil pressure regulating vaive
Inner Free length 5.1 7 in. (131 .3 mm)
Compressed 3.98 35-43 lbs.
in. at
(101.1 mm at 157-192 N)
Outer Free length 2.97 in. (75.4 mm)
(41.4 mm at 66 to 79 N)
Return oil check valve
(19.05 mm at 48 to 59 N)
Oil filter relief valve
Free length 5.9 in. (150 mm)
(109.5 mm at 99 to 123 N)
Power shift transmission valve springs
Transmission oil filter relief valve
(66.3 mm at 108 to 132 N)
Lube relief valve Free length 2.83 in. (71 .8 mm)
(54.1 mm at 52 to 64 N)
Compressed 4.44 in. at 58.5 to 71 .5 lbs.
(112.8 mm at 260 to 319 N)
Return oil check valve Free length 2.31 in. (58.5 mm)
(19.0 mm at 48 to 59 N)
Oil cooler relief valve Free length 4.55 in. (115.5 mm)
(89.7 mm at 159 to 194 N)

Function return oil filter relief
valve Free length 2.75 in. (69.85 mm)

Compressed 1-81 in. at 27 to33 lbs.
(46.03 mm at 120 to 142 N)
Pressure control valve Free length 4.61 in. (117.1 mm)
Compressed 3.50 in. at 45 to 55 lbs.
(88.9 mm at 200 to 244 N)
Directional control valve Free length 2.31 in. (58.67 mm)
(19.05 mm at 48 to 59 N)
Seat pressure regulating valve spring
Compressed 2.25 in. at 24 to 32 lbs. (
(57 mm at 107 to 149 N)

Hydraulic Repair Specifications and Special Tools 70-00-3
Miscellaneous Hydraulic Components Continued

Torques
Clutch valve housing to oil pressure
regulating valve housing 20 ft-lbs (27 N-m) (3 kgm)
Oil pressure regulating valve housing
to dutch housing 35 ft-lbs (47 N-m) (5 kgm)
Filter relief valve housing to
transmission case 45 ft-lbs (61 N*m) (7 kgm)
Power shift oil pressure regulating
valve housing to dutch housing 45 ft-lbs (61 N-m) (7 kgm)
Hydraulic Pumps
External gear transmission pump (QUAD-RANGE transmission)
Hem Measurement Part Dimensions

Gear Bore Depth 0.9353 to 0.9369 in. (23.75 to 23.80 mm)
Drive gear O.D 2.6195 to 2.6205 in. (66.53 to 66.56 mm)
Drive gear Width 0.9320 to 0.9326 in. (23.67 to 23.69 mm)
Drive gear I.D 1.1835 to 1.1845 in. (30.06 to 30.09 mm)
Idler gear O.D 2.1075 to 2.1085 in. (53.53 to 53.56 mm)
Idler gear Width 0.9320 to 0.9326 in. (23.67 to 23.69 mm)
Idler gear |.D 0.7518 to 0.7528 in. (19.10 to 19.12 mm)
Idler shaft O.D 0.7497 to 0.7503 in. (19.04 to 19.05 mm)
Priority lube check
Valve spring Free length 1 ,25 in. (31 .5 mm)
Manifold-to-case cap screw Torque 20 ft-lbs (27 N-m) (2.7 kgm)
Manifold-to-pump cap screw Torque 20 ft-lbs (27 N-m) (2.7 kgm)
Lube tube clamp-to-manifoJd
cap screw Torque 35 ft-lbs (47 N-m) (4.7 kgm)
internal Gear Transmission Pump (Power Shift)
Drive gear counterbore LD 4040 2.3025-2.3035 n. (58.48-58.54 mm)

4240 2.4525-2.4535 n. (62.29-62.32 mm)
Drive gear O.D 3.3195-3.3205 n. (84.31-84.34 mm)
Drive gear bushing O.D 4040 2.2985-2.2995 n. (58.38-58.41 mm)
4240 2.4485-2.4495 n. (62.19-62.22 mm)
Drive and internal gear bore Depth 0.9327-0.9337 n. (23.69-23.72 mm)
Drive and internal gear Thickness 4040 0.9301-0.9311 n. (23.62-23.65 mm)
4240 0.9306-0.9312 n. (23.63-23.65 mm)
Internal gear LD 3.5695-3.5705 n. (90.66-90.99 mm)
Internal gear O.D 4.4370-4.4380 in. (112.70-112.73 mm)
internal gear diameter in
pump body I.D 4.441-4.443 in. (1 12.8-1 12.9 mm)

Pump-to-housing special
Manifold-to-pump cap screw Torque 20 ft-lbs (27 N*m) (2.7 kgm)
Pump-to-clutch housing Torque 50 ft-lbs (68 N-m) (6.9 kgm)

Hydraulic Pumps Continued

Wem Measurement Part Dimension
Main Hydraulic Pump

3 cu.in. pump (49 mL) Row 23 gpm (87 L/min)
Standby pressure 2200-2300 psi (151.7-158-6 bar)
(154.7-161.8 kg/cm 2 )
4 cu. in. pump (66 mL) Flow 26.5 gpm (100 L/min)
Standby pressure 2250-2300 psi (155.2-158.6 bar)
(158.2-161.8 kg/cm 2 )
Pump shaft End play 0.001-0.003 in. (0H2-0.08 mm)
Pump piston
3 cu. in. pump (49 mL) O.D 0.8740-0.8744 in. (22.20-22,21 mm)
Bore I.D 0.8747-0.8753 in. (22.22-22.23 mm)
Spring working load* 1.62 in at 34-40 lbs. (41 mm at 151-178 N)
4 cu. in. pump (66 mL) O.D 0.9630-0.9634 in. (24.46-24.47 mm)
Bore I.D 0.9637-0.9643 in. (24.48-24.49 mm)
Spring working load* 1.78 in. at 47-53 tbs. (45 mm at 209-236 N)
*Must match to within 1 .5 lbs
(67 N)
Pump piston plug Torque 100 ft-lbs (136 N*m) (13.6 kgm)
Thrust washer
3 cu. in. pump (49 mL) Thickness 0.1230-0.127 in. (3.12-3.23 mm)
4 cu. in. pump (66 mL) Thickness 0.0422-0.0452 in. (1.07-1.15 mm)
Inlet valve Lift 0.060-0.080 in. (1 .52-2.03 mm)

Inlet valve (installed) Distance from finished face 0.5250-0.5370 in. (13.34-13.64 mm)
Inlet valve plug Torque 100 ft-lbs (136 N-m) (13.6 kgm)
Discharge valve seat (installed) . . . Distance from finished face 0.8700-0.8705 in. (22.10-22.11 mm)
Stroke control valve spring Working load 3.3 in. at 125-155 lbs. (84 mm at 556-689 N)
Crankcase outlet valve spring Working load 2.2 in at 45-55 lbs. (56 mm at 200-245 N)
Stroke control valve houstng-to-

purnp Torque 85 ft-lbs (115 N-m) (11 .5 kgm)
housing cap screw
Pump-to-pump support cap screw Torque . 85 ft-lbs (1 15 N-m) (1 1 .5 kgm)
Pump drive shaft cap
screw Torque 35 ft-lbs (47 N-m) (4.7 kgm)
Pump drive special cap screw .... Torque 35 ft-lbs (47 N-m) (4.7 kgm)
Drive coupler cap screw Torque 35 ft-lbs (47 N-m) (4.7 kgm)
PFWD Pump Drive
Coupler-to-damper screws Torque 35 ft-lbs (47 N-m) (4.7 kgm)

Pump drive-to-coupier cap screws Torque 35 ft-lbs (47 N-m) (4.7 kgm)
Keeper-to-drrve cap screws Torque 20 ft-lbs (27 N-m) (3 kgm)

Hydraulic Repair Specifications and Special Tools 70*00-5
Rocks haft and Implement Hitches

Lift Cycle Time
4240 2.5 - 275 seconds
4040 2.39 - 2.68 seconds
Rockshaft Test Flow

4240 10-11 gpm (37.85 - 41.64 L/m)
4240 W/Lift Assist 12 - 13 gpm (45 - 49 L/m)
4240 Hi-Crop 8-9 gpm (30.28 - 34.07 L/m)
4040 8-9 gpm (30.28 - 34.07 L/m)
4040 W/Lift Assist 10-11 gpm (37.85 - 41.64 L/m)
Thermal refief valve Operating Pressure . . . 3550 - 3950 psi (245 - 272 bar)
(250 - 278 kg/cm 2 )
Surge relief valve Operating Pressure . . . 2650 - 3000 psi (183 - 207 bar)
(186 - 211 kg/cm 2 )
Throttle valve spring Free Length 1 .25 in. (32 mm)
Working Load 0.75 in. at 0.5 - 0.7 lbs.
(19 mm at 2.2 - 3.1 N)
Rockshaft piston
4240 O.D 4.2460 - 42480 in. (107,62 -108.12 mm)
4040 O.D 3.8710 - 3.8730 in. (98.33 - 98.38 mm)
Rockshaft cylinder
4240 1.D 4.2460 - 4.2480 in. (107.62 - 108.12mm)
4040 1.D 3.8755 - 3.8785 in. (98.44 - 98.51 mm)
Piston cover-to-rockshaft housing
Cap Screw Torque 170 ft-lbs. (230 N-m) (23 kgm)
L.H. rockshaft bushing

4240 |.D 2.876 - 2.880 in. (73.05 - 73.15 mm)
4040 1.D 2.626 - 2.630 in. (66.70 - 66.80 mm)
R.H. rockshaft bushing (Inner)
4240 1.D 2.503 - 2.507 in. (63.58 - 63.68 mm)
4040 1.D 2.251 - 2.255 in. (57.175 - 57.277 mm)
R.H. rockshaft bushing (Outer)
4240 1.D 2.503 - 2.507 in, (63.58 - 63.68 mm)
4040 1.D 2.251 - 2,255 in. (57.1 75 -57.277 mm)
L.H. rockshaft
4240 O.D 2.872 - 2.874 in. (72.95 - 72.99 mm)
4040 O.D 2.6210 - 2.6240 in. (66.57 - 66,65 mm)
R.H. rockshaft
4240 O.D 2.499 - 2.501 in. (63.48 - 63.53 mm)
4040 O.D 2.2470 - 2.2490 in. (57.07 - 57.12 mm)
Bottom cover cap screw Torque 35 ft-ibs. (47 N-m) (4.7 kgm)
Lift arm cap screw Torque 270 - 330 ft-lbs (366 - 447 N-m) (36.6 - 44.7 kgm)

.
Rockshaft and Implement Hitches Continued

Rockshaft housing-to-transmission
case cap screw Torque 85 ft-Jbs (1 1 5 Nm) (1 1 .5 kgm)
Flow control valve O.D 0.6530 - 0.6534 in. (16.58 - 16.60 mm)
Bore I.D 0.6539 - 0.6549 in. (16.61 - 16.63 mm)
Maximum clearance . . 0.0019 in. (0.05 mm)
Spring free length .... 1-7/64 in. (27 mm)
Spring working load. . . 0.9 in, at 12 - 15 lbs. (23 mm at 56 - 69 N)
Control valve O.D 0.7480 - 0.7490 in. (19.00 - 19.02 mm)
Bore I.D 0.7500 - 0.7520 in. (19.05 - 19.10 mm)
Maximum clearance . . 0.0040 in. (0.10 mm)
Spring free length .... 2.15 in. (55 mm)
Spring working load. 1.4 in. at 7
. .
- 9 lbs. (36 mm at 68 - 88 N)
Operating cam spring Working load 3.35 in. at 32 - 40 lbs. (85 mm at 145 - 176 N)
Thermal relief valve spring Free length 0.57 in. (15 mm)
Working load 0.45 in. at 12 - 1 5 lbs. (1 1 .4 mm at 55 - 68 N)
Load control shaft O.D 1.1230 - 1.1250 in. (28,52 - 28.58 mm)
Transmission case bushing at

smallest point I.D 1.1280 - 1.1300 in. (28.65 - 28.70 mm)
Draft link support bushing I.D 1.1540 - 1.1600 in. (29.31 - 29.46 mm)
Case-to-drawbar special washers

4240, 4040 Thickness 0.036 in., 0.048 in., 0.062 in.
(0.9 mm, 1.2 mm, 1.6 mm)
Adjustments See page 70-15-16

Center link attaching bracket
cap screws - 4240, 4040 Torque 300 ft-Ibs. (406 N-m) (40.6 kgm)
ROCKSHAFT LIFT ASSIST

Lowering valve O.D 0.3739 - 0.3743 in. (9.49 - 9.51 mm)
Bore I.D 0.3745 - 9.3755 in. (9.51 - 9.54 mm)
Lowering valve spring Working load 7/8 in. at 4 - 7 lbs. (22 mm at 18 - 31 N)
Surge relief valve spring Working load 1-7/64 in. at 130 - 1 50 lbs. (28 mm at 578 - 667 N)
Cylinder support-to-trans-
mission case cap screw Torque 170 ft-Ibs (230 N-m) (3 kgm)
Lift arm special pin cap screw , . Torque 35 ft-Ibs (47 N-m) (4.7 kgm)
For 4240 Hi-Crop Tractors, refer to 4040 rockshaft specifications.

Selective Control Valve and Remote Cylinder

l MEASUREMENT PART DIMENSION
Selective control valve Flow 3-16 gpm (11 - 60 L/m)

Remote cylinder extension Time 1 .5 - 2.0 sec.
Stroke 8 in, (203 mm)
Flow control vafve stop Length 0.94 in. (24 mm)
Pressure valve spring Free length .... 1.72 in. (43.7 mm)
Working load ... 1.20 in, at 36 - 44 lbs. (30.5 mm at 160 - 196 N)
Return valve spring Free length .... 1 .53 in. (39.0 mm)
Working load ... 1.20 in. at 18 - 22 lbs. (30.5 mm at 90 - 98 N)
Flow control valve spring Free length . 2.95
. . , in. (75 mm)
Working load .2.15
.
. in. at 40.5 - 49.5 lbs. (55 mm at 180 - 220 N)
Detent piston spring Free length 1.60 in. (40.5 mm)
Working load . . . 1,25 in. at 19 - 23 lbs. (32 mm at 84-102 Nl)
Control valve O.D. .0.4960 - 0.4970 in. (12.60 - 12.62 mm)

Flow control valve O.D. .0.7480 - 0.7490 mm)
in. (18.99 - 19.03
Metering valve O.D. .0.6235 - 0.6245 in. (15.84 - 15.86 mm)
Selective control va/ve cap screw . . . Torque 35 ft-lbs (47 N-m) (4.7 kgm)
Remote cylinder piston rod guide

Piston rod special lock nut Torque 300 ft-lbs (407 N-m) (40,7 kgm)
Cylinder end cap - cap screw Torque 120 ft-lbs (163 N*m) (16.3 kgm)
SPECIAL TOOLS
Miscellaneous Hydraulic Components
TOOL NUMBER USE
*A D-15012NU To charge seat accumulator.

Charging Kit
*B 2364 Adapter Assembly
*C--6877 O-ring Washers
*D6577 Tru-seal Nut
*Order From
Service Tools
R34733
I Fig. 1 -Nitrogen Charging Kit

70-QQ-8 Specifications and Special Tools Hydraulic Repair
Miscellaneous Hydraulic Components-

Continued
TOOL NUMBER USE
Used with regulator and charging kit to

precharge brake accumulator Obtain
ôseei
Fig. 2-Nitrogen Cylinder
Used with nitrogen and charging kit to

'Mtw' iitltl
,
I$$$-v" ^-V :V
R75G68H!
Fig. 3-Pressure Regulator

TOOL NUMBER USE
*JDH-57 Sleeve To remove sleeve from HYDRA-

Removal Too] CUSHIONED Seat regulating
valve housing.
R 31112
Fig. 4-SIeeve Removal Tool
Hydraulic Pumps *JDT-33 Sea) To install oil seal in internal

Driver gear pump body.
\
-^Mf|î^f^lp^^^fWi^t-'"
:$&'-.
.-i&sipi r :*.-,? .v; :
'.^^fcw.
r#\Kg$:îfiifr.: v ,
'
^""^^ '':'':
:.i:".r.::.::-,
-Hr,
*
" ?$ :
ft 264SCH
FAj. 5-JDT-33 Transmission Pump Seat Driver
*A-JDT-18 To protect pump shaft on inter-

Protector nal gear pump during assem-
bly.
R 28162N
Fig, 6-JDT-18 Protector
R 26696N
Fig. 7-JDH-19A Crankcase Outlet Vatve Adjusting Toot
*JDH-1 9 A Crankcase To adjust crankcase outlet

Outlet Valve Adjusting valves on main hydraulic
Tool pump.

70-00-10 Specifications and Special Tools
Hydraulic Repair
TOOL NUMBER USE
*AJDH-31-A To install main pump shaft oil

Seal Driver seal.
*B JDH-35-A To remove main pump shaft oil
Seal Puller seal.
R 26697N
Fig. 8-Shaft Seal Replacement Tools
*A D-05007ST
Splitting Stand
To remove tractor front end for
*B D-05149ST main hydraulic pump repair.
Attachments
3 23Q&8N
Fig. 9-Spiitting Stand and Attachments
(a) *AJDH-40 Seat To remove discharge valve

Puller seats from main hydraulic
pump.
#2$ 2 03Z
y
Fig. 10-Speciai Tools
*B--JDH-39 Seat
Driver
To
seats
install
in
discharge valve
main hydraulic pump.
* Order From:
Service Tools inc.
Box 314
Owatonna, MN 55060
(

TOOL NUMBER USE
*OTC-614 Handle To install oil seal in main pump

*JDH-18 Seal Driver housing.
R 26695N
Fig. 11-OTC-8U Handle and JDH-18 Seal Driver
Rockshaft and Implement Hitches
Used for rockshaft removal, see page 70-00-1 2 for instructions

on making tool.
P.28450N
Fig. 12-Rockshaft Lift Tool
*JDH-28 Valve seat driver for install

guides in control valve hous-
ing.
R 27244N
Fig. 13-Valve Seat Driver
Used in rockshaft valve adjustment. See page 70-00-13 for

instructions on making tool.
*Order From
Service Toots inc.
R 2S449N
Box 314
Fig. 14-Extended Arm Owatonna, MN 55060

70-00-12 Specifications and Special Toois Hydraulic Repair
TOOL NUMBER USE

*A - D-01045AA Bushing and Seal Driver
Bushing and Set for bushing and seal
Seal Driver Set installation and removal.
R?S0g?S
Fig. 15~Bushing and Seal Driver Set
*JDH-45 Seal Driver for installing seal in lift
Driver assist cylinder.
*Order From
Service Tools Inc.
Box 314
R 28346N
Owatonna, MN 55060
Fig. 16-Seai Driver for Lift Assist Cylinder

TOOL NUMBER USE
*JDH-50-2 Used to install load control

Bushing Driver shaft bushings.
R 3Q011N
Fig. 17~JDH~50-2 Bushing Driver
Selective Control Valve, Breakaway

Coupler and Remote Cylinder
*NJD-150 Reseating tool to grind valve

Reseating Tool seats in selective control
valves.
Fig. 18-Reseating Toot
*JDhM5C Special Adjusting cover used to adjust

Adjusting Cover poppet valves in selective con-
trol valves.
*JDH-28 Driver to install inner detent

Driver piston guide.
v
*Order From
Service Tools Inc.
Box 314
Owatonna, MN 55060
Fig. 19-SpeciaI Adjusting Cover and Driver

"
70-00*14 Specifications and Special Tools Hydraulic Repair

(9.53 mm)
3/8 in. dia.
R2844SN Fig. 20-Rockshaft Valve Operating Arm Extension Tool
TTBTl in.
DRILL
19 .750 8 HOLES
23.5 m .925 .656 1.752
r 2,539
39 - 1,535
44 - 1.732
44.5 - 1.752
57.5 - 2.264. 1.732; 2.
'
61.5 - 2,421
4.5 - 2.539
67.5 - 2.657 5,709-
72,5 - 2,854
88 - 3.465
92 ~ 3.622
145 5.709
- 8.500
216
8- in.
n(203nm}p
(203 mm r L 2,264
r
3 n n.
T
8 in.
1.752
76. mm]
(
(203 mm
4 in.
(102 er )
1. t.l
0.75 in.
ISL (19 ran) .5 in, .25 in.
FhH "(13 mm) (6 mm)
O m 2 in.
(51 mm)
6 ft, J. In.
-(1.8 m)- (51 mm)
o
6 ft,
RS8444S "(1.8 m)"
I H r~(38 mm)
Fig. 21-Rock$haft Lift Tool

.
Hydraulic Repair Miscellaneous Hydraulic Components 70-05-1
Group 05
MISCELLANEOUS HYDRAULIC COMPONENTS
CHARGING CIRCUIT VALVES I
(QUAD-RANGE TRANSMISSION
EQUIPPED TRACTORS)
Oil Pressure Regulating Valve Housing
Removal
1. Clean area around valve housing.
2. Place large clean container under housing to

catch reservoir oil.
53$:
AOil Cooler Relief C Shims

Valve DGasket
6 Pressure Regulating EClutch Valve
Valve Housing
Fig. 2-Vatve AssembliesOil Pressure

Regulating
7. remove valve assemblies from valve

Carefully
Fig. 1-Oit Pressure Regulating Valve housing. Be sure to identify each valve, spring, and
Housing shims for reassembly in their respective bores (Fig. 2).
3, Remove steering return hose from housing. NOTE: Clutch valve service information is found in
4. Remove clutch operating linkage from housing.
Inspection
5, Remove filter relief vafve housing-to-pressure
1 Check each valve for burrs, damage, or scored
regulating housing pipe.
conditions that could cause valves to leak or stick in
bores. Repiace valves as necessary.
6. Remove eight cap screws securing pressure
regulating valve housing-to-clutch housing, and re-
2. Check valve springs for broken coils and for
move housing.
proper compression. Use the following specifications.

.
70-05-2 Miscellaneous Hydraulic Components

Hydraulic Repair
Inspection Continued 8. Align the clutch valve housing gasket and attach
the clutch valve housing to the oil pressure regulating
Oil Pressure Regulating Valve Housing valve housing with eight cap screws.
Spring Specification 9. Tighten cap screws to 20 ft-lbs (27 Nm) (3 kgm).

Oil cooler relief vaJve
Free length 5.9 in. (150 mm) 10. Be sure gasket surface on clutch housing is
Compressed at 36.5 to 44.5 lbs clean.
(163-198 N) 4.54 in. (115.3 mm)
Oil Pressure regulating valve dutch valve housing
1 1 Install oil passage adapt-
Inner ers in clutch housing.
Compressed at 35 to 43 lbs. 12. Align clutch valve housing with adapters and
(157-192 N) 3.98 in. (101.1 mm) install oil pressure regulating valve housing on clutch
OIJ pressure regulating valve
housing.
Outer
Free length 2.97 in. (75.4 mm) Tighten cap screws to 35 fMbs (47
1 3. Nm) (5 kgm).
Compressed at 14.7 to 17.9 lbs.
(66 to 80 N) 1.63 in. (41.4 mm) 14, Connect pipes and hoses and return "saved"
hydraulic oil, if clean, to 1he main reservoir.
3. Examine valve housings for cracks, damaged
vaJve bores, and plugged or leaking passages. Re- 15. Perform hydraulic system tests as directed in
place housings if any of these conditions exist. Group 10 of Section 270 to determine if malfunction
has been corrected.
4. Check for torn, damaged or misaligned gaskets
or damaged O-rings that could cause internal or ex- Oil Filter Relief Valve Housing
ternal leakage.
Removal
1, (Not Illustrated) Clean area around valve hous-
1. Assemble valve housings in a clean area. ing.
2. Replace O-rings and gaskets as necessary. 2. (Not Illustrated) Place a large container under
housing to catch reservoir oil.
3. Be sure all parts are clean and dry, then dip in
clean John Deere Hy-Gard Transmission and Hydrau-
lic Oil before assembly.
4. Install valves and springs in their respective

bores in housing.
5. Be sure valves are positioned in correct direction.

i ; [ l
: i; :;|HjSiirti ::!::{ ::3
6. Install the same number of shims as removed

from the oil pressure regulating valve unless tests
indicate otherwise.
7. Install valve plugs.
Fig. 3-Oif Fitter Relief Valve Housing

' .
Hydraulic Repair
Miscellaneous Hydraulic Components 70 -05-3
3. Remove filter relief valve housing-to-pressure Assembly and Installation

regulating housing pipe,
1 Assemble valve housings in a clean area,
4. Remove oil cooler return pipe.
2. Replace O-rings and gaskets as necessary.
5. Remove function return line.
3. Be sure all parts are clean and dry, then
dip in
6. Remove cap screws clean John Deere Hy-Gard Transmission and Hydrau-
securing housing to trans-
mission case, and remove housing. lic Oil before assembly.
'
,-o
""
u -" : '"^
-
" "nY... '
- -
f '--*,,
"
/ ^Î*5^m^^~ bores in housing.
5. Be sure that the oil filter relief valve is equipped

with O-ring.
6. Be sure valves are positioned in correct direction.
7. Install valve plugs,
8. Be sure gasket surface on transmission case is

clean.
If: a 9. Install oil filter relief
transmission case.
1 0. Tighten cap screws to 45

valve housing with gasket on
ft-ibs (61 Nm) (7 kgm),

* 2753?^
11- Connect pipes and hoses and return "saved"
AReturn Oil Check Valve C^-O-Ring hydraulic oil, if clean, to the main reservoir.
B Filter Relief Valve
12. Perform hydraulic system tests as directed in
Fig. 4-Vaive AssembliesFilter Relief Valve Housing
Group 10 of Section 270 to determine if malfunction
has been corrected.
7. Carefully remove valve assembles from valve
housings. Be sure to identify each valve, spring and
shims for reassembly in their respective bores.
Inspection
1. Check each valve for burrs,

damage, or scored
bores. Replace as necessary.
2. Check valve springs for broken coils

and for
proper compression. Use the following specifications.
S 9rin 9
l
Specification
Return oil check valve
Free length 2,31 in. (58.7 mm)
Compressed at 10.3 to 13.2 Jbs.
(48 to 59 N) o.75 in. (19.05 mm)
Oil Filter Relief Valve
Free length 5.9 in. (150 mm)
(103 to 126 N) 4.31 in. (109,5 mm)

.
70-05-4 Miscellaneous Hydraulic Components

Hydraulic Repair
CHARGING CIRCUIT VALVES

POWER SHIFT TRANSMISSION EQUIPPED TRACTORS
Oil Pressure Regulating Valve Housing Inspection
Removal
1. (Not Illustrated) Clean area around oil pressure
2. (Not Illustrated) Place a large dean
container
under housing to catch reservoir oil.
'''"*'.*'&
.;. ftf :..
:
He? -^
ft mmm^
A Valve Housing I Spring
Fig. 5 Oil Pressure Regulating Valve Housing
B Transmission ON J Shim
Filter Relief Valve KWasher
CSpring LPlug
3. Remove oil cooler return pipe from housing. DPlug MSpring
4. Remove steering return hose from housing. ELube Relief Valve N Return Oil Check Valve
5. Remove oil filter relief housing-to-oil pressure
FSpring OSpecial Plug
regulating valve housing pipe.
G Plug P Cooler Relief Valve
H Pressure Regulating QSpring
6. Remove hydraulic pump return pipe from hous-
ing.
Valve R Plug
7. Remove electrical connector from housing. rtg. 6-Exploded View of OH Pressure Regulating Vaive Housing
NOTE: Take care not to damage gasket behind
vaive housing, if gasket is damaged or not reusable, 1 Carefully remove valve assemblies from housing.
the pedal vaive will have to be removed and a new Be sure to identify each valve, spring, and shims for
gasket installed. reassembly into their respective bores.
8. Remove cap screws securing valve housing and
remove housing. 2, Check each valve for burrs, damage, or scored
bores. Replace valves as necessary.

3. Check springs for broken, rusted or pitted colls 4. Install valve housing. Be sure that gasket is in
and for proper compression. Use the following specifi- good condition. Tighten housing cap screws to 45 ft-lbs
cations. (61 N-m). Install hose, pipes, spring and electrical
connector.
Spring (Fig. 8) Specification
Transmission oil filter (C)
FUNCTION RETURN OIL FILTER
relief valve RELIEF VALVE
Free length 3.71 in. (94.2 mm) Removal
Compressed at 24,3 to 29.7 lbs.
(108 to 132 N) 2.60 In. (66.3 mm)
Lube relief valve (F)
Free length 2.83 in. (71 .8 mm)
(52 to 64 N) 2.13 in. (54.1 mm)
Oil pressure regulating valve (I)

(260 to 319 N) 4.44 in. (112.8 mm)
Return oil check valve (N)
(48 to 59 N) 0.75 in. (19.0 mm)
Oil cooler relief valve (P)
Free length 4.55 in. (115.5 mm) AValve Housing B Filter Bore
Fig. 7-Function Return Oil Filter Relief Valve
(159 to 194 N) 3.53 in. (89.7 mm)
1. Clean area around return oil filter cover. Place
4. Check valve housing for cracks, damaged valve
clean container under filter area. Remove filter cover
bores and plugged or leaking passages. Replace
and filter.
housing if any of these conditions are present.
2. Remove the two cap screws and remove valve
5. Check damaged, or misaligned gaskets
for torn T
housing (A, Fig. 7) from filter bore (B).
or damaged O-rings that could cause internal or ex-
ternal leakage. Inspection
1. Assemble valve housing in clean area. Replace

allO-rings. Replace gaskets as necessary. Be sure all
parts are clean and dry, then dip in clean John Deere
HY-GARD Transmission and Hydraulic Oil before as-
sembly.

bores. Be sure that valves (B,E,H, and P, Fig. 6} are
equipped with O-rings.
NOTE: The oil pressure regulating valve (H) is

equipped with shims (J). Install the same number of
shims unless tests indicated otherwise.
3. install return oil check valve (N, Fig. 6) with head

end of valve toward the bottom of the valve housing. 3 2610SN * j"*^
A Retaining Ring D Valve

BSpecial Washer EHousing
C Spring
> Fig. 8~Exploded View of Function Return OH
Fitter Relief Valve Assembly

70-05-6 Miscellaneous Hydraulic Components Hydraulic Repair
Remove retaining ring (A, Fig. 8), special washer Inspection

(B} T spring (C) and valve (D) from housing (E).
Check valve (D) and valve housing (E) for damage

or scoring. Replace as necessary.
Check spring (C) for damage to coils and for correct im

compression of 0.75 in. (19.05 mm) at 10.8 to 13.2 lbs.
(48 to 59 N). Replace spring rf necessary.
Assembly and Installation *Si^HpPito
1. Replace O-rings. Dip all parts in John Deere

HY-GARD Transmission and Hydraulic Oil.
2. Install valve assembly into valve housing. Be

sure that valve is equipped with an O-ring.
valve housing into jpS 'i* J j

3. Install filter bore. Replace filter
{.
and filter cover.
OIL COOLER CHECK VALVE tj^ "ffiH
Removal
POWER SHIFT PERMA-CLUTCH
A Special Tee GSpecial Connector
B Nylon Ball HO-Ring
C Spring Pin I Steel Ball
DO-Ring J Spring
E Connector K Spring Guide
FO-Ring
Fig. 1Q-Exploded View of Oil Cooler Check Valves
On "PERMA-CLUTCH", check connector seat (G,

Fig. 10) steel ball
T (I), spring (J) and spring guide (K) for
damage.
ill pj I On "Power
or spring pin (C) for
Shift", check tee seat
damage.
(A), nylon ball (B),
Installation
1. install parts for either oil cooler check valve in

order as shown in Fig. 10. Be sure spring guide (K) or
A"Perm -Clutch" Tractors C"Power Shift" Tractors spring pin (C) are in correct position,
B Special Connector D Special Tee
2. Be sure hose clamps and connectors are tight.
Fig. 9-Oif Cooler Check Valves
Replace control support cover.
1. To remove thecooler check valve from either

oil
a PERMA-CLUTCH equipped tractor (A, Fig. 9) or

Power Shift Transmission equipped tractor (C), first
remove the control support cover.
2. Disconnect clamps and hoses.
3. On "PERMA-CLUTCH", remove special con-

nector (B, Fig. 9). On "Power Shift", remove special
tee (D). (
TM-1181 (Jur-80) Litho in U.SA. Tractors - 4040 and 4240

.
PRESSURE CONTROL VALVE 6. If necessary to disassemble elbow from adapter,

remove snap ring (C, Rg. 12). Remove elbow from
Removal
adapter.
1. With engine off, lower rockshaft and cycle all
hydraulic control levers to relieve hydraulic oil pres- Inspection and Repair
sure.

;:::Hr;;;-"':n;:;:ftd^l|:I:.-:::*:;.-**';^ H IrrrtrHrrii;
;;>^
ruBBSiaaer:
rr JFKl
A Elbow C-^Junction Block

& Pressure Control Vafve Line
Fig. 1 1 -Pressure Control Vafve Removal
Clean area around the pressure control valve (A,

2. A Valve Body F O-Ring
Fig, 11} in therockshaft housing. Place a clean con- B Bleed Orifice G Adapter
tainer under the area. C Spring H Swivei Elbow
3. Loosen the pressure control valve line (B) at the
D Shim 1 Snap Ring
junction block (C) and disconnect line at elbow (A).
E Valve with Orifice
4. Remove adapter and swivei assembly from Fig. 13-ExpIoded View of Pressure
Control Vafve
rockshaft housing.
5. Carefully remove pressure control vafve assem- 1 Inspect valve (E, Fig. 13) for scoring or damage
bly from bore. that could cause excessive leakage. Be sure that the
orifice inside the valve is not plugged or damaged.
2. Replace valve and vafve body if valve is heavily

scored or shows evidence of sticking.
3. Check valve body (A) for damage or internal

scoring. Passages and bleed orifice (B) must be open.
4. Examine adapter (G) and elbow (H) for damage

that could cause leakage.
5. Check valve spring (C) for damaged coils and

correct compression.
Pressure Control Vafve Spring Working Load 3.50 in
(88.9mm) at 45 to 55 lbs. (200 to 244 N)
2r <f
A Adapter D Back-up Ring
BElbow E O-Ring
C Snap Ring
Fig, 12-Pressure Control Valve Connection


1. Replace O-rings and backup rings. Dip parts in
clean John Deere HY-GARD Transmission and Hy-

draulic Oil. -.' ;',.. ^v-:V'^;:;im; : -
2. Place spring, shim(s) and valve in valve body.
NOTE: Unless tests indicate otherwise,

same number of shims as were removed.
install the
m&sM
AValve CValve Housing
3. Install valve assembly in rockshaft pressure BSpring
control valve bore.
Fig. 15-ExplodQd View of Directional
4. Install new
O-ring and back-up on swivel elbow, Control Valve
install in adapter with snap-ring. Install assembly in

rockshaft housing. Connect hydraulic lines to elbow 3. Remove valve plug and carefully slide valve (A,
and junction block.

Fig, 15) and spring from bore.
4. Examine valve for signs of scoring, burrs or

5. Run pressure control valve tests as described in damage that could cause valve to stick in bore or leak.
Group 10 of Section 270 to determine proper valve A leaking valve could allow charge circuit oil to return to
operation. the main reservoir.
DIRECTIONAL CONTROL VALVE 5. Check internal passages in valve for plugged

conditions. Plugged passages could prevent valve
Repair from operating. Clean passages, if necessary. Replace
valve if heavily scored or damaged.
6. Check valve spring (B) for damage and proper

working load.
Directional Control Valve Spring Working Load 0.75 in.
(19.1 mm) at 10.8 to 13.2 lbs (48 to 59 N)
7. Remove directional control valve housing by first

disconnecting selective control valve linkage and re-
moving selective control valve. When removing the
directional control valve housing (C, Fig. 15), note
packing and O-ring locations.
8. Check valve housing for cracks and plugged or

damaged passages or bore.

1. Replace packings and O-rings. Dip all parts in
John Deere HY-GARD Transmission and Hydraulic
Oil.
ADirectional Valve Housing BValve Plug
2. Install valve, spring and plug in housing.
Fig r 14-Directionaf Control Valve Location
3. Install directional control valve housing on rock-
1. Check directional control valve housing (A, Fig.
shaft valve housing. Be sure that packings are in place.
14) and area around valve plug (B) for signs of external 4. Install rockshaft flow control valve adjusting plug
leakage. with shims.

5. Install selective control valve housing. Connect
linkage.
(

HYDRAULIC OIL COOLER Installation

Repair 1. Be sure oil cooler is clean and dry before rein-
stalling.
2. Slide cooler onto supports and install upper and
lower cap screws.
3. Connect oil cooler-condenser.
4. Connect oil cooler pipes and hoses. Torque
clamps to 35 in-lbs. (3.9 N-m).
NOTE: See Section 90, Group 05 for installation
instructions on the condenser portion of a cooler-con-
denser unit
SEAT VALVE HOUSING

Removal
iV CAUTION: Before removing seat valve
* housing, sit on seat and move height ad-
justment lever up and down several times to re-
lieve hydraulic pressure.
A Cap Screw C Main Hydraulic Pump Line

B Return Line D Oil Cooler
Fig. 16-HydrauIic Oil Cooler
Cleaning
If cleaning the exterior of the oil cooler is the only

required service, remove cap screw (A, Fig. 16),
Slide cooler half-way in one direction, then halfway
in the other direction to clean.
NOTE: On air-conditioned tractors, the air condi- Fig. 17-Cover Panel
tioning condenser is integral with the oil cooler.
1. Remove three screws securing cover panel to
Removal seat
NOTE: Oil cooler should be repaired and internally

cleaned by a qualified radiator mechanic.
1. Disconnect cooler-to-main hydraulic pump line
and drain cooler. If It is a cooler-condenser unit, see
Section 90, Group 05 for pre-removal instructions for
condenser.
2. Disconnect cooler return line (B). Remove upper
left-hand (A) and lower right-hand cap screws from
end of slide supports and remove oil cooler.
Inspection
Examine oil cooler for leaks or cracks. If necessary,
test with air pressure by plugging outlet applying 10 Fig, 18-Seat Suspension
psi {0.6 bar) (0.7 kg/cm s to cooler inlet, and sub-
)
2. (Not Illustrated) Lift up seat and place a block of
merging in water.
wood under frame assembly.
IMPORTANT: Test only oil cooler portion of an
3. Loosen seat ride lever-to-seat frame pivot cap
oil cooler-condenser unit Use NO MORE than 300
screw.
psi (20 bar) (20 kg/cm 2
) air pressure.
4. Remove cotter pin from pin securing ride control
If leaking or air bubbles appear, repair, using the
> same methods as used
piston to seat.
in radiator repair

Removal Continued 1. Remove cap screw (A, Fig. 20) securing stop
Remove snap plate and boot to seat valve housing.
5. ring securing height adjusting
lever to seat valve rod and remove rod from lever.
2. Remove cap screw (B) securing cylinder to seat (
valve housing.
Gently push rod down to valve as far as possible to
prevent bending during removal from Sound-Gard
3. Remove cap screws (C) securing manifold to
seat position valve housing.
body.
R 27525?
A Manifold MPlug
BGasket NShims
CValve Housing OSpring Guide
DSnap Ring P Spring
Fig. 19-Seat Valve Housing Removal ECheck Ball Assembly Q-Pressure Regulating
FSeat Position Valve Valve
6. Remove pressure oil hose. GSeat Position Lever Rod R Valve Sleeve
7, Remove discharge hose. HWasher S~Filter
&r Remove air bleed hose from cover nippfe. 1 Snap Ring T Spring
J Boot U Check Ball
9. Remove clip securing ride control lever to rod. K^Stop Plate V Inlet Elbow
NOTE: On 4040 disconnect accumulator to seat L Retaining Ring WAccumulator
valve hose at housing, X Cylinder
10. Remove cap screw securing seat valve to Fig. 21 -Exploded View of Seat Valve Housing
Sound Gard Body. 4. Remove snap ring (I, Fig. 21) retaining seat
Disassembly position valve, and remove valve assembly.
5. Remove snap ring (L) and remove plug (M) from
top of pressure regulating valve bore.
6. Remove shims (N), spring (P), spring guide (O),
and pressure regulating valve (Q),
7. Remove pressure regulating valve sleeve (R)
using JDH-57 removal tool.
R 28520N
AO-rings B Backu p/wings
Fig. 22-Pressure Regulating Valve Sleeve
8, Use the above drawing for reference when in-

R 27E2m stalling O-rings and back-up rings on pressure regu-
AValve Stop Cap Screw C Manifold Cap Screws lating NOTE: Manufacturers identification
valve sleeve.
\
BCylinder Cap Screw mark on upper end of sleeve must be next to the
Fig. 2Q-Seat Position Valve Housing pressure inlet port to eliminate hydraulic flow noise.
TM-T181 (Jun-80) Litho in U.S.A. Tractors - 4040 and 4240


1. Check seat pressure regulating valve spring
compression.
Seat Pressure Regulating Valve Spring Working

Load 2.25 in. (57 mm) at 24 to 32 lbs- (107 to 143 N).
2. Inspect valves for damage or burrs that could

cause excessive leakage.
3. Inspect inlet elbow screen for a plugged condi-

tion.
4. Inspect O-rings for damage.

S 7831'JS-l
1. Reverse disassembly procedure to reassemble
valve housing. AJDH-43 Thermal Relief &0715 Fitting
2. Install housing onto tractor.
Valve Test Kit CAccumulator
IMPORTANT: Be sure that the seat inlet line is Fig. 24-Checkmg Accumulator Pre-Charge
connected to the orificed end of the fitting on the
attenuator. On later model tractors, a relief has 2. Connect a hand pump and 200 psi (14 bar)
been added to the corners on the steering side pressure gauge to hydraulic oil side of accumulator (C,
(without orifice) for identification. Fig. 24), using fitting 0715 (B) and JDH-43 (A) as
shown in Figure 24.
3. Charge accumulator with the hand pump until a

150 psi (10 bar) pressure reading is obtained.
^\^^4f\j 4. Allow fluid to discharge slowly while observing

pressure gauge. The pressure registered on the gauge
before the abrupt pressure drop is the accumulator
pre-charge.
5. Charge accumulator as necessary. Reinstall onto

valve housing.
Checking Accumulator Pre-Charge

Alternate Method (Checking gas end)
R 31116
IMPORTANT: Volumetric capacity of the gas
ATee C Attenuator end of the seat
accumulator is small, therefore,
B Steering Line DSeat Pressure Line every precaution must be taken to limit pressure
loss to a minimum. If extreme care is taken pres-
Fig. 23-Pressure Line Connection
sure loss can be limited to 1-3 psi (0.1-0.2 bar)
(0.1-0,2 kg/cm 2) per-charge check.
Checking Accumulator Pre-Charge
1. Relieve hydraulic pressure and remove accumu- 1. Relieve hydraulic oil pressure by on seat
sitting
lator from valve housing. and moving height adjustment lever up and down
several times.

.
70-05-1 2 Miscellaneous Hydraulic Components

Hydraulic Repair
Checking Accumulator Pre-charge

tinued
Con-
^*^-,
w
<sf
*<U f
1 .
'
r
^|fe%^.^ (T)
^y.^::^::;y-^.r.y:y-
RB0136B1 *<J
A Seal Accumulator F Charging Hose

A Pressure Gauge B Seat Accumulator
BTru-Seal Nut 6577 G Nitrogen Tank
C O-Ring Washer 6877 H Cylinder Valve
Fig. 25-Checking Seat Accumulator Ga$ Pressure DAdapter Assembly 5364 1
Pressure Regulator
E Gas Cock Screw J Regulating Screw
2. Remove plug from nitrogen charging port.
Fig. 26-Charging Seat Accumulator
3. Install one O-ring washer (6877) on adapter as-
sembly (2364). Install Tru-seal nut (6577 with Teflon 3. Install one O-ring washer (C
Fig. 26) on adapter T
side toward accumulator} on adapter assembly, assembly Tru-seal nut (B) (with Teflon side
(D). Install
and
install in plug port of seat accumulator. towards accumulator) on adapter assembly.
4. insert R34802 O-ring around pressure gauge 4. Turn gas cock depressing screw (E) counter-
valve depressing pin. clockwise and instaff on adapter assembly (D).
5. Use a heavy-duty tire pressure 5. With nitrogen regulator (I) attached to cylinder,
gauge to check
accumulator pre-charge. Pressure gauge should read turn regulator screw (J) counterclockwise until free'
between 85-95 psi (5.9-6.6 bar) (6-67 kg/cm 2). If not 6. Slowly open cylinder valve
(H). After cylinder
within specifications see pre-charging accumulator.
needle stops moving, fully open valve,
Pre-Charging Accumulator 7. Before installing adapter assembly on accumu-

lator, turn
regulating screw clockwise to purge air from
IMPORTANT: Use dry nitrogen only to precharge charging hose. Turn regulating screw (J) back out until
the accumulator. Dry nitrogen does not mix with
free.
oil. non-combustible. It will not cause oxida-
It is
tion or condensation within the accumulator. 8. Install adapter assembly in plug port of accumu-
DO
NOT use air or any combustible gas as these may lator.
cause oxidation and condensation.

9. Rotate gas cock screw (E) clockwise
to open
1, Remove accumulator from seat valve housing. accumulator gas check valve.
2. Remove plug from charging 10. Turn cylinder regulating screw (J) clockwise
port. to
get 85-95 psi (5.9-6.6 bar) (6-6.7 kg/cm 2 ). Check
all
connections for leakage.
1 1 Turn cylinder regulator screw (J) counterclock-

wise until free.
12. Turn gas cock screw (E) counterclockwise

to
seat gas check valve. Bleed gas pressure from charg-
ing hose.
13. Remove adapter assembly from accumulator.

Check seat for leakage and install plug.

TRANSMISSION-HYDRAULIC OIL SYSTEM CLEANUP PROCEDURE

NOTE: This procedure is intended for use in trac- 5. Rush each compartment for at least fifteen min-
tors inwhich the transmission-hydraulic system oil has utes.
become contaminated. It will help prevent failure in
hydraulic system components due to debris in the oil. 6. Return oil to transfer unit and, after the tractor
has been repaired; return the clean oil to the tractor
IMPORTANT: This procedure is not a substitute
reservoir.
for careful cleaning of parts and cavities if there
was major component failure. Hand wash all parts
that are suspected to trap or contain failure debris
Installing Hydraulic Cleanup Kit
during repair and reassembly of tractor. Badly
contaminated oil should not be reused.
Preliminary Cleanup
R7905S
R 7*
AOil Filter Cover G Mate Coupler (2 used)
B Oil Filter Cover H Pipe Nipple (2 used)
C Oil Filter Cover 1 Street Elbow
Fig. 27-D-0S1SSST Oil Transfer Unit
D Oil Filter Cover J Power Shift Test Plug
E Dust Cap (2 used) K Perma-Clutch Test Plug
1. If an oil transfer unit (Fig. 27) is available, cir- F Female Coupler
culate the oil removed from the tractor in the unit for oil
Fig. 28-AR86239 Cleanup Kit
cleanup.
IMPORTANT: Replace badly contaminated oil. Perma-Clutch Tractors

2. During repair, hand wash all parts and compo- 1. Remove the oil filter cover from the case.
nents, such as clutches and planetary packs suspect-
ed to trap failure debris. Also wash out bottom of 2. Install oil filter cover (D T Fig. 28) with a new 10
transmission case. micron filter.
3. Pump at least 10 gal. (38 L) of clean oil from the

and place the con-
transfer unit into a clean container
tainer under the suction screen port and remove the
plug and screen,
4. Operate the transfer unit with the inlet hose of the

unit in the container. Direct the discharge into areas of
the case that are difficult to clean.

Perm a -Clutch Tractor Continued Power Shift Transmission Tractors

1. Remove the oil filter covers.
A Filter ReJief Valve O Nipple, Coupler and

Test Plug Dust Cap (2 used)
B Street Hbow D Filter Cover AClutch Filter Cover O Pipe Plug
B Function Return Oil Filter Cover
Fig. 29-lnstaffing Cleanup Kit
Fig. 30-Instaffing Special Filter Covers
3. Install a pipe nipple, male coupler and dust cap
<C, Fig. 27) in the tapped hole in the filter cover (D).
a) Install filter cover (C, Fig. 28) on the clutch (front)
oil filter (A, Fig. 30).
4, Removethe oil filter relief valve special plug and

installthe special plug (A) provided in the kit. Be sure to b) Install the same function return filter cover (B)
reinstall valve spring. that was removed.
5. Install the street elbow (B) in the tapped end of

the special test plug (A).
6. Install the pipe nipple, male coupler and dust cap

(C).

.
Hydraulic Repair Miscellaneous Hydraulic Components 70*05-15
3, Move the appropriate valve control lever rear-

ward to circulate oil to the reservoir. With engine at
1500 to 1700 rpm, circulate oil for thirty minutes min-
>
imum.
NOTE: Start with valve metering leer at the ten

o'clock position. If the hose "jumps", adjust the meter-
ing lever toward the turtle position to prevent pump
cavitation.
4, Install a jumper hose in the upper right-hand

selective control valve. Flush the control valve-to-re-
turn circuit for one minute in each direction.
NOTE: Cycle ail hydraulic controls at five second

intervals for one minute in each
Begin with direction.
ACooler Relief Valve C Nipple, Coupler and upper right-hand selective control valve then lower
Test Plug Dust Cap (2 used) right-hand valve. Cycle left-hand side. Repeat the
BStreet Elbow D Filter Cover
flushing procedure every hour for three hours. The
Fig, 31 -installing Cleanup Kit
tractor must continue running at 1500 to 1700 rpm for
the entire three hours. Check for oil filter restriction as
follows.
(C) in the tapped hole in the filter cover (D, Fig. 31).
5, While the tractor is operating check for , oil filter
4. Remove the oil filter relief valve plug and install restriction after the first ten minutes, thirty minutes, one
the special plug (A) provided in the kit. Be sure to
hour, two hours and three hours.
reinstall valve spring.
NOTE: When checking for filter restriction, operate
5. Install the street elbow (B) in the tapped end of the tractor at 2000 rpm with ait controls in neutral.
the plug (A). Hydraulic oil temperature must be at least 120F

(49C).

(C) in the street elbow.
System Cleanup
1 Operate the engine at 1 500 to 1 700 rpm for thirty
minutes with all control valves in neutral. Cover oil ij,
cooler with cardboard to raise oil temperature to 120F
(49C).
2. Install one end of a hose in the left-hand side of a

selective control valve coupler. Securely attach the
other end of the hose in the oil filler tube.
R7SOSS05..-
A0700 (D-1) Fitting B 6943 (0-300 psi) Gauge

C2106 (D-19) Hose
Fig, 32~Te$t Hose Parts
6. Assemble the test hose using the parts in Fig. 32.
>

70-05-1 6 Miscellaneous Hydraulic Components Hydraulic Repair
System Cleanup Continued

(
R79155B5
A Outlet Pressure Coupler B Inlet Pressure Coupler
fig. 33-Checking Fitter Outl&t PressurePerma-Clutch
7. Note oil pressure reading at filter outlet (A) and

inlet (B, Fig, 33)See Fig. 10 for power shift connec-
tions.
8. If the pressure differentia! exceeds 50 psi (345

kPa) (3.45 bar), stop the tractor and replace the filter.
9. After tractor has run for three hours T operate

tractor in high speed for fifteen minutes and recheck.
10. Remove the cleanup kit and return the tractor.
IMPORTANT: Check tractor for continued gen-

eration of contaminants if more than two filter
changes are required within twenty hours after
tractor is returned to field.

.
Hydraulic Repair Hydraulic Pumps 70-10-1
Group 10
HYDRAULIC PUMPS
EXTERNAL GEAR PUMP 5. Remove cap screw securing discharge pipe and
(QUAD-RANGE TRANSMISSION) transmission lube pipe topump and remove pipes from
pump.
Removal
6. Remove priority lube check valve fitting, spring
and ball.
7. Remove pump-to-transmission case cap screws

and remove pump.

1. Inspect hex. drive shaft and hex. drive surface in
gear. Note condition of end of shaft and of shaft plug

bushing. Replace as necessary.
2. Inspect gears, pump body and cover, bushings

and bushing surfaces.
ITEM MEASUREMENT
Gear Bore Depth 0.9353 to 0.9369 in.
(23.75 to 23.80 mm)

Fig. 1-Removing Transmission Pump Drive Shaft
Driver Gear O.D 2.6195 to 2.6205 in.
(66.53 to 66.56 mm)

1 Remove center link attaching bracket. Driver Gear Width 0.9320 to 0.9326 in.
(23.67 to 23.69 mm)

2. Remove plug. Driven Gear I.D 1.1835 to 1.1845 in.
(30.06 to 30.09 mm)

Idler Gear 0,D 2.1075 to 2.1085 in.
shaft. (53.53 to 53.56 mm)

Idler Gear Width 0.9320 to 0.9326 in.
4. Remove rockshaft assembly from tractor as in- (23.67 to 23.69 mm)

structed in Group 15, this section. If tractor is not
Idler Gear I.D 0.7518 to 0.7528 in.
equipped with rockshaft, remove transmission cover. (19.10 to 19.12 mm)
Idler Shaft O.D 0.7497 to 0.7503 in.
(19.04 to 19.05 mm)
3. Remove priority lube check valve spring and

check for a free length of 1.25 in. (31.5 mm).
>
Fig. 2-Transmission Oil Pump Removal
TM-1181 (Feb-78) Lhho in U.S.A. Tractors - 4040 and 4240

.
70-10-2 Hydraulic Pumps Hydraulic Repair
Assembly and Installation INTERNAL GEAR PUMP

(Power Shift Transmission)
Removal and Disassembly i
1. Separate the tractor between the clutch housing
and engine as instructed in Section 10, Group 25.
A^ldler Shaft CDriven Gear E Priority Lube

B Idler Gear DPump Manifold Valve Assembly
Fig, 3-Transmission Oil Pump (Perma-Ctutch Tractors)
1 If idler shaft (A, Fig. 3) has been removed, install

new shaft using a new idler gear (B) as a guide. Press
shaft into housing 1.21 in. (30.7 mm) from bottom of
gear bore.
Fig. 4-Removing Clutch Pack and OH Pump
2. install lube priority check ball, spring and plug (E)
in manifold (D).
2. Remove cap screws securing clutch pack and
3. Lubricate both sides and the bushing of both remove clutch pack with pump.
transmission oil pump gears and install. Be sure gears
turn freely. 3. Remove front clutch drum-to-clutch pack cap
screws and, without disassembling remainder of pack,
4. install manifold, and tighten cap screws to 20
remove pump assembly from clutch pack.
5- Install transmission drive shaft, differential drive 4. Remove snap ring from dutch shaft and remove
shaft and low range pinion lube tubes in pump. C1 clutch drum.
6. Install pump with lubrication tubes and tighten

cap screws to 20 ft-lbs (27 Nm) (2.7 kgm).
7. Tighten transmission oi! pump discharge, trans-

mission drive shaft and differential drive shaft lube
tubes to manifold cap screw to 35 ft-lbs (47 Nm) (47
kgm).
8. Insert hex. drive shaft far enough to turn pump

gears. Be sure pump gears turn freely.
9. Clean reservoir screen and connect inlet pipe.
10. Install hex. drive shaft plug and re-install rock-

shaft assembly.
Fig. 5-Pump Body-to-Housing Cap Screws
5. Remove six pump body-to-housing cap screws.
TM-1181 (Feb-78) Litho in U.S. A,

. '
1 Use the following specifications when examining

pump parts:
Item Measurement
Driven Gear Counterbore I.D. . . 2.4525 to 2.4530 in.
(62.29 to 62.30 mm)

Driven Gear O.D 3.3195 to 3.3250 in.
(84.31 to 84.46 mm)

Driver Gear Bushing O.D 2.4485 to 2.4495 in.
(62,19 to 62.22 mm)

Drive and internal Gear
Bore (depth) 0.9280 to 0.9380 in.
(23.57 to 23.83 mm)

Drive and Internal Gear
Thickness 0.9306 to 0.9312 in.
Fig, 6-Pump Housing-to-Body inner Cap Screw (23.64 to 23.65 mm)

Internal Gear I.D 3.5695 to 3.5705 in.
6. Remove inner cap screw retaining pump body to (90.66 to 90.69 mm)
pump housing and remove body from pump for in* internal Gear O.D 4.4370 to 4.4380 in.
spection of parts. (112.70 to 112.73 mm)

Internal Gear Bore Diameter
Repair and Assembly (in pump body) 4.407 to 4.417 in.
(111.9 to 112.2 mm)
MlM -
ISfl. .
-' ^':., -. ...
J ;-.>j!jn...."T| t .^^HV/t . .
r k-:i [:>
::'. -:';.;"'
Fig. 8-lnstalting Oil Seal
1Pump Body 7 Bushing pump seai pump body using JDT-33

2Packing 8Gasket 2. Install oil in
3Oil Seal 9Steel Ball (2 used) driver and OTC 814 Mandrel.
AInternal Gear 10Bushing
5 Drive Gear 11Clutch Manifold
6Pump Housing
Rg r 7-Exploded View of Power Shift Transmission Pump
>

70-10*4 Hydraulic Pumps Hydraulic Repair
Repair and Assembly Continued
K'TSfcSSft
AOil Seat C Spur Gear

B Internal Gear Packing
Fig. 1 UCheck Balls in Place in Manifold
Fig. 9-Pump Body Parts
6, With steel balls in place in manifold and shaft seal

3. Install internal gear (B, Fig. 9), chamfer down;
protector coated with oil, install pump and housing over
spur gear (C), flat side out, and packing (D) or O-ring.
shaft aligning gasket and oil passages.
4. Install pump body on housing and tighten cap

7. Torque manifold-to-pump cap screws to 20 ft-lbs
screw to crescent in body to 20 ft-lbs (27 Nm) (2.7
(27 Nm) (2.7 kgm) and re-assemble pump to clutch
kgm).
pack.
Fig. 10-JDT-18 Protector Over dutch Shaft
5. Install gasket and bushing (if removed), and install

JDT-18 oil seal protector over end of clutch shaft.

REPLACING MAIN PUMP SHAFT OIL Installation

SEAL SAE
1. (Not Illustrated) Coat lips of new seal with
(With Pump On Tractor)
Multipurpose-type grease.
Removal
1 . (Not Illustrated) Remove bottom frame plate.
"r"ri" rrr"

Fig. 14-JDH-3UA Seal Driver in Place
2. Install JDH-31-A Seal Driver over pump shaft. Be

Fig. 12-Pump Drive Shaft sure suppliers identification on seal is facing outward.
2. Crank engine to position coupler halves for re- 3. Install coupler shaft and tighten coupler shaft cap
moval of lock nuts and bolts. Remove bolts. screws to 35 ft-lbs (47 Nm) (4.7 kgm).
3. Remove drive shaft cap screws and drive shaft.
4. (Not Illustrated) Remove snap ring securing oil
seal in pump housing.
R 28521N
A Bushings C Clearance Points

B Outer Ends of Recesses
Fig. 15-Bushing Placement
NOTE: When instatiing coupler halves, make sure

Fig. 13-JDH-35-A Seal Puller installed the bushings (A, Fig. 15) are located at the outer ends
of the recesses in the coupler halves. This is to provide
5. Install JDH-35-A Seal Puller over splines of pump running clearance at points C.
shaft, and thread puller into seal ID.
4. Install coupler halves and tighten cap screws to
6. Tighten puller screw to remove sea! and seal 30 ft-lbs (41 Nm) (4.1 kgm).
puller from pump. 5. Install coupler half capscrew lock nuts and tight-
en to 30 ft-lbs (41 Nm) (4.1 kgm).
6. Install bottom frame plate.

. .
MAIN HYDRAULIC PUMP 15. Remove air bleed line from check valve tee.
16. Attach D-05006ST Splitting Stand to side
Removal frames.
1. Remove muffler, air stack, side shields, grill
17. Attach D-05007ST Splitting Stand with
screens and hood. D-05149ST attachments (see special tools) to front
end.

.
. : : >:: : \ \ : :!3yr Sea: . . ^S =*
Fig. 16-Preparation for Pump Removal

Fig. 17-Front End Removed
2. Disconnect steering lines from steering valve.
18. Remove front end
3. Disconnect oil cooler return line.
4. (Not Illustrated) Close fuel shut-off valve.
5. Remove fuel return line from tank.
6. Remove radiator tie rod support.
7. Remove fuel tank sender wire from fuel tank.
8. Disconnect air conditioning and horn wiring (if
equipped).
9. (Not Illustrated) Remove bleed line from steering

motor.
10. Remove cap screws securing baffle plates and

remove plates.
1 1 Remove fuel inlet line from tank. Fig. 18-Pump Removal Steps
12. Disconnect oil cooler to reservoir line. 19. Remove pump-to-cooler hose special cap
13. Remove side frame-to-steering screw.
motor cap
screws. 20. Remove pump inlet hose from elbow at side of
pump.
14. On tractors with Power Front Wheel Drive, dis- 21 Remove pump seal drain line from front of tee
connect six pipes from control valve. on hydraulic pump.
22. Remove pump seal drain line from rear of tee on
hydraulic pump.

23. Disconnect pump pressure line from adjustable

elbow on pump.
24. Remove pump-to-pump support cap screws and

carefully remove pump.
Fig. 19-Pump Removed

Fig. 21 -Pump Shaft End Piay - 4 cu in. (66 mi) Pump
Repair 3. Note end play. If it is incorrect, be sure shaft

bearing is inspected and the cause of incorrect end
Pump Shaft End Play play is corrected.
Disassembly and Inspection

Pistons
Fig. 20-3 cu in. (49 ml) Pump in Holding Fixture
1. Install pump in a pivoting D-01006AA (JDM-16).

Bench Holding Fixture or similar holding device. Be
sure area is clean and well-lighted.
2. Install a dial indicator and check pump shaft end

play (Fig. 21).
IMPORTANT: Be sure to check end play. End

> play should be 0.001 to 0.003 inch (0.02-0.08 mm). A Plug and Sheath C Piston Spring
Excessive end play may indicate bearing wear or B Piston
absence of the correct number of adjusting shims. Fig. 22-Removing Pump Pistons (3 cu. in. Pump)

r "
DISASSEMBLY AND INSPECTION Continued

1. Remove piston plugs (A, Fig. 22), pistons (B),
and piston springs (C). Piace assemblies in JDH-21
Parts Tray so they will be returned to the same bores
from which they were removed.
2. and piston bores for scoring or

Inspect pistons
pitting. Badly scored piston could cause piston to stick
in bore or result in low pump output.
3. Inspect piston plugs for unusual wear or scoring.
Replace as necessary.
4. Use the following specifications when inspecting

pump piston assemblies for wear:
B 2l*296fl
3 CU. IN. {49 ml) PUMP

A Pump Shaft D Place Shim Material
Component Measurement Specification BThrust Washers Here
CBearing Cup E Bearing
Piston O.D. 0.8740-0.8744 in.
F Pump Crankcase
(22.20-22.21 mm) Fig. 23-Pump Shaft Removal
Piston bore I.D. 0.8747-0.8753 in.
(22.22-22.23 mm) 2. To remove pump shaft (A, Fig, 23), tap shaft
Spring Working Load* 1 .62 in. at 34-40 lbs. lightly on the spline end to loosen the outer bearing cup
(41 mm at 151-178 N) (C). Insert a soft shim (D) material between the bearing
cup and cone on the high cam side to slightly tip the
4 CU. IN. (66 ml) PUMP shaft. Avoid damaging the thrust washers.
3. Carefully remove the shaft.
Piston O.D. 0.9630-0.9634 in.
=!){{!"
'"jjjjf
(24.46-24.47 mm) .. .::;;:i::::
:::
r:; ^:
j
-
1 JH J||:|iJ H H
E :
^^'^
Piston bore I.D. 0.9637-0.9643 in. : -a .
r?
:I :I ilHIf JIIIIIIIIIIt*! =
r
"
r III! Jlin! ehIII =!!*! r ^t :
^ =
=l
(24.48-24.49 mm) '"::fliff"--^ T'

;
:
:J
; :
"***;::;:
:HHH:;;t;;t it III f :; I r :;u ::;H ::::;:
Spring Working Load* 1.78 in. at 47-53 lbs.
:;:: : ::^
(45.2 mm at 209-236 N)
:
;t::: ::t:::t:;::*
;;;::::;:: .::;; ... .; r:: ;::;:;;:;:;:;::::::;;:;;:;:: ;:;;::;;:;:::

JK::;:::;:;:::;:;::::;:;. ; ;
* IMPORTANT: Springs must be matched to within ::::

:
:;:
:
lllll;H^!illf'l:^:. 'V
1 .5 lbs. (6.7 N) of one another. Replace springs as a
: :
wBm^M^mmmmî -
Bit
".".'.
. :'...
set. Be sure color of all new springs is the same.

'':':
\vi^^^m*^r.v 1 :
=!:-:::!ir^!:r. ":" *:*
Pump Shaft and Housing

.
;:;:::::-.:.
.
r ~. : '$. :*!*: iS: : : :. tf--:
at;;;:: ::*:: ff
J
1 Remove four cap screws securing stroke control

.
FiiZJwH
vafve housing to pump housing and remove stroke El-is
HM
'lTi^''" T'-T"=iJ^fe^::;sr aaBi :'-e:t-.-*:mammaB^^n^maas&F
ill i
III pi
us Id "* "
1
H""
-:*2 ._:..: J ' '....".iisiAUi. A IjtjpJ ^ rJ* s
?r?^5|!"\! "r""i!il "
APump Shaft B Knife-Edge Pulter
Fig. 24-Removing Shaft Bearings (4 cu. in. Pump)

4. To remove shaft bearings, place shaft in a press

and remove. Do not allow pump shaft to fall onto floor.
5. Inspect the pump housing for scored surfaces.
6. Inspect pump shaft, shaft bore, bearings, seal,

and quad ring packings. Wear or damage at these
points could cause leakage.
A Housing BÊnd of Puller C^JDH-40 Puller
Fig. 26-PuHing Discharge Vaive Seat
3. if NECESSARY, remove discharge valve seat

using JDH-40 seat puller. Be sure puller catches be-
tween seat and housing (A, Fig, 26),
ANeedle Bearings D Shaft Cam

BSpacer EThrust Washers
C Race
Fig. 25-3 cu, in. Pump Shaft
7. inspect needle bearings (A, Fig. 25), race (C), and

pump shaft cam (D) for scoring or pitting. Replace as
necessary.
8. Inspect thrust washers (E). New thrust washer

thickness is 0.1265 inch (3.14-3.21 mm) on 3
0.1235 to
cu. in. (49 ml) pumps and 0.0422 to 0.0452 inch
(1.07-1.15 mm) on 4 cu. in. (66 ml) pumps.
*'8 &"* SK "

Discharge Valves ... "' .
.
.
ADischarge Valve BJDH-40 CValve Seat

1. Remove stroke control valve housing if not al-
ready removed. Ftg. 27-Removing Vafve Seat (3 cu. in. pump shown)
2. Check discharge valve, stop, spring guide, and

seat.
TM-1W1 (Sep-77) Litho in U.S.A. Tractors - 4040 and 4240

.
70-10-10 Hydraulic Pumps

Hydraulic Repair
Discharge ValvesContinued
(
R 2i;29SN
A inlet Vafve CModified Driver

BPump Housing DModified Vafve Guide
Fig. 29-Driving Out Inlet Valve Assembly
3. Remove inlet valve assemblies ONLY if damage

is evident. Drive valve from housing using an
inlet
R27157 discharge valve guide (with chamfer ground
off). Use a small enough driver to
fit guide.
NOTE: If the preceding method is not

used, the inlet
valve will not be reliable for re-use,
Fig. 28-Using JDH-39 to Install Discharge Valve Seat
(3 cu. In. pump shewn) install new inlet valve assembly by
4.
tightening
inietvalve plugs to 100 fUbs (136 Nm) (13.6 kgm)
4. To install seat, gently drive JDH-39 seat driver torque. End of guide should be 0.533 to 0.537
on inch
seat shoulder until driver bottoms on finished (13.54-13.64 mm) from end of finished face of housing.
face of
discharge valve bore.
Stroke Control and Crankcase Outlet Valves
Met Valves
1. Disassemble stroke control valve and crankcase
1 Inspect inletvalve assemblies pump
In housing. outlet valve assemblies ONLY if there is evidence of
Do not remove unless necessary. malfunction.
2. Measure valve lift to determine if valve spring Use care vafve sleeves (H and R, Fig. 30) are
2. if
retainer is excessively worn. driven out. Use a driver that is recessed in the center
and will drive only on the outer edge of the sleeve.
a) Lift should be 0.060-0.080 inch (1.52-2.03
mm). Inspect stroke control valve and crankcase valve
3.
b) A cocked retainer may indicate a broken assemblies for burrs, weak springs, eroded
seats,
spring. leaking packings, or plugged crankcase filter
screen
(K).
a) Stroke control valve spring (O) working

load
should be 3.3 inch at 125-155 lbs. (84 at mm
556-689 N).
b) Crankcase outlet valve spring (J) working

load should be 2.2 inch at 45-55 lbs. (56 mm
at 200-245 N).

Assembly and Adjustments
k 6S7SSr
AShim EO-Rings J Outlet Valve Spring N Bushing Plug

BStroke Control Valve F Packing K FilterScreen and OControl Valve Spring
Housing
G Crankcase Outlet Valve Packings P Spring Guide
COptional Pump Shut-Off HOutlet Valve Sleeve L Plug with Washers QStroke Control Valve
D Plug with Pin I Spring Guide MAdjusting Screw R Control Valve Sleeve
Fig. 30-Stroke Control Valve Housing Assembly
install new O-rings, packings, and

NOTE: Always
oil Use kit available. Dip all parts in clean John
seals.
Deere Hy-Gard Transmission and Hydraulic Oil prior to
assembly.
Stroke Control Valve Housing
1. Install stroke control valve and crankcase outlet

valve assemblies in housing. Do not install crankcase
outlet valve plug with pin (D, Fig. 30).
2. lnstalIJDH-l9A adjusting tool (arrow) with 1/8 in.
(3.2 mm) thick washer.
Fig. 31-JDH-19A Adjusting Screw in Stroke

I Control Valve Housing

Assembly and AdjustmentsContinued
1/8" (3
R 2U301H Fig. 33-instailing Seal Using OTC-814 Driver

and JDH-18
AScribe Line CJDH-19 Crankcase Outlet
BAdjusting Washers Valve Adjusting Tool 2. Install quad ring and oil seal in housing. Install
seal using JDH-18 seal driver. Seal supplier's identifi-
Fig. 32-Adjusting Tool JDH-19 cation should face outward. Coat seal lips with SAE
multipurpose-type grease.
IMPORTANT: If JDH-19 adjusting tool (C, Fig.
32) is used, install tool to within 1/8 in. (3.2 mm) of IMPORTANT: Do not position oil seal beyond
housing. JDH-19 tool does not have a washer. snap ring groove. To do so restricts oil relief outlet
causing oil seal failure.
3. Add adjusting washers (B) until scribe line (A) is
flush with top of tool nut.
4. Remove tool and install plug with pin.
Pump Assembly
1. Install pump shaft bearing cup in housing.
ASpacers* B Race CThrust Washer

Fig. 34-Pump Shaft Assembly (4 cu. in. pump shown)
3. Install thrust washer (C, Fig. 34), spacer (A), and

roller bearing over pump *Note that the 4 cu. in.
shaft.
pump shaft uses two extra spacers not used on the 3
cu. in. pump shaft.

.
23
20 V 1,6
/ f
2
L
6 y f l l I I JLA
R22123F
1Plug (8 used) 11 Discharge Valve (8 used) 20Race

2O-Ring (8 used) 12 Spring 21Cone
3Inlet Valve (8 used) 13Guide 22 Bearing Cup
Housing
A 14Stop 23 Shim
5Pump Piston used) (8 15 Discharge Valve 24Cap Screw
6Spring used)(8 16Spacer 25O-Ring
7Sheath (8 used) 17Thrust Washer 26Plug
8O-Ring used)
(8 18 Pump Shaft 27Quad Packing
9 Piston Plug
(8 used) 19 Roller Bearing 28 Seal
Oil
10Seat (8 used) 29Snap Ring
Fig. 35-Expioded View of 3.0 Cu. In. Main Pump
NOTE: On 4.0 cu in,-pump$ two additional spacers are used between the thrust washers and race.
4. Place needle bearing race (B, Fig. 34) over shaft Place stroke control valve housing assembly with
7.
cam. Install needle bearings, adjusting shims on pump housing. Tighten cap screws
to 85 ft-lbs (115 Nm) (11,5 kgm).
IMPORTANT: Use ONLY John Deere Hy-Gard
Transmission and Hydraulic Oil on needle bear- 8. Check for 0.001-0.003 in. (0.03-0.08 mm) pump
ings. shaft end play as instructed earlier in this Group.
5. Install remaining spacer(s), thrust washer, and 9. Add or deduct shims to obtain correct end play.
roller bearing.
10. Install piston assemblies being sure proper pis-

6. Install pump shaft assembly in pump housing. ton goes back into its respective bore.
1 1 Torque piston plugs to 100 ft-lbs (136 Nm) (13.6

kgm).

Installation and Adjustment PFWD HYDRAULIC PUMP DRIVE

1 . Reverse the steps of Removal to install the hy-
draulic pump in the tractor.
--A2
IMPJrl ,
, jm?A t 1
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-
. ;
iw 'j-
ARear Coupling DPump Drive Shaft

BCushion Coupling ECollar
R 26679N
CFront Coupling F Keeper
ALock Nut 0Cap Screw Fig, 37-Pump Drive for PFWD Tractors
BCoupler Half EDrive Shaft

C Special Screw FCap Screw Removal
Fig. 36-Pump Drive Assembly 1. Loosen the cap screws at the front of the pump
drive.
2. Refer to the following torque specifications when 2. Loosen and remove cap screws attaching front
installing pump and pump drive assembly and see coupling (C, Fig. 37) to drive shaft (D).
installation instructions on page 70-10-5. 3. Slide pump drive forward on shaft and remove
coupling (C) then slide drive rearward to remove from
Location Torque
pump shaft. Tap pump drive sharply to loosen collar
Pump-to-pump support cap 85 ft-lbs from shaft.
screws (115 Nm) (11.5 kgm)
Coupler shaft cap 35 ft-lbs Installation
screws (47 Nm) (4.7 kgm)
1. Preassemble pump drive (D), collar (E) and
Special pump drive screws* 35 ft-lbs
keeper (F) as shown in Figure 37.
(47 Nm) (4.7 kgm)
2. install assembly onto hydraulic pump drive shaft.
Coupler half capscrews 35 ft-lbs
Do not tighten cap screws. Make sure chamfer on
(47 Nm) (4.7 kgm)
keeper is not next to collar.
Coupler half capscrew lock 30 ft-lbs
3. Install rear coupling (A, Fig. 37) on engine pulley.
nuts (41 Nm) (4.1 kgm)
Torque screws to 35 ft-lbs (47 Nm) (5 kgm).
4. Place cushion (B) on rear coupling and install
3. Be sure all hydraulic lines are tight.
front coupling (C) over cushion.
4. Check reservoir for proper oil level.
5. Slide pump drive rearward and install cap screws
5. Make main pump tests as instructed earlier in this
through drive shaft into coupling (C), torque to 35 ft-lbs
group.
(47 Nm) (5 kgm).
6. Turn stroke control adjusting screw out to relieve
6. With the front and rear coupling halves clamped
spring pressure.
together to hold a gap of from 0.098 to 0.178 in.
7. Place all hydraulic controls in neutral and run
(2.5-4.5 mm) between couplings, tighten the keeper
engine at 1700-1800 rpm.
screws to pump shaft evenly until snug. Then tighten
8. Turn adjusting screw in until:
each cap screw evenly, one at a time, to 20 ft-lbs (27
a) 2200-2300 psi (150-159 bar) (154-158 kg/
Nm) (3 kgm). Tighten them a second time to insure that
cm 2 ) is recorded for 3 cu. in. (49 ml) pump.
collar is properly seated and that cap screws are at
b) 2250-2300 psi (155-159 bar) (158-162 kg/
proper torque.
cm 2) is recorded for 4 cu. in. (66 ml) pump.

Hydraulic Repair Rockshaft and Implement Hitches 70-15-1
Group 15
>
ROCKSHAFT AND IMPLEMENT HITCHES
i|:v
lit!
:JJ '
R34S99
A Piston Cover D LifUAssist Cylinder

&Throttle Valve EQui k- Coupler
C Lift Arm F LinkLift Fig. 2-Removing Rockshaft Piston
G Surge Valve
6. To remove rockshaft piston, rotate liftarms
Fig. 1 -Rockshaft with Lift Assist
(using a short jerking motion) rearward to remove
piston from rockshaft cylinder. (See Fig. 2,)
ROCKSHAFT HOUSING ASSEMBLY
IMPORTANT: Do not allow crank arm to contact
Throttle Valve, Piston Cover, and Piston
the forward edge of the piston cylinder. Damage to
the cylinder and crank arm could result.
Removal
1. Lower the rockshaft,
2. Remove throttle valve special bushing and throt-

tle valve assembly, (B, Fig. 1) from piston cover (A).
3. Remove piston cover- to -rockshaft cap screws

and remove piston cover.
4. Disconnect lift links (F) from lift arms (C).
5. Disconnect the lift assist cylinder (D) from lift arm

(if equipped).

70-15-2 Rockshaft and Implement Hitches Hydraulic Repair
Inspection
Biai?V
* " ::::
yv :: -"-'- :;
---
:
s.^%sm ;:
:^':.-. .. arias;
A Rockshaft Piston B Packing C Slipper Seal

Fig. 4-instaIIing Slipper Seaf
R 29I30K
AJam Nut E Throttle Valve Shaft

Check slipper seal and packing on piston for dam-
B Special Bushing F O-Ring age. Replace only If damaged. (See Fig. 4.)
CSpring G Backup Ring
DThrottle Valve H Piston Cover Installation
Fig. 3-Piston Cover Assembly 1. Lubricate all seals and mating surfaces with John
Deere HY-GARD Transmission and Hydraulic Oil or its
Throttle Valve equivalent.
Disassemble throttle valve and examine spring (C,

Fig. 3), valve (D), and shaft (E) for damage. 2. Install rockshaft piston. Use of a piston ring
compressor will aid installation.
Spring compression rate should be 0.75 in. at 0,5 to

0.7 lbs (19 mm
at 2.2 to 3.1 N) Check vatve and throttle
3. Install assembled throttle valve in piston cover.
valve shaft to be sure they move freely in their bore.

4. Install piston cover with packings and torque cap
Check O-ring and backup ring for damage screws to 170 ft-lbs (230 N*m) (23 kgm).
(F, G).
5. Adjust throttle valve to desired rate of drop by

Piston
loosening lock nut and turning throttle valve shaft
Inspect rockshaft piston and cylinder for scoring or screw.
damage. Note particularly the area where the crank
arm may have contacted the edge of the cylinder. NOTE: The throttle valve can be inspected and
Remove any burrs or scratches and be sure cylinder adjusted with the rockshaft on the tractor
and piston are clean.
6. Connect hitch lift links to lift arms. Connect the
IMPORTANT: the extent of scoring Is ques-
If lift-assist cylinder to the lift arm (if equipped)-
tionable perform the rockshaft leakage test on
page 270-25-17.
Piston O.D. 4.246-4.248 in (107.62-108.12 mm)

Cylinder I.D. 4.2505-4.2535 in (107.96-108.04 mm)

ROCKSHAFT HOUSING 8. Whenever the rockshaft is removed, reference

measurements must be taken to insure correct posi-
Removal and Disassembly tioning of the hydraulic control inner support when the
rockshaft is reinstalled. Refer to 10-20-3, for proper
procedure.
9. Raise the rear of the SOUND GUARD Body 2 in.

(50.8 mm) and block in place.
NOTE: Tractors equipped with open operator sta-

tion must have the operator station removed for rock-
shaft removal.
10. Remove piston and piston cover as described

previously in this group. (See page 1.)
Fig. 5-Operating Linkage
1. Lower the rockshaft and disconnect the center

link and lift links. Disconnect the lift cylinder from the lift
arm (if equipped).
2. Remove the rockshaft load selector and operat-
ing linkage from the control valve housing.
3.(Not Illustrated) Relieve hydraulic pressure and
drainoil from rockshaft cavity using the following pro-
cedure, before removing, left-hand selective control

Fig. 6-Rockshaft Removal
valve and linkage.
A. Place the rockshaft console lever in the full
forward position. 11. Install rockshaft lift tool. Remove rockshaft. In-
B. Place the lever for the left-hand selective structions for making lift tool are provided on page
control valve in the float position. 70-00-14.
C. Remove the throttle valve from the rockshaft
piston cover.
D. Place a clean container beneath the selective
control valve and open receptacles.
E. Apply maximum 35 psi (2.4 bar) air pressure
into the throttle valve bore.
4. (Not Illustrated) Disconnect the hydraulic pres-
sure and return lines at the rockshaft.
5.Disconnect the lift-assist cylinder line (if
equipped) at the piston cover.

6. Remove dipstick and rockshaft to transmission
cap screws.
7. Remove sensing line from control valve housing.
Also remove end at piston cover.

Removal and Disassembly Continued
:::.::::':;: ]Y:Z":^ |S;i:tSJT;t{$;::t::i;

:
Ftg. 7-Removing Rockshaft Housing Over Servo Cam Follower AServo Cam Cap Screw B Rockshaft CBottom Cover
IMPORTANT: Raise rockshaft housing vertically Fig. 9-Remov'mg Rockshaft

untilhousing is clear of rockshaft servo cam fol-
lower which is located on the load control arm. 13. Remove rockshaft bottom cover (C, Fig. 9).
14. Remove servo cam cap screw (A) and remove

rockshaft and cam. The rockshaft must be removed out
the left-hand side of the housing.
15. Remove crank arm, (B, Fig. 10) and piston rod.
R 27129*
Fig. 8-Rock$haft Lift Arm
12. Remove cap screws from lift arms and remove

lift arms. (See Fig. 8,)
R2? 132:1
A Piston Rod B Crank Arm CRockshaft

Fig. 10-Rockshaft, Crank Aim, and Piston Rod

Hydraulic Repair Rockshaft Implement and Hitches 70-15-5
R297Z9U
A^LH. Lift Arm DCrank Arm G R.H. Lift Arm J Piston Rod
B Rockshaft EServo Cam H Cap Screw KPiston
CSpring Pin FSpacer (use as required) ( Lock Plate L Packing
M Slipper Seal
Fig. 1 1 -Exploded View of Rockshaft
Inspection and Repair Assembly and Installation

Inspect rockshaft piston and cylinder for scoring and
damage as previously described. (See page 2.)
Inspect rockshaft piston slipper seal and packing for

damage. Examine rockshaft bushings for excessive
wear or damage.
4240;
L.H. Bushing I.D. 2.876-2.880 in. (73.05-73,15 mm)
R.H. Bushing (Inner) I.D. 2.503-2.507 in. (63.58-63.68
mm)
R.H. Bushing (Outer) I.D. 2.503-2.507 in. (63.58-63.68
mm)
L.H. Rockshaft End 2.872-2.874 in. (72.945-72.995
mm)
R.H. Rockshaft End 2.499-2.501 in. (63.475-63.525
mm)
4040:
LH. Bushing I.D. 2.626-2.630 in. (66.70-66.80 mm)
R.H. Bushing (inner) I.D, 2.251-2.255 in. (57.18-57.28
ALeft Hand Bushing C Right-Hand Outer Bushing
mm) BRight-Hand Inner Bushing
R.H. Bushing (Outer) I.D. 2.251 -2,255 in. (57.18-57.28
Fig. 12-Rockshaft Bushing installation
mm)
1 Dip rockshaft O-rings in clean John Deere Hy-
L.H. Rockshaft End 2.621-2.624 in. (66,57-66.65 mm) .
Gard Transmission and Hydraulic Oil, or equivalent,

R.H. Rockshaft End 2.247-2.249 in. (57.07-57.12 mm)
and install in housing.

Assembly and Installation Continued

2. Replace bushings as necessary. Be sure holes in
bushings align with oil passages in housing.
3. Use disks from the bushing driver set as follows:
4240 Disk Number

LH. Bushing 27529, 27530
R.H. Bushing 27523, 27524
4040
L.H. Bushing 27524, 27527
R.H. Bushing 27519, 27521
NOTE: Use the disks for R.H, bushing to install the

inner bushing. The bushing will have to be installed
from the left side of the housing using an extension
Fig. 14-lnstatIation of Spacer
handle. Install R.H. outer bushing from right-side of
housing and LH. outer bushing from left-side of hous-
Be sure oil holes 10. Replace rockshaft oil seals.
ing. in outer bushings are aligned with
passages in housing. 11. Install piston and piston cover as instructed
previously. (See page 2.)
i??Sij;
Iflte
Fig. 13-lndexing Rockshaft and Crank Arm
4. Install crank arm and piston rod in housing.
5. Install servo cam with cam lock cap screw toward

the lower rear of the housing and cam side upward,
Fig. 15-tndexing Rockshaft Lift Arms
6. Install rockshaft in housing, aligning index marks
on crank arm and rockshaft. Be sure cam is in proper
position with locating hole on rockshaft, (See Fig. 13.)
12. Install rockshaft lift arms. Be sure to index arms
with rockshaft (Fig. 46). Tighten cap screws to 300
7. Add as many spacers as will freely assemble ft-lbs (407 Nm) (40.7 kgm) torque. Strike with hammer
between cam and right-hand side of housing to elimi- and re-tighten to 270-330 ft-lbs (366-447 Nm) (36.6-
nate excessive rockshaft end play. (See Fig. 14.) 44.7 kgm) torque.
8. Tighten servo cam cap screw and bend ears on 13. Install rockshaft valve housing (if removed).
lock.
14. Replace rockshaft-to-case gasket.
9. Install rockshaft bottom cover with packing.
Tighten cover cap screws to 35 ft-lbs (47 Nm) (4.7
kgm) torque.
TM-1181 (Sep~77) Utho in U.S.A. Tractors - 4040 and 4240

Installation ROCKSHAFT CONTROL VALVE

NOTE: Before installing rockshaft assembly, in-
HOUSING
spect load control arm cam follower assembly for wear Removal
or damage.
Fig, 17-Rockshaft Control Valve Housing Removal
Fig. 16-fnstatiing Rockshaft Over Servo Cam follower

1. On tractors equipped with lift assist; remove the
line from the surge relief valve to the side of the control
1. Place load selector arm in "MAX" position and valve housing. Remove the fitting at the piston cover.
align load selector control link roller in the valve hous-
2. Remove the sensing line from the top of the
ing with rear side of the servo cam follower. control valve housing to the piston cover.
3. On all tractors; disconnect right-hand selective
Lower rockshaft housing onto transmission case,
2.
control valve linkage and remove selective control
using care not to damage linkage or load control arm
valve and control valve cover,
extension.
4. Disconnect rockshaft operating linkage and load
selector linkage at the control valve housing.
3. Torque cap screws to 85 ft-lbs (115 Nm) (11.5
5. Remove cap screws from control valve housing
kgm), torque nuts from 55 ft-lbs (74 Nm) (7.4 kgm).
and remove valve housing.
NOTE: Rockshaft control valves and flow control
4. Connect hydraulic pressure and return lines and valve can be removed without removing valve housing,
all linkage. Adjust linkage as instructed on page 16, 6. If thermal relief valve is suspected to be at fault,
test as instructed on page 270-25-15, The test may be
done with the housing removed from the rockshaft.

IMPORTANT: Repairs to rockshaft valve hous-
must be performed in a clean, well lighted
ing parts
environment; preferably a separate area isolated
from the general shop area.
>

70*15-8 Rockshaft and Implement Hitches Hydraulic Repair
R 29744N
AO-Ring H Ball LControl Valve P Packing

B Backup Ring I Thermal Relief (2 used) QShim
CInlets Body and Seat M-^Steel Ball (2 used) R Flow Control
D Thermal Relief Plug JMetering Shaft N Control Valve Valve Spring
E Spring Guide (2 used) Spring (2 used) SFlow Control Valve
F Shim KMetering Shaft O Flow Control T Return Check
GSpring Guide (2 used) Valve Plug Bait and Plug
U Control Valve Housing
Fig. 18-Rock$haft Vaive Housing
1. Remove rockshaft control valve cover (unless 4. Remove thermal relief valve special plug from
removed previously). bottom of housing and remove thermal relief valve (D)
for inspection and repair.
2. Remove springs (N Fig. 1 8), balls (M), valves (L),
and metering shafts (K). Remove and replace metering 5. If valve linkage is not in need of repair, see valve
shaft guides (J) only if necessary. assembly on page 10.
Inspect valves (L), and valve springs (N) for wear

3.
or damage. Examine the bores in valve housing for
scoring or damage. The housing must be replaced if
bores are damaged.

.
Use the following specifications as reference: Operating Linkage
ITEM MEASUREMENT SPECIFICATION Removal

Flow O.D. 0.6530-0.6534 in.
Control (16.58-16.60 mm)

Valve Bore LD. 0.6639-0.6549 in.
{16.61-16,63 mm)
Spring Free Length 1-7/64 in.
{27 mm)
Spring Working Load 0.9 in.12-15 lbs,
at
(23 mm 56-69 N)
at
Control O.D. 0.7480-0.7490 in.
valves (19.00-19.02 mm)
Bore LD, 0.7500-0.7520 in.
(19.05-19.10 mm)
Spring Free Length 2.15 in.
(55 mm)
Spring Working Load 1.4 in. at 7-9 lbs.
(30 mm at 31-40 N)
Thermal Spring Free Length 0.57 in. (14.5 mm)
Relief Spring Working Load 0.45 in. at 12-15 lbs.
Valve (11.4 mm at 55-68 N)

Valve Extended Length 3.35 in. at 32.5-39.5 in R 297451*
Cam {85 mm at 145-176 N)
Operating
Fig. 20-Rockshaft Control Vaive Linkage Removal
1 Remove spring pin from inner load selector con-

trol arm.
2. Remove outer load selector arm and shaft.
3. Rotate rockshaft operating cam counterclock-

wise,remove spring pin from lower operating arm, and
remove arm.
4. (Not illustrated) Remove operating shaft quill and

remove operating shaft.
5. (Not illustrated) Remove hex. plug and valve

operating cam shaft from opposite side of housing.
6. (Not illustrated) Rotate linkage upward out of

$$?24$ft
housing and remove spring from valve operating cam.
Fig. 19-Utpping Control Vatves Remove linkage from vaive housing.
NOTE: Control valves can be lapped, insert dowel

in valve, apply lapping compound to valve and rotate t
valve in vaive housing bore.

Operating Linkage Continued

Repair
R 29746N
AValve Cam Shaft H Spring Washer NLoad Selector Arm T Valve Operating Shaft
BWasher I Special Nut 0Outer Load UOperating Link
C Adjusting Screw J Link with Pin Selector Arm VNegative Signal
DSpecial Pin K Inner Load P Load Selector Shaft Limit Link
E Return Spring Selector Link 0Operating Arm WNegative Signal
F Adjusting Cam L Roller RO-Ring Limit Cam
GAdjusting Link MOuter Load SQuill
Selector Link
Fig. 21 -Rockshaft Control Vaive Linkage
1 . Inspect linkage for wear and damage (particularly Assembly and Installation
at pivot points).
1. (Not Illustrated) Hook cam spring to pin in valve
housing.
2. Inspect operating valve cam spring (E, Fig. 21)
for correct tension. Inspect special pin (D) that spring
attaches to in housing. Note that pin clearance is
provided for linkage lubrication.
3. Check load selector link roller (L) for flat spots or

damage.

: '
AValve Adjusting Cam CSpecial Nut

BAdjusting Link DAdjusting Screw
Fig. 22-Qperating Cam Assembly
2. Assemble valve adjusting cam (A, Fig. 22), ad-

ArOperating Shaft DOperating Ann
and washer onto ad-
justing link (B), special nut (C), BQuilt ESpring Pin
justing screw (D). When assembled, the washer must CO-Ring
be flat within 0.045 in. (1.14 mm). (See Fig. 2.)
F7g. 24-Operating Arm, Shaft, and Quilt
3. Assemble operating link and negative signal limit

link to cam link.
4. Install this linkage subassembly in the valve

housing as shown. Align operating link hole with valve
cam shaft hole,
5. (Not Illustrated) Install valve cam shaft with

washer to secure cam assembly. Torque cam shaft to
12ft-lbs (16 Nm) (1,6 kgm).
6. Install shaft plug with O-ring.
7. Hook return spring to adjusting cam.

:"' '.
".*.-... .-.
; -"."" . "'/; ';.,. /\

'
'.-.;.& J? | . _:!
.'.:":.,."
::.' '
:
;
\ >*U;
^ :i
^*j>i^^^|:- -:-
:
:"j? ^j ; X "/ =:'' ;
:
:
:
:
:
:
!-r
:
:
: :-.
fig. 23-tnsteitirig Rockshaft Linkage

Assembly and Installation Continued CONTROL VALVE HOUSING ASSEMBLY

AND INSTALLATION
1. (Not Illustrated) Lubricate all parts, O-rings, and
packings clean John Deere
in HY-GARD Transmission
and Hydraulic Oil.
2. (Not Illustrated) Install thermal relief valve as-

sembly. Install seat, valve body, ball, spring guide pin,
spring and special plug. Test valve operation as in-
structedon page 270-25-15. Add or deduct shims on
3550-3950 psi
pin to obtain specified relief pressure of
(245-272 bar) (250-278 kg/cm 2 ).
R 29747M
Fig. 25-lnstalling Load Selector Linkage
8. Install operating shaft (A, Fig. 24) through quill

(B).
9. Install O-ring (C) over operating shaft into quill.
10. Install quilf into housing, aligning pin on operat-

ing shaft in operating link, and torque to 1 00 ft-lbs (1 36 r? ?254li
Nm) (13.6 kgm).

Fig. 26-lnstalling Guides Using JDH-28 Driver
11. Hold operating link housing and
forward in in-
stall operating arm with attaching hole upward. 3. Install metering shaft guides (if removed). Use
JDH-28 driver.
12. Assemble load selector control arm and load
selector links.
13. Connect the load selector linkage to the

operating linkage at the roller link.'
14. With the operating link held upward, place as-

sembly in valve housing. Be sure hole in negative
signal limit cam is located on the pin on the inside of
the valve housing.
15. Install the load selector shaft O-ring in housing.
16. Install load selector shaft with arm through

housing bore so that load selector arm is pointing
upward.
17. Install inner load selector control arm on shaft.

Drive spring pin flush with arm to be certain linkage
travel is complete. mm Fig. 27-lnstalIing Rockshaft Valves

4. Install metering shafts, valves, balls, and springs Load Control Arm
into valve housing.
Removal and Repair
5. Install flow control valve, spring, and same
1. Remove the rockshaft housing assembly as in-
number of shims as were removed. Install valve ad-
structed on page 3.
justing plug in valve cover.
6. Install valve housing cover with packings, install

return check ball and plug.
R 29749N
Ar-lnlets CCam Follower
B Servo Cam
Fig. 28-ControI Valve Housing inlets A Slotted Nut I Arm

{Lift Arm Raised for Photographic Purposes) B Lock Plate J Follower
C Lock Spring KSpecial Cap Screw
D Special Pin L Pin
7. Place inlets (A, Fig. 28) in rockshaft housing, E Special Screw M Arm Support
F Extension N Follower
8. Carefully install valve housing over gasket so GWasher OPin
roller of load selector control link is on back side of cam H Retaining Ring
follower. Carefully secure valve housing to rockshaft
Ftg 29-Load Control
r Arm Assembly
housing.
2. Examine load control arm extension pivot points

9. (Not Illustrated) Turn valve operating cam ad-
for wear and damage.
justing screw counterclockwise to bottom its flared end
intothe valve operating cam. Then turn the screw
3. If load control arm is to be removed, it must be
clockwise 1 /2 turn for initial rockshaft operation. See
removed with the differential housing. See Section 50,
page 16 for final valve setting.
Group 35 for instructions on removal and installation.
10. Connect operating linkage and hitch lift links.
4. When installing load control arm extension as-
sembly, install adjusting screw (E, Fig. 29) to secure
11. Adjust linkage as instructed on page 70-15-16.
extension (F) to arm. Install spring (C), lock plate (B),
and nut. Be sure to install roil pin (D) in each end of
extension screw.

Draft Link Support and Load

Control Shaft
Removal and Repair
1. Check for leakage around drawbar (draft link)
support and transmission case. Leakage could indicate

worn load control shaft or damaged load control shaft
O-rings or sealing rings.
Fig. 31 -Removing Load Control Shaft Driver
4. Inspect load control shaft (particularly at flex

points) for wear and scoring. Use a fine abrasive to
clean up shaft.
5. Examine bushings, sealing rings, and O-rings in
the transmission case. Examine bushings in the sup-

R 29750N port. Use the following specifications as reference:
Item Measurement Specification

A Draft Link Support G Load Control
BDrawbar Pin Shaft Bushing
Load control shaft CXD, 1.1230-1.1250
C Pin Retainer H^Snap Ring in.
D Upper Bushing I Grease Fitting (28.52-28.58 mm)

E Bushing J Retainer Transmission case LD. 1.1280-1.1300 in.
FPin K Lower Bushing bushing (at smallest point) (28.65-28.70 mm)
L Washer Draft link support ID, 1.1540-1.1600 in.
Fig. 30-Draft Link Support bushing (29.31-29.46 mm)
2. Remove snap rings (H, Fig. 30) and shaft reinstallation
tainers (J) from draft link support. IMPORTANT: Do not replace transmission case
bushings unless necessary. Frequent replacement
3. Lift draft link support using jack and carefully will enlarge bushing bore and could cause leakage.
remove load control shaft and driver. Lower the sup-
port.

5
Hydraulic Repair Rockshaft and Implement Hitches 70-1 5-1
2. To remove transmission case bushing, drive

bushing outward inserting driver through opposite
bushing diameter.
3. If bushing is replaced, sealing ring and O-ring

should also be replaced.
a) Chill the bushing.
b) Drive bushing with sealing ring and O-ring

into case using JDH-50-2 driver, 27512
disk and 27489 handle from the Bushing
Driver Set.
H 2UC29K
IMPORTANT: Be sure drivers are free from
nicks and burrs. A rough driver surface could re-
sult in damage to sealing rings.
ACollapsed Sealing CLoad Control Shaft
Ring Bushing
BO-Ring DSealing Ring Groove
Fig. 32-Seafing Ring installation
1 . If only sealing ring and O-ring (A and B, Fig. 32}

are to be replaced:
a) Examine bushing sealing ring groove (D) for
nicks or sharp edges. Clean bushing and
groove using a fine abrasive,
b) install O-ring in bushing (C) and lubricate the
groove.
c) Heat new sealing ring in 1 60F (70C) water to
make more pliable.
d) Bend ring (A) as shown in Fig. 32 and install
R Z9751H "Ph
in groove.
e) Reshape ring using fingers and end of load A Retainer Ring FSealing Ring
control shaft. B Retainer GO-Ring
f) Lubricate sealing ring.
CRetainer Ring HTransmission Case
D Support Bushing Bushing
EWasher I Load Control Shaft
Fig. 34-Load Control Shaft Installation
4. When replacing draft link support outer bushings

(D, use Disk 27501 and 27508 from the
Fig. 34),
Bushing Driver Set. install retaining ring (C),
5. Align draft link support with transmission case

load control shaft bore and install special washer (E) as
required on one side between case and support. Use
the 0,048 in. (1.22 mm) thick washer.
6. Install as many special washers as required on

the opposite side to provide minimum draft link sup-
port-to-case clearance.
7. Lubricate load shaft (I) with John Deere Hy-Gard

Transmission and Hydraulic Oil and install shaft
through support and case. Use care not to damage
sealing rings.
I
Fig. 33-fnsteIting Transmission Case Bushing
TM-1181 (Sep-77).Lkho in U.S.A. Tractors - 4040 and 4240

INSTALLATIONContinued
8. Install load control shaft retainers (B) and retainer
rings (A) in draft link support. Lubricate retainer fitting
until grease just begins to show.
ROCKSHAFT CONSOLE
LINKAGE REPAIR
()
^
9 ^ô
Fig. 36-Friction Plate installation
%
5. Adjust as instructed on page
MJ
Rockshaft Linkage Adjustments
R 28569M
If adjustment is suspected to be at fault, perform all
checks and adjustments as instructed in Section 270-

ALever and Knob H Friction Plate
25-9.
B Shaft I Spring
CAdjusting Screw J Bushing
D Lever Stop K Upper Arm NOTE: Perform the following adjustments with no

E Spring Washer L Rod load on the hitch unless otherwise instructed. To be

F Jam Nut M Swivel certain there is no air in the system, cycle the rockshaft
GFaced Washer
several times. These adjustments should be performed
Fig. 35-Rockshaft Console Control Linkage in the sequence they appear in this manual
1. Remove load selector knob and remove console DO NOT pressurize lift assist cylinder unless it is
cover. properly connected at both ends. (If equipped)
2. Check for excessive wear and looseness of fit in

moving parts.
3. Examine friction plate (H, Fig, 35) and washers

(G) for wear. When installed, a 7 to 8 lb. (31-36 N)
force should be required to move the lever with rod
disconnected.
4. Replace worn parts as necessary.

Hydraulic Repair Rockshaft and implement Hitches 70-15-17
Load Selector Lever Adjustment

1. With the engine off and the rockshaft lowered,
move the console load selector knob from "MIN" to
"MAX" position.
2. The load selector lever on the rockshaft valve

housing should reach either end of its travel before the
console knob reaches either end of the slot in the
console.
3. Adjust swivel on linkage at the hydraulic control

inner support, if necessary.
Rockshaft Valve Clearance Adjustment
NOTE: Before checking or adjusting rockshaft valve

clearance on tractors equipped with lift assist cylinders,
perform the following steps (a through d).
a) Lower the hitch and disconnect the lift assist

cylinder oil line at the rockshaft piston cover.
b) Disconnect return line from eibow at the surge

relief valve in the piston cover.
AExtended Arm BSpecial Plug
Fig. 37-Rockshaft Operating Valve Adjustment

c) Cap the nipples from which the fineswere
removed. To allow free hitch movement, as- ROCKSHAFT VALVE CLEARANCE
sist cylinder lines should be left open. Use ADJUSTMENT
steel caps from Master Hydraulic Fitting Flow
1. Place load selector lever in the "MIN" slot.
Test kit.
2. Disconnect linkage from the rockshaft control

d) After checking and adjusting valve clearance,
valve operating arm,
reconnect lines and operate rockshaft to re-
move air from system.
3. Using an extended arm (A, Fig. 37), extend the
rockshaft valve operating arm to 10" (254 mm) from
center of valve operating shaft.
See page 70-00-13 for instructions on making ex-

tended arm.
4. Run engine at slow idle.
A CAUTION: Use care to avoid injury by the

lift arm or hitch In case valve is operated
too rapidly or unexpectedly.
TM-1181 (Feb-78) Litho in U.S. A, Tractors - 4040 and 4240

Adjustments Continued
5, At the 10" (254 mm) mark, measure the distance
the arm Is moved to change rockshaft rotation direc-
tion. This distance should be:
A. New Tractors (as received from factory) -
3/16 to 3/8" (4.76-9.53 mm)
B. Tractors with rockshaft usage - a measured

distance of less than 3/16" (4.76 mm) is ac-
ceptable due to valve seating. The valve
clearance need not be adjusted as long as
some movement of the extended arm is ob-
served without a change in rockshaft rotation
direction. When required, readjust the valve
to obtain 3/16 to 3/8" (4.76-9.53 mm) move-
ment of the extended arm to obtain a change
in rockshaft rotation direction.
6. If necessary, remove plug (B) from side of control

valve housing and turn adjusting screw counterclock-
wise to increase the distance or clockwise to reduce
the distance,
AHand Throttle CLoad Selector Lever
BRockshaft Console Lever DDepth Adjusting Knob
7. After checking and adjusting valve clearance,
reconnect lines and operate rockshaft to remove air Fig. 39-ConsoIe Lever Positions
from system.
2. Turn adjusting screw clockwise to its limit.
Rockshaft Console Lever Rod Adjustment
3. Place load selector lever (C, Fig. 39) in "MAX"
position and run engine at slow idle.
4. Move rockshaft console lever (B) forward to

lower the hitch.
MAX
-b
4
\i
3
MIN
2
Fig. 38-Load Control Arm Extension 8'-

1. Remove load control arm extension adjustment
hole plug from rear of transmission case. S29141N
Fig. 40-Lever Positions
TM-1181 (Feb-78) L'ttho in U.S.A. Tractors - 4040 and 4240

5. Turn the rockshaft depth adjusting knob (D) to

move the rockshaft adjustable stop and the rockshaft
console lever rearward.
a. Rockshaft should start to raise when the front

edge of the console lever is aligned with "1" on the
console guide.
b. If rockshaft does not raise as specified, adjust

the rockshaft operating rod yoke at the valve operating
arm until adjustment is correct.
NOTE: if rockshaft raises too soon, lengthen

the
rod, if rockshaft raises too Iate r shorten the rod.
Load Control Arm Extension Adjustment
*
*4 Fig. 42-Adjusting Load Control Arm Extension
(W>
"i r\
MAX
lAX^j 4. Turn the load control arm extension adjusting
rtf^n " screw counterclockwise until rockshaft starts to raise.
8
j
5. Move the rockshaft console lever forward to
- -6 lower the hitch, using depth adjusting knob, move lever

- -5 rearward. Rockshaft should start to raise when rear
- -4
edge of lever is at "1 " on console guide. If not, readjust
load control arm adjusting screw.
iz*
l
h :
3-Point Hitch and Quik-Coupler
Tl
K -
8
^
R29138N
0 ^-*
Fig. 41 -Lever PositionsExtension Adjustment
1. Place the load selector lever in the "MAX" posi-

tion and run the engine at slow idle.

lower the hitch.
3. Turn the depth adjusting knob to move the rock-

shaft console leverand adjustable, stop rearward. Stop
when the rear edge of the )ever fe at " 1 " on the console A^-Center Link CDraft Links
guide. B Lift Links DLift Assist Cylinder
Fig. 43-3-Point Hitch with Optional Lift Assist
The 3-point hitch consists of an adjustable center

link (A), two adjustable lift links (B, Fig. 43}, two draft
links (C), and an optional Quik-Coupler.
TM-1181 (Jul-78) Litho in USA. Tractors - 4040 and 4240

3-POINT HITCHContinued
Sway blocks control hitch and implement side mo-
tion.
Pins in the lower lift link-to-draft link yokes may be

installed to prevent or to allow lateral implement float.
Use the following illustrations as a guide to disas-

sembly and assembly of hitch components.
A-^Pin (2 used) H Upper Body

B Quik-Lock Pin I Yoke
C Upper End J Cottier Pin
D Spring Pin K-^Pin
ELock LQuik-Lock Pin
FGrease Fitting MPin
G Plug NCotter Pin
OLift Link
ASpring Pin HSpring

BLatch Handle I Latch
CHook JBall Pin
DLock K End with Ball
ECenter Link Body L End Lock*
FEnd and Pivot MBody with Guide
GAttaching Bracket N Spacer Washer
*End lock is installed with Hat toward front of tractor.
R 30015N
Fig. 44-Lift Link (4040 shown)
-y .
&Z&
Os
R 31554
Fig. 45-Draft Links and Center Link (4040 shown)
TM-1181 (JuI-78) Lttho in U.S.A. Tractors - 4040 and 4240

Hydraulic Repair Rocks haft and Implement Hitches 70-15-21
1 Pin 19Spacer (4 used)
^~ 2Quik-Lock Pin
3 Ball
4 Spring Pin (2 used)
5 Handle (2 used)
6 Lever
7 Cap Screw
(2 used)
{4 used)
20 Link (4 used)
21 Latch (2 used)
22Spacer (2 used)
23Spring Pin (2 used)
24Pin (2 used)
25Retaining Ring (8 used)
8 Plate 26Pin {2 used)
9Screw (2 used) 27Link (4 used)
10Cap Screw (4 used) 28Pin (2 used)
11Spring Pin (4 used) 29Cap Screw (2 used)
12Bracket (2 used) 30Adapter (2 used)
13 Nut (2 used) 31Spring Pin (2 used)
14 Shield (2 used) 32Adapter (2 used)
15Cap Screw (2 used) 33Pin (2 used)
16 Spring (2 used) 34Cotter Pin (2 used)
17 Rod (2 used) 35 Frame
18 Bar {2 used) 3GHook
29
Legend for Fig. 46
IS?}*
Fig. 46-Heavy-Duty Quik Coupler
1. Remove the rockshaft piston cover, if necessary,
LIFT ASSIST as directed on page 70-15-1.
Rockshaft Piston Cover, Lowering Valve, 2. Remove the lowering valve plugs (D, Fig. 47) and
and Surge Relief Valve remove valve (B) and spring (C) for inspection,
NOTE: Both the towering valve and the surge relief
valve can be removed and inspected without removing A) The lowering valve spring should compress
the rockshaft piston cover. See page 270-25-16 for to 0.866 in. at 4-5 lbs. (22 mm at 18-22 N).
surge valve test procedure. Add or deduct shims as
necessary to obtain proper relief specification. B) Lowering valve O.D. is 0.3739-0.3743 in.
(9.497-9.507 mm).
C) Lowering valve bore I.D. is 0.3745-0.3755 in.
(9.512-9.538 mm),
Remove the surge relief valve and inspect parts

3.
forwear and damage. Spring (H) should compress to
1-7/64 in. at 130-150 lbs. force (28 mm at 578-667 N).
4. Dip all parts in clean John Deere Hy-Gard
Transmission and Hydraulic Oil prior to assembly.
5. Be sure lowering valve works freely in its bore.

Also, be sure that open end of valve faces to the
left-hand side of the piston cover and that the valve
spring is Installed over the plug with spring pin on the
right-hand side of the piston cover.
* 297531*;
6. Install piston cover.
A Piston Cover HSpring
B Lowering Valve I Relief Cap
CSpring J Throttle Valve
0 Plug with pin KThrottle Valve Shaft
E Relief Body L Spring
F Relief Poppet
M Bushing
G Shims N^Jam Nut
Fig. 47-Piston Cover

.
Lift Assist Cylinder 3. inspect oil seal (B, Fig. 49) and wiper seal (A) for
Disassembly and Repair wear or damage. Replace as necessary.
4. When replacing wiper seal, use JDH-45 Seal
Driver (A, Fig. 50).
>*#
A Return-to-Sump Line C Lift Assist Cylinder

B Charge Pressure Line DCylinder Pressure Line
Fig. 48-Lift Assist Oil Lines
A CAUTION: Cylinder assembly does not

* have an internal stop. Use care when han- A-^JDH-45 Seal Driver BCylinder Barrel
dling to avoid unintentional disassembly of rod
and barret. DO NOT pressurize cylinder unless Fig, 5(hWiper Seai installation
properly Installed on tractor.

1. Disconnect cylinder pressure line (D, Fig. 48) at 5- Inspect bushing in the piston end for wear or
cylinder (C) and remove cylinder. damage. If bushing is replaced, It must be pressed into
2. Remove piston by pulling from cylinder barrel by its bore.
hand.
Installation
1 Connect the charge pressure line (B, Fig, 48) to

special plug on top of control valve housing. Be sure
-., .- ^BÎBI^Ste^;^
check ball is in control valve before installing special
plug.
2. Install 90 fitting with special bushing in side of
control valve housing. Connect return-to-sump line (A)
to fitting in piston cover and 90 fitting.
3. Connect cylinder pressure line (D) to cylinder (C)
and to elbow in piston cover.
4. Use the following torque specifications when in-
stalling lift assist cylinder on tractor.
a) Lift assist cylinder support-to-transmission
case cap screw - 170 ft-lbs (230 Nm) (23
kgm).
b) Lift arm special pin lock nut - 35 ft-lbs (47
Nm) (4.7 kgm).
R 300Q8N
AWiper Seal D Adjustable Elbow

BOil Seal E Piston Rod
CBarrel F Bushing
Fig. 49-Uft Assist Cylinder

.
POWER WEIGHT - TRANSFER HITCH

Repair Installation
1 Inspect all power weight-transfer hitch parts for
wear or damage. Repair or replace as necessary.

NOTE: Quik coupler, drawbar, PTO master shield,
and 3-point hitch center fink must be removed. Lift links
should be adjusted to 34-7/8 in, (886 mm). See tractor
2. Remove and disassemble control valve housing.
Operator Manual for sway block position.
Check valves and valve seats for wear or damage.
1. Attach power weight-transfer hitch coupler to

draft links using spacer sleeve between draft link ball
and pin.
2. Install control valve housing on tractor.
3. Install elbows (5 and 6, Fig. 52) in special rock-

shaft piston cover.
4. Connect two oil lines (7) and another elbow (6).
5. Install oil line from upper piston cover port to

right-hand side of the control valve with elbow (8).
6. Connect other oil line (7) with elbow in front port

on left-hand side of control \za\\/e and in the bottom port
of the piston cover.
R 27281N
7. Connect oil line (3) to rear port on control valve
A Relief Valve DBushing and to connector (23).
BValve Operating Screw EValve Operating Shaft
C-Boot FControl Valve 8. Connect one oil line (27) with coupler (26) to rear
port of control valve and to rod end of remote cylinder,
Fig. SUExpfoded View of Control Valve
9. Connect other oil line (27) with couplers to stop

3. Examine valve springs for distortion and for the
rod side of remote cylinder and to the load control arm
following specifications.
extension adjustment opening in the transmission
case.
SPRING COMPRESSED TO AT THIS FORCE
10. Remove pipe plug on the right-hand side of

Upper valve oper- 13/16 in. 4,5-5.5 lbs.
rockshaft housing (located below rockshaft vaive
ating shaft (21 mm) (20-24 N)
operating arm).
Lower valve oper- 1-1/8 in. 180-220 lbs.
ating shaft (29 mm) (800-978 N)
Control valve 15/32 in, 8-10 lbs.

(12 mm) (36-44 N)
Relief Valve 1 -5/8 in. 180-220 lbs.

(41 mm) (800-978 N)
4- Replace any worn or damaged parts.
5. Check transfer link to be sure it telescopes freely.

I
26 ^fiL 5^-4
24 ^ rjy î
22
R20232N
1O-Rtng (7 used) 11 Nut 21Adapter

2Elbow 12Gauge 22Union Adapter
3Oil Line 13Support 23Connector
4O-Ring (4 used)
5 Elbow
14Cap Screw (2 used) 24Dust Cover used)
(2
15Nut (2 used) 25Ring (2 used)
6Elbow 16Grommet 26Coupler (2 used)
7Oil Line (2 used) 17Clamp 27 Hose
8Elbow 18Oil Line 28Connector
9Cap Screw 19 Elbow 29O-Ring
10Clip 20Washer
Fig. 52-Hose Connections
11. Connect gauge oil fine to rockshaft housing.
12. Mount gauge support with gauge to rear of

control lever console next to the operator's seat.
13. Attacrr gauge oil line to gauge.

Hydraulic Repair Selective Control Valve and Remote Cylinder 70-20-1
Group 20
SELECTIVE CONTROL VALVE, BREAKAWAY COUPLER,
AND REMOTE CYLINDER
SELECTIVE CONTROL VALVE AND E. Apply maximum 35 psi (2.4 bar) air pressure
BREAKAWAY COUPLER into the throttle valve bore.
4. Remove hex screws retaining the selective con-

trol valve to the rockshaft housing flange, and remove
selective control valve.
5. Check valve adjustment using the procedure

given on page 8.
Breakaway Coupler Disassembly

1. Drive a punch into the expansion plugs (25, Fig.
2) in the coupler housing and pry them out.
2. Remove retaining rings (24), springs (23),

operating levers (29), and snap-ring (8).
3. Use a brass drift to drive receptacle assembly

from housing.
4. Remove steel balls (12) from receptacle.
5. Press down on receptacle plug (20) and remove

Fig. 1 -Selective Control Valve Mounting Positions snap ring from receptacle.
Removal 6. Drive plug, spring, and ball (18) from receptacle

using a brass drift.
1. Before removing selective control valve assem-
bly, check operating linkage for binding, wear, or bro-
ken parts. Be sure that linkage is not preventing the
selective control valve from operating properly.
2. Disconnect control linkage from selective control

valve operating arm.
3. When removing left-hand SCV relieve hydraulic

pressure and drain oil from rockshaft cavity using the
following procedure:
A. Place the rockshaft console lever in the full
forward position.
B. Place the lever for the left-hand selective

control valve in the float position.
C. Remove the throttle valve from the rockshaft

piston cover.
I
D. Place a clean container beneath the selective
control valve and open receptacles.

70-20-2 Selective Control Valve and Remote Cylinder Hydraulic Repair
Breakaway Coupler Assembly and Repair

1. Replace any parts that are worn or damaged.
NOTE: Dip all internal parts in John Deere Hy-Gard

Transmission and Hydraulic oil prior to assembly. Be
sure to keep all parts clean.
2. Replace O-rings and backup rings.
3. Replace the oil seals (27, Fig. 2) in the breakaway

coupler housing. Install with the grooves in the seals
facing each other.
4. Install valve ball (I, Fig. 3), spring (H), and plug (G)
in each receptacle and replace snap ring.
5. Install snap ring (9, Fig. 2) on each receptacle,

replace steel balls (12), and sleeve (22) over assembly
to hold balls in place for installation.
6. Install receptacle assembly in coupler. Snap-ring

ABackup and O-ring HSpring
holds in place. BRetaining Ring I Ball
CSpring J Lever
DSleeve K Backup and O-ring
EOil Seals LReceptacle with Balls
FSnap Ring and Snap Rings
GPlug MBackup and O-Ring
Fig. 3-Breakaway Coupler Assembly
20
14 17 19 |
35
28090N
34 ^
1Snap Ring (2 used) 8 Snap Ring(2 used) 17Backup Ring (2 used) 26Housing
2Spring Guide (2 used) 9Snap Ring (2 used) 18 Ball (2 used) 27Oil Seal (2 used)
3Spring (2 used) 10Backup Ring (2 used) 19 Spring (2 used) 29 Lever (2 used)
4Ball (2 used) 11
O-Ring (2 used) 20Plug used)(2 30Cam
5Plug pressure,
(1 12Ball (12 used) 21 Snap Ring (2 used) 31_Washer
return)
1
13 O-Ring (4 used) 22Sleeve (2 used) 32Cap Screw
6Cover used)
(2
14 Backup Ring (4 used) 23Spring (2 used) 33Washer
7Plug (1 pressure,
15 Receptacle (2 used) 24 Retaining Ring (2 used) 34 Retaining Ring
1 return)
16 O-Ring (2 used) 25Plug (2 used) 35 Cover used) (2
Fig. 2-Exploded View of Breakaway Coupler

SELECTIVE CONTROL VALVE

Disassembly
AValve Cap D Detent Pin and Guide AFlow Control Vatve B Detent Pin
B~-Metering Valve E Flow Control Stop Valve
CVatve Guide Fig. 5-Flow Control Valve Removal
Fig. 4~Cap Removal

3. Remove flow control valve (A Fig. 5) and spring.
A CAUTION: Poppet valve springs are com-

pressed. Carefully remove valve cap. If
springs momentarily hang up in housing, the valve
4. Remove snap ring and pull
detent piston bore.
outer guide from
NOTE: It may be necessary to remove rocker as-

guides can be propelled from the housing with
sembly to remove detent piston assembly. With rocker
considerable force. assembly removed, detent piston assembly can be
pushed out by pushing on the detent pin.
1. Remove retaining screws and cap (A, Fig. 4)
from housing.
2. Remove the flow control valve stop, valve guides,

springs, pressure and return valves from housing. Note
which parts are removed from each bore. Damage may
indicate housing or seat damage.
Fig. 6-Removing Rocker Assembly
5. Rotate valve housing in vise so rocker (D, Fig. 6)

faces upward.
6. Drive out pin (A) holding control arm shaft (B) to

the rocker assembly. Remove rubber keepers (C).
Remove arm and shaft.

Disassem bly Continued
H^jf: ::::::.-. ;::::?;:!"". :r
Ênxftr
^KH:::;:;:::::: ":;;:;;:*
A Rocker B^Detent Cam C"Float" Cam

R 28G89N
Fig. 7-Rocker and Cam Removal
A Return Valve Seat B Pressure Valve Seat
7. Remove cam holding screws and remove rocker
Fig. 8-Checking Valve Seats
assembly from housing (A, Fig. 7).
If resurfacing valve seats is necessary, repair as

8. Remove operating cams, noting position of each
follows:
cam for reassembly,
Wash the valve housing, making sure valve seats

9. necessary, remove inner detent guide by re-
If
are free of any foreign material.
moving follower and driving out wrth a brass drift.
Dip the coarse stone with NJD 150-R Driver in
solvent and insert the driver into the valve bore (Fig. 9).
Housing
Inspect housing for wear or damage. Remove nicks

and burrs with a fine file. Replace housing if cracked.
Inspect valve and valve seats for damage (Fig. 8).
NOTE: if SCVLeak Test (page 270-30- 14) indicates

a leak, repiace vafves and perform test again.
IMPORTANT: Do not grind valve seats unless

there are visible signs of damage.
ASpeed Wrench end Socket B Reseating Tool (Fine)

C Reseating Tool (Coarse)
Fig. 9-Using NJD-150 Seat Repair Kit

.
Apply downward pressure on the speed handle until Cap

the roll pin is approximately one-half way in the siot in
1 Inspect cap and cap packing for damage (30, Fig.
the pilot guide. This is to insure that spring is not
1 1 ), replace as necessary.
completely compressed, causing improper force on
stone.
2. Check flow control valve stop (A, Fig. 10) for
damage. Replace backup ring and O-ring as neces-
Rotate the speed wrench and coarse stone 50 turns.
sary, A short stop can cause jerky operation. Length is
0.94 in. (24 mm).
Wash the valve bores, and dip the JD 150-F pilot
with fine stone in solvent.
Rotate the speed wrench 20 turns using the same

precautions required with the coarse stone.
Wash bores and valve seats.
With bluing on the valve seating surface, check the

seat surface by turning the valve in its bore. Repeat
procedure if a good seat pattern is not evident.
R 28301N
A Flow Control Valve Stop C Backup ring
Dfa
B O-Ring
2
Fig. 10-Flow Control Valve Stop
! 8 9
12
11
I
17 !f Vf'
R 2SG91N
1 Snap Ring 9 Pin 18 Spring (2 pressure, 25Spring

2 Outer Guide 10 Follower 2 return) 26 Metering Valve
3 Backup Ring 11 Roller 1 9 Valve Guide (4 used) 27O-Ring
4 O-Ring 12Housing 20O-Ring (4 used) 28 Backup Ring
5 Spring 13 Backup Ring (6 used) 21 Backup Ring (4 used) 29Thrust Washer
6 Detent Piston 14 O-Ring (6 used) 22 Packing 30Cap
7 Detent Pin 15 Roller (4 used) 23 Flow Control Valve 31Spring Pin
8 Inner Guide 16 Spring Pin (4 used) Stop 32Arm
17Valve (4 used) 24 Flow Control Valve 33Cap Screw {4 used)
Fig. 11 -Exploded View - Selective Control Valve Assembly

.
Inspection and Repair Continued

Valves and Detent Piston Assembly
1 Inspect valves for scoring or damage and replace 1. Dip new O-rings, backup washers, and parts in
as necessary. clean John Deere HY-GARD Transmission and Hy-

2. Check valve rollers (15, Fig. 11) for flat spots, draulic OiL Use care to keep all parts clean.
pits, or wear. Replace as necessary.
3. Check pressure, return, flow control, and detent

piston springs for the following specifications and re-
place as necessary.
FREE WORKING
SPRING LENGTH LOAD
Pressure Valve 1.72 in. 1.20 36-44 lbs.

in. at
(43.7 mm) (30.5 mm
160-196 N)
at
Return Valve 1.53 in. 1.20 m. at 18-22 lbs.
(39.0 mm) (30.5 mm at 90-93 N)
Row Control 2.95 in. 2.15 m. at 41-50 lbs.
Valve (75.0 mm) (55 mm at 182-222 N)
Detent Piston 1.60 in. 1.25 in. at 19-23 lbs.
(40.5 mm) (32 mm at 85-102 N)
mm3Ei
4. Inspect detent assembly for scoring or damage.

A-JDH-28 Driver
Be sure pin will move freely in guides.

Fig. 12-inner Detent Piston Guide installation
5. Inspect rocker, operating and detent cams. (End of driver shown)
2. Drive inner detent piston guide into bore using

JDH-28 driver (Fig. 12).
R 28092N'
1Housing 5 Detent Cam 10 Pin (2 used) 14 Spring Pin

2Cap Screw (4 used) 6Rocker 11 Valve Operating Cam- 15 O-Ring (2 used)
3Special Screw (2 used) 7 Set Screw (4 used) "Roar 16 Plug (2 used)
AValve Operating Cam 8 Keeper (2 used) 12 Packing 17 O-Ring (2 used)
"Regular" 9 Packing 13Arm with Shaft
Fig. 13-Exploded View of Selective Control Valve Rocker Assembly

Hydraulic Repair Selective Control Vafve and Remote Cylinder 70-20-7
5. Install detent piston spring (D). Install O-ring,

backup ring, outer guide (E) and retaining snap ring.
6. Install pressure and return valves in their proper

bores (see Fig. 15).
NOTE: Pressure valves use two O-rings and two

backup rings each. Return valves use only one O-ring
and one backup ring.
7. Install JDH-15C Special Adjusting Cover. Tighten

cover cap screws just enough to retain poppet valve in
place.
mm?iz%
A Detent Pin
Fig. 14-lnstalling Detent Pin
3. Install detent pin (A, Fig. 14) in bore. Install detent

pin with short shank part of pin first.
R 2S302N
A"Float' Cam' DCam Pins

B Detent Cam E Rocker
C "Regular" Cam F Adjusting Screw
Fig. 16-Rocker and Cam Assembly
8. Separate "float" and "regular" operating cams for

proper installation.
9. Insert detent cam (B, Fig. 16) in rocker assembly

(E) and install cam pins (D).
A^Pressure Valves D Detent Piston Spring
B Return Valves E Outer Guide 10. Invert the housing for installation of the rocker
C Detent Piston
assembly.
Fig, 15-Detent and Valve Assembly
4. Install detent piston (C, Fig. 15) with shoulder

facing outward.

Assembly Continued Adjustment
NOTE: With the selective control valve in neutral, (

the pressure and return poppet
valves are adjusted by
setting a specified distance between the operating
cams and the valve rollers. This specified distance
insures that the return valves open before the pressure
valves, and that maximumflow through the selective
oil
control valve can be maintained.
1. Remove the selective control valve cap, the four

poppet valve guides and springs, and the flow control
valve stop.
A Detent Follower D Detent Cam with Pins

B "Regular" Operating E"Roar Operating
Cam Cam
CRocker F Pressure Valve
Follower
Fig. 17-Hocker and Cam installation

R34763
11. Insert detent piston follower (A, Fig. 17) in bore AAdjusting Cover C Back Off or Remove
in housing. B Pressure Valve Lock D Return Valve Lock
Screws Screws
12. Place operating cams on poppet valve followers
Fig. 18-JDH-15C Special Adjusting Cover
(F). Pointed end of cams are installed toward the
detent piston follower (A). 2. Back off locking screws (B and D, Fig. 18) so
screws are flush with bottom of adjusting cover (A).
NOTE: "Float" cam (E) is shorter than the "regular" Back off or remove screw (C).
cam (B) and is installed on the numbered side of the
housing. 3. Tighten JDH-15C Special Adjusting Cover (A) on
the selective control valve housing.
13. Install rocker assembly (C) with the pointed end
of the detent cam (D) over the detent foflower (A). 4. Invert the valve housing so the rocker assembly
faces upward in a vise.
14. Install special cam screws through housing into
rocker and install operating arm with shaft
in the same
manner.
15. Align arm shaft hole with hole in rocker and

install spring pin to retain shaft.
TM-1181 (Jun-80) Lithe in U.S.A. Tractors - 4040 and 4240

.
W4610
ft 2B008N
A Cam Holding Screw D Lock Screws A Dial Indicator D Pressure Adjusting

B Cam EValve Seats B Return Adjusting Screw
CValve Follower Rollers Screw E Cam Holding Screw
C Allen Wrench Bore
Fig. 19-PreIiminary Setup F Lock Screw
(SCV cut-away shown)
Fig. 20-Adjusting Selective Control Valve
Loosen the cam holding screws (A,

5. Fig. 19) so
the cams (B) rest on the valve follower rollers (C), 9. Install a dial indicator (with minimum 0.140 in.
Leave screws slightly loose. [3.55 mm] travel). Dial indicator contact (A, Fig. 20)
should be 2 in. (51 mm) from the center of the rocker
6. Turn all cover lock screws (D) in to hold afl
shaft. Zero the indicator at the midpoint of its travel.
valves on their seats (E).
Maintain this zero reading during ail four valve adjust-
IMPORTANT: Do NOT use a wrench on any of ments.
the adjusting cover lock screws. Tighten with
fingers only. 10. Tum all adjusting screws (B, D) in until they just
touch the cams. Do not apply pressure. If the screws
7. Rotate the rocker assembly to visually make sure
appear uneven, check the cam for tilt,
the valve operating cams are riding on the valve fol-
lower rollers. (The valves could rotate 90 preventing
1 1 Back out the cam adjusting screws over the
proper cam contact.}
return valves (B) 1/8 turn, and the screws over the
Rotate the rocker to its neutral position. The
8. pressure valves (D) 1/4 turn.
detent follower can be felt as the small neutral notch in
the detent cam passes over it. The rocker should be 12. Loosen the two adjusting cover lock screws (F),
nearly level with the top edge of housing. opposite the lever side of the housing. Adjust only one
side at a time.

.Q40-.08O in.
(1 .22-2.03 mm)
IMI
R34611
^^
ACam Holding Screw
C Cam Adjusting Screws
BCams
D Lock Screws R34612
Fig. 21 -Positioning Cams
A Rocker Assembly D Cam Adjusting Screws

13. Tighten both cap holding screws (A, Fig. 21) B Cam EAllen Wrench
tight enough not to move during normal operating O- DiaJ Indicator F Pressure Valve
conditions, They will not be tightened again. G Return Valve
Fig, 22-Adjusting Selective Control Valve

14. Use a pry-bar or large screwdriver through cam
holding screw bore (E, Fig. 20) to pry cams (B, Fig. 21)
NOTE: Refer to Fig. 20 for pressure and return
up against the adjusting screws (C).
valve location.
IMPORTANT: Adjust only the valves that are up 14. Rotate the rocker (A, Fig. 22) in both directions.
and seated with the adjusting cover lock screws.
a) As the cam (B) touches the return valve
Each time the cam adjusting screws are backed
roller, the dial indicator should read 0.008-
away from the cams, the cams must be pried back
0.040 inch (0.20-1.02 mm).
up against the adjusting screws. DO NOT LOOSEN
b) As the cam touches the pressure valve roller
cam holding screws.
in the other direction, the indicator should
read 0.048-0.080 inch (1.22-2.03 mm).
c) Turn the cam adjusting screws in to de-
crease or out (and cams pried up) to in-
crease the distance to obtain these specifi-
cations.
NOTE: Occasionally check the "zero" reading on

the dial indicator as directed in Steps 8 and 9. (

Selective Control Valve and Remote Cylinder Hydraulic Repair 70-20-11
15. Back out the adjusting cover valve locking 2. Attach control lever linkage so the lever is 1/4-
screws on the lever side of the housing. 1/2 inch (6-13 mm) from float stop when lever is in the
retract detent position (Fig. 3).
16. Turn in the adjusting cover valve locking screws
on the opposite side of the housing to hold the other
3. Check and fill the main reservoir with John Deere
pressure and return valves on their seats.
HY-GARD Transmission and Hydraulic Oil.
NOTE: The same zero reading must be maintained

during all four valve adjustments. 4. Perform the selective control valve tests as de-
scribed on page 270-30-11.
17. Adjust these two poppet valves the same way
the first two were adjusted.
Inlet Check Valve (Optional)
NOTE: Remember, pressure and return valves are
diagonally located from each other in the valve hous-
ing.
18. After all four valves are adjusted, recheck the

zero reading and all four valve adjustments.
19. Install the flow control valve and spring, stop,

(with pin pointing inward), valve springs, and guides.
Torque cap screws to 35 ft-lbs (47 N-m) (4.7 kgm).
NOTE: Be sure flow control valve stop is started

squarely in the bore.
IMPORTANT: Do not remove valves. If valves

H 23304N
are removed, they must be readjusted in the hous-
ing.
AInletCheck Valve DO-Ring

B Metering Valve E Backup Ring
Selective Control Valve Installation
C Thrust Washer
1. Wfth packings in place, install selective control Fig. 24-lnlet Check Valve
valve on rockshaft housing or rockshaft valve cover.
1. Inspect O-ring (D, Fig. 24) and backup ring (E)
for damage: Replace as necessary.
2. Install the check valve (A) in the left-hand selec-

\/k - 1/2 IN. tive control valve or the valve that tends to settle.
(6 - 13 MM.)
1 3. Be sure the check vafve is installed open end first

in front of the metering valve (B). The metering valve
and inlet check valve (A) are a matched set and must
be used together. Install a teflon washer between the
metering valve and the cap before assembly.
R 28017N
A Float Lockout Stop BSCV Levers in

Retract Position
Fig. 23-Adjusting Selective Control Valve Levers

REMOTE CYLINDER
Disassembly
1? 13 14
1O cb=
15 16
2 34 5
J
31 30^>
B16336N
1Plug 14Stop Valve 27Groove Pin

2Stop Rod Packing Adapter 15Stop Valve Spring 28Stop Rod Arm
3V-Packing 16Oil Passage Gasket 29Cap Screw
4Stop Rod Packing Adapter 17 End Cap 30O-Ring
5Stop Rod Packing Spring 18Cap Screw 31Backup Ring
6Remote Cylinder 19 Gasket 32Oil Seal
7Washer 20Special Lock Nut 33Stop Screw
8Stop Rod Spring 21 Backup Ring 34-Washer
9Stop Rod Washer 22O-Ring 35 Stop Lever
10 Stop Rod 23 Piston 36Spring Pin
11 Snap Ring 24O-Ring 37 Piston Rod Stop
12Bleed Valve Spring* 25 Piston Rod Guide Gasket 38Piston Rod with Yoke
13Bleed Valve and Ball* 26 Piston Rod Guide *Used on "Over-ride" only
Fig. 25~Expioded View of Hydraulic Stop Remote Cylinder
1. Remove cylinder end cap (17, Fig. 25). Repair and Assembly
1. Inspect all parts for wear and damage. Replace
2. Remove stop valve assembly (14) by pushing
parts as necessary.
stop rod (10) into the cylinder to its limit. Do not lose
steel ball on stop rod. After removing bail, (if equipped)
2. Replace all O-rings, gaskets, backup washers,
bleed valve (13) can be removed from stop rod.
seals, and packings.
3. Secure rod with yoke (38) when removing special

lock nut (20).
3. Clean and dip all parts in John Deere HY-GARD
Transmission and Hydraulic Oil.
4. Remove piston (23) and rod from cylinder.

4. Press new piston rod oil seal (32, Fig. 25) into
guide with sealing lip toward outer end of bore.
5. Remove stop rod assembly by driving groove pin
(27) from stop rod arm (28). Push rod into cylinder all
the way to prevent distortion of rod while driving pin.

RffivlSZ
APiston Rod with Yoke F Special Lock Nut LStop Rod Packing Spring
B Rod Stop and Lever G End Cap with Gaskets
- M Stop Rod Packing Adapter
C Piston Rod Guide HGasket N Packing
DCylinder IStop Valve Spring OStop Rod Packing Adapter
E Piston with O-Ring JStop Valve PGroove Pin
and Backup Rings K Stop Rod and Spring Assembly QStop Rod Arm
Fig. 26~Hydraulic Stop Cylinder Assembly
5. Install stop rod V-packing (N, Fig. 26) with seal-

ing edge toward cylinder.
6. Install piston rod guide (C) and gasket. Do not

tighten guide cap screws at this time.
7. Install stop rod assembly. Push rod through V-
packing using stop valve assembly.
8. Install piston rod guide cap screws to 35 ft-lbs (47

N-m) (4.7 kgm) torque.
9. Push stop rod all the way into the cylinder and
install groove pin (P).
10. Install stop valve assembly. With ball in the

recess, push valve assembly into cylinder.
11. Install piston rod (A).
12. Install backup rings with O-ring between them

on the piston.
13. Install piston on rod and push piston into cylin-

der.
Fig. 27-Tightening Piston Rod Nut
> 14. With the yoke-end of the piston rod held in a

vise, tighten the special lock nut to 300 ft-lbs (407 N-m)
(40.7 kgm).
Assembly Continued Bleeding the Remote Cylinder

1 5. Locate the piston rod stop on the piston rod with
the stop lever opposite the stop rod arm.
16. Install gasket on end cap.
1 7. Install the two oil passage gaskets. Place spring

over end of stop valve and install end cap.
18. Tighten end cap screws to 120 ft-lbs (163 N*m)

(16.3 kgm) torque.
19. Bleed air from cylinder.
ASelective Control Valve BMetering Valve Arm

C Remote Cylinder
Fig. 28-B!eeding the Remote Cylinder
1. Connect the remote cylinder to a breakaway
coupler on a selective control valve (A, Fig. 28).
NOTE: Be sure hose on stop side of cylinder i$

connected to left-hand receptacle to assure remote
cylinder extension.
2. Start tractor and operate cylinder eight times to
remove trapped air in the cylinder.
NOTE: Air will bleed faster if the cylinder is placed

in a vertical position with the hose end upward.

Miscellaneous Specifications and Special Tools 80-00-1
Section 80
MISCELLANEOUS
GROUP 00 - SPECIFICATIONS 00-1 GROUP 10 - WHEELS
Front Wheels
GROUP 05 - FRONT AXLES Removal, Inspection and Repair 10-1
Adjustable Tread Axle Assembly 10-1
Checking Pivot Pin Bushing Rear Wheels
Wear 05-1 Removal 10-2
Removal 05-1 Disassembly 10-3
Inspection and Repair 05-2 Rear Wheel Tread 10-3
Installation 05-2 Double Rear Wheels 10-3
Knee Assembly
Removal 05-3
Inspection and Repair 05-3
Assembly and Installation 05-4
Toe-ln Adjustment 05-5
Power Front Wheel Drive Axle 05-5
Group 00
SPECIFICATIONS
Front Axles
ITEM SPECIFICATION
Axle pivot pin bushing I.D. (assembled) 1,497 to 1 .503 in. (38.01 to 38.16 mm)
Axle pivot pins (front and rear) 0,D 1 ,494 to 1 .495 in. (37.95 to 37.97 mm)
Knee bushing I.D 1 .747 to 1 .753 in, (44,4 to 44.5 mm)
Front axle pivot bolt shims 0.01 5 in. (0.4 mm)
Steering spindle end play 0.010 to 0.040 in. (0.2 to 1 mm)
Toe-in adjustment 1/8 to 3/8 in. (3 to 9 mm)
ITEM TORQUE VALUE
Axle pivot bolt, front 220 ft-ibs (298 Nm) (29.8 kgm)
Axle-to-knee bolts (adjustable tread axle) 320 ft-ibs (433 Nm) (43.3 kgm)
Tie rod end-to-steering arm nut 100 ft-lbs (135 Nm) (13.5 kgm)

80-00-2 Specifications and Special Tools Miscellaneous
Steering arm-to-spindie cap screw 170 fHbs (230 Nm) (23.0 kgm)
Tie rod clamp nuts 35 ft-lbs (47 Nm) (4.7 kgm)
Steering gear arm-to-steering spindle cap screw 300 ft-ibs (406 Nm) (40.6 kgm)
Rear Wheels
H"EM SPECIFICATION
Maximum single rear wheel tread (heavy loads) 1 1 in. (2.79 m)

Minimum tire-to-fender clearance 1 in. (25 mm)
ITEM TORQUE VALUE
Special Wheel Bolts 300 ft-lbs (407 Nm) (40.7 kgm)

Cap Screw Wheel)
(Pinion Half to 160 ft-lbs (217 Nm) (21 J kgm)
Steel Disk Wheel Retaining Cap Screws (Double Wheels) 300 ft-lbs (407 Nm) (40.7 kgm)
Rim Clamp Bolts 170 ft-lbs (231 Nm) (23.1 kgm)
SPECIAL TOOLS
TOOL NUMBER USE
Front Axles
JDG-7 Lift Bracket used in front axle

removal.
Fig. 1-JDG-7 Lift Bracket*

Miscellaneous Specifications and Special Tools 80-00-3
TOOL NUMBER USE
A - D-05007ST Splitting Stand to remove front

I axle.
B - D 05149ST Adapters for use with

D-05007ST Splitting Stand.
R 280BSN
Fig, 2-Spfitting Stand and Adapter
A - D-01045AA Bushing and Seal Driver Set for

bushing and seal installation
and removal.
* Fig. 3-Bushing and Seal Driver Set
TM-1181 (Sep-77) Who in U.S.A. Tractors - 4040 and 4240

:
80-00-4 Specifications and Special Tools Miscellaneous
TOOL NUMBER USE (
Wheels
JCKM8 Snap Ring Tool to remove axle
snap ring.
:l::-:;:|!;!:;;;i!:-'
:
\ ;
; : :
:
'1%;''
:^'-$&i'' <r'
:
tili^LS.::iY':Jfi
|BS!fe;
~r. ::: : ;t ;t:-;H:: :
^::".^~.
.
jifllrilPhf^H^
:-^wm^^jmpaSiiimM^
r
:
ii;| 1 1] j iiaiilB^SEHPÎIliBBr
. . :u.':::::JP^MfllEn^BL'iHi:^: : .
::;;- '^Wj^mlM^^^^-
'
::!:i;-|iill ':..; Jn^îS||;: ::

^j' :
"
W0Sz-$^^g&
:'
?* 'r&ja&jiHp:
Fig. 4-JOG-18 Snap Ring Tool
D-05018ST Wheel Lift to remove rear

wheel.
Fig. S-D-0S018ST Wheel Lift
<
TM-1181 (Sep-77) Utho in US, A Tractors - 4040 and 4240

Miscellaneous Front Axles 80-05-1
Group 5
I
FRONT AXLES
Checking Pivot Pin Bushing Wear Removal
;c:;::::::;:::::::;:j:;:::::::::::rj{fe;S
Fig, 1-Checking Pivot Pin Bushing Wear Fig. 2-Front Axle Removal Steps
1. Install JDG-7 Front Lrft Bracket on front end. 1. Remove tie rods from steering arm.
2. (Not Illustrated) Install JDG-7 Front Lift Bracket

2, Attach an overhead hoist to lift bracket. on front end.
3, Attach a dial indicator base to axle. 3. (Not Illustrated) Attach an overhead hoist to lift
bracket.
4. Position contact point of indicator arm on bottom 4. (Not Illustrated) Place support stand under trac-
of front support.
tor.
5, (Not Illustrated) After zeroing indicator dial, raise 5. Extend axle, if necessary, to provide access to
front end of tractor until wheels leave ground. front pivot bolt,
6. D-05007ST and Adaptors

Attach Splitting Stand
6. (Not Illustrated) Read indicator for amount of D-05149ST assembly. Be sure stand is
to the axle
wear on bushing. If wear exceeds 0.040 in. (1 mm), supporting the weight of the front axle before removing
inspect bushing and pivot pin for wear.
pivot bolts.
7. Remove nuts from pivot bolts,
8. (Not Illustrated) Raise hoist until weight of front

end is removed from axle.
9. (Not Illustrated) Remove pivot bolts.
10. Carefully roll axle assembly rearward off pivot

pins.

80-05-2 Front Axles Miscellaneous
Inspection and Repair 4. Use disks and driver from removal procedure to
1. (Not Illustrated) Use an inside micrometer to
install new bushing.
check front bushing inside diameter (
(Not Illustrated) Inspect bottom of rear pivot pin
5.
Pivot pin bushing I.D.

and top of front pivot pin for grooving or signs of wear.
is 1 .497 to 1 .503 inches (38.01
to 38.16 mm).
6. The O.D. of both front and rear pivot pins is
1.4940 to 1.4950 in. (37.95 to 37.97 mm).
Installation
ADriver B^-Large Disk CSmall Disk

Ftgr 3-Removing Pivot Pin Bushing
2. Use Driver No. 27489 with Disk No. 27509 and

Disk No. 27508 to remove pivot pin bushings.
R 26620N
$0^ <*>
Fig. 5-Front Axie and Support
1. Insert pivot pins in their bores..
2. Move axle into position under front support.
NOTE; When installing front pivot pin bolt use the

necessary number of shims to obtain clearance be-
tween axle and support. Thickness of each shim is
0,015 in. (0.4 mm).
3. Install front pivot pin bolt with head of bolt facing

forward, and tighten nut to 220 ft-lbs (298 Nm) (29.8
kgm). If slots in nut do not line up with cotter pin hole in
bolt, tighten nut to the nearest castellation and insert
D"X" Pattern E Bushing Bore Grease Hole cotter pin.
Fig. 4-lnstafiing Pivot Pin Bushing 4. Install rear pivot pin bolt with head of bolt facing
forward, and tighten nut securely.
3. When installing either front or rear pivot pin
bushing, make sure "X" pattern (D, Fig. 4) is 180
10 from grease hole (E) in bushing bore.
TM-1181 (Sep-77) Litho in U.S.A. Tractors - 404O and 4240

. .
5. (Not Illustrated). Connect tie rods to steering arm. Inspection and Repair
6. (Not Illustrated). Tighten tie rod-to-steering arm

nut to 100 ft-lbs (135 Nm) (13.5 kgm).
KNEE ASSEMBLY
Removal
1 Jack up side of axle containing knee assembly to
be repaired (Fig. 6).
2. Remove hub cap, cotter pin and slotted nut.
NOTE: When removing wheel assembly with bear-

ings, do not let bearings fall out.
3. Remove wheel.
4. Remove steering arm-to-spindle cap screw. Fig. 7-Checking Knee Bushing
Use an inside micrometer or telescoping gauge

1
tomeasure inside diameter of both upper and lower

bushings in knee (Fig. 7).
2. The I.D. of the knee bushing is 1 .747 to 1 .753 in.
(44.4 to 44.5 mm).
3. Use a heavy drift punch to remove bushing.
Fig. 6-Removing Spindle
IMPORTANT: Prevent spindle from striking

ground when removing (Fig. 6).
5. Strike steering arm with a hammer to remove

spindle (Fig. 6).

.
Fig. 8~lnstalling Knee Bushing Fig. 10-Checking Knuckle End Play
1 Make sure grease hole in bushing is aligned with 4. (Not Illustrated). Install steering arm on spindle.
grease hole in knee when installing bushing.
5. (Not Illustrated). Tighten steering arm-to-spindie
2. Use Driver No. 27489 with Disk No. 27514 and cap screws to 170 ft-lbs. (230 Nm) (23 kgm). Strike
Disk No. 2751 1 to install knee bushings. steering arm with hammer and re-torque.
6. Place a dial indicator on axle.
7. Move knuckle up and down while observing indi-

cator. End play should be 0.010 and 0.040 in. (0.25 to
1.01 mm)
8. Add or subtract washers to obtain correct end

play.
Fig. 9-lnstaliing Spindle
3. Make certain pins in knee and axle align with

notches in thrust washers when installing.
(
TM-1181 (Sep~77) Litho in U.S.A. Tractors - 4040 and 4240

Toe-In Adjustment NOTE: Distance from center of inner tie rod end (A,
Fig. 12) to end of tie rod tube (B) should not exceed
1- Turn steering wheel until the front wheels are
1-7/8 in. (48 mm).
pointing straight ahead, parallel to the centerline of the
tractor.
7. Tighten tie rod clamp nuts to 35 ft-lbs (47 Nm)
(4.7 kgm).
POWER FRONT WHEEL DRIVE AXLE

Removal
rgjS^rggK
Fig. 1 1-Correct Toe-In
2. Measure distance from left tire to right tire at rear

of tires.
3. Measure distance from left tire to right tire at front

of tires. (Fig. 11)
.-_ . .
Jifcfr - M
:<
fe"nnwm "^îiiBif-fffflll I
NOTE: Front measurement should be 1/8 to 3/8 in,
(3 to 9 mm) less than rear measurement
J||ipll ^^^p^p^^ 1
4. Remove bolts from tie rod tubes. gjBii aBBi

Fig, 13-Axte Housing and Steering Mechanism
5. Loosen clamps on inner end of tie rods.
1. (Not illustrated) Install JDG-7 Front Lift Bracket

6. Turn tie rod tubes in or out until toe-in is correct.
on front end.
2. (Not illustrated) Fasten an overhead hoist to Lift

1-7/8" (48 mm) Bracket.
MAX*
3. Remove tie rods from steering arm.
4. Remove front wheels.
5. Remove return oil pipe from adjustable tee.
6. Remove flexible oil line from adjustable tee.
7. Remove oil lines from control valve, also charge

R 267G4N line.
ACenter of inner Tie Rod End B End of Tie Rod Tube
Fig. 12-Tie Rod Tube Extension
>

.
Removal Continued
Fig. 14-Cortirot Valve Removal
8. Disconnect wiring connector and discharge line.
9. Disconnect drain lines.
10. Remove control valve bracket-to-control valve

cap screws.
1 1 Lower control valve assembly.
12. (Not Illustrated) Place caplugs over ends of

pipes, hoses and fittings,
1 3. Extend axle if necessary to provide access to

front pivot bolt.
14. Attach Splitting stand D-05007ST and Adaptor

D-05149ST to the axle assembly. Be sure the stand is
supporting the weight of the front axle before removing
pivot bolts.
15. (Not Illustrated) Raise hoist until weight of front

end is removed from axle.
16. Remove pivot bolts.
17. Carefully move axle assembly rearward off of

pivot pins.
18. Follow inspection, repair and installation proce-

dures on p. 80-05-2. For service of the Power Front
Wheel Drive Unit, see Section 50,
<

.
Miscellaneous Wheels 80*10-1
Group 10
WHEELS
FRONT WHEELS
Removal, Inspection and Repair
1.
assembly
(Not Illustrated) Raise side of axle containing
to be repaired.
Wm
1
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NiBal
^B^BPiPifflpi - 1
^^BP? .:
:!
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^P^B-^ 2"^"* '
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ij:;Tit:t"
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ism 'W Mky9k it?--. -j
Fig. 2-Removing Bearing Cups
9. Position a punch in special cut-out in hub, then

drive bearing cups from hub (Fig. 2).
10. (Not Illustrated) Inspect oil seal for leakage,

R 26705N cracks or brittleness.
Fig. 1-Front Wheel Assembly

1 1 (Not Illustrated) Remove oil seal by driving from
spindle with a punch.
2. Remove hub cap,

Assembly
3. Remove cotter pin.
4. Remove slotted nut.
5. Remove hub with wheel from spindle.
6. Remove bearings.
7. Inspect both inner and outer bearing cups for

wear.
8. Inspect bearings for worn rollers.
Fig. 3-fnstaHing OH Seal
1. Use an old chisel with a rounded off point to

carefully drive oil seal onto spindle (Fig. 3).
TM-1181 (Sep-77) Litho in U.S,A. Tractors - 4040 and 4240

60*10-2 Wheels Miscellaneous
Assembly Continued 4, Use JDG-18 Snap Ring Tool to remove axle

snap ring (Fig. 4).
2. (Not Illustrated). Use a punch to drive bearing
I
cups into hub and make sure cups are
f fully seated.
3. (Not Illustrated). Pack bearings with wheel bear-

ing grease.
4. (Not Illustrated). Insert bearings in hub.
5. (Not Illustrated). Pack oil seal lips with John

Deere Multi-Purpose lubricant or equivalent,
6. (Not Illustrated). Place hub on spindle.
7. (Not Illustrated), install adjusting nut and tighten

until a slight drag is felt when the wheel is rotated,
8. (Not Illustrated). If slots in nut do not line up with

cotter pin hole, back off nut to nearest castellation and
insert cotter pin.
REAR WHEELS
Removal Ftg. 5-Removing Wheel
1. (Not Illustrated). Clean the axle with a steel

brush.
5, Loosen the three special bolts approximately 3/8
in. (10 mm).
2. (Not Illustrated), Position the tractor so that the

rack on the axle is up.
6, Tighten the two jack screws evenly (maximum
200ft-lbs [271 Nm] [27.1 kgm] torque) until the sleeve
loosens.
3. (Not Illustrated). Jack up the tractor.
7. Move D-05018ST Wheel Lift into position.
8. Turn the pinion gear to move wheel off of axle.
NOTE: If sleeve is difficult to break loose, also

loosen the three special screws on inside of the wheel.
If sleeve will still not break loose, strike the end of the
axle several times with a heavy hammer; then evenly

retighten the jack screws. Repeat this procedure until
the sleeve loosens.
Fig. 4-Removing Snap Ring

Miscellaneous Wheels 80-10-3
Disassembly Assembly
1. (Not illustrated). Remove plug from hub which Reverse the disassembly steps and tighten to the
covers pinion shaft hole. torque specified below.
Sleeve retaining cap screws

(6, Fig. 7) 160 fUbs (217 Nm) (22 kgm)
Ill Special bolts
(8, Fig. 7) 300 ft-lbs (300 Nm) (41 kgm)
Rear Wheel Tread

NOTE: When pulling heavy loads, Umit single rear
wheel tread to 110 inches (2.79 m).
A CAUTION: For tractor stability, never

operate with single tires having tread width
less than 60 inches (1.52 m).
IMPORTANT: Tires must have at least one inch

(25 mm)clearance with the fenders. The minimum
Fig. 6-Removing Pinion and Pinion Shaft
tread setting for all tire sizes is 42 in. (1.07 m)
between the tires, with each tire equidistant from
2. Use a punch to drive out pinion shaft.
the center line of the tractor.
3. Remove pinion from wheel.

DOUBLE REAR WHEELS
R 267 18H
Fig. 7-Cast Disk Drive Wheel
R26716I3
4. Remove retaining rings from the two jack screws.
AMinimum Gap of 4" Between Tires
5. Remove jack screws. BHub
CWheel Retaining Ring
6. Remove sleeve retaining cap screws. D Center of Tires
Fig. 8-Wheel Spacing
7. Remove sleeve.
8. Remove special bolts.
I 9. Remove sleeve.
ThA-1181 (Feb-78) Lhho in U.S.A. Tractors - 4040 and 4240

80-10-4 Wheels Miscellaneous
DOUBLE REAR WHEELSContinued

When using double wheels, always maintain a min-
imum gap (A Fig. 8) of 4 inches (100 mm) between
tires. Insufficient gap may damage tires.
When a wheel must be repositioned or removed, it is

very important that the inner wheel rim clamp nuts and
hub special bolts be securely tightened. The outer steel
disk wheel retaining cap screws should be tightened to
300 ft-ibs (407 Nm)
(40.7 kgm) torque. After driving
tractor for about 20 revolutions of the wheel, and
BEFORE working tractor, retighten wheel retaining cap
screws to 300 ft-lbs (407 Nm) (40.7 kgm) torque. After
working tractor for about 3 hours and again at 10
hours, retighten wheel retaining cap screws and keep
them tight.
When removing a double wheel wheel

for single
operation, always remove wheel and
the steel disk
operate tractor on the cast disk wheel. Be sure to
operate within tread limitations.

5
8
6
7
9
Operator Station Repair Specifications and Special Tools 90-00-1
Section 90
>
OPERATOR STATION REPAIR
Page
GROUP 00 - SPECIFICATIONS AND GROUP 05 - AIR CONDITIONING
SPECIAL TOOLS SYSTEM Continued
Specifications Receiver- Dryer
Air Conditioning System 00-3 General Information 05-15
Cap Screw Torque Chart 00-4 Removal 05-15
Special Tools 00-5 Repair 05-15
Installation 05-1
GROUP 05 - AIR CONDITIONING SYSTEM Evaporator
Refrigerant Couplings General Information 05-16
General Information 05-1 Removal 05-1
Service 05-1 Repair 05-16
Compressor Removal 05-2 Installation 05-16
Leak Testing Compressor 05-2 Regulatory Controls
Voltmetric Efficiency Test 05-2 Expansion Valve
Shaft Seal Leak Test 05-3 General information 05-17
Compressor Clutch and Shaft Seal Removal 05-1
Assembly 05-4 Repair 05-18
Disassembly 05-5 Installation 05-1
Assembly 05-8 Temperature Control Switch
Checking and Adding Compressor Oil 05-12 Generai Information 05-18
General Information 05-12 Removal 05-18
When Compressor
Servicing 05-12 Installation 05-19
When System Components
Servicing Compressor Relief Valve
Other Than Compressor 05-13 General Information 05-19
Compressor Installation 05-13 Removal 05-1
Condenser, Receiver-Dryer, and Repair 05-19
Evaporator Installation 05-1
Condenser 05-14 Air Intake System
General Information 05-14 Pressurizer Blowers and Switch
Removal 05-14 General Information 05-21
Repair 05-14 Removal 05-21
Installation 05-14 Repair 05-21
Installation 05-21
Blower Switch Removal 5-22
Switch Repair 5-22
Switch Installation 5-22
Air Filters
Removal 05-22
Service 05-22
Installation J . 05-22
>

1
90-00-2 Specifications and Special Tools Operator Station Repair
CONTENTS OF THIS SECTION Continued

Page Page <
GROUP 10 - HEATING SYSTEM GROUP 20 - MISCELLANEOUS COMPONENTS
System Components Sound-Gard Body Frame
Heater Valve General Information 20-1
General Information 10-1 Repair 20-1
Removal 10-1 Body Door and Door Panels
Repair 10-1 General Information 20-2
Installation 10-1 Removai
Heater Core Door 20-2
General information 10-1 Door Stop 20-2
Removai 10-1 Door Handle and Latch 20-2
Repair 10-1 Door Panel 20-3
Installation 10-2 Hinge Replacement
Heater Blowers 10-2 Replacing The Upper or Center
Heater Pipes and Hoses 10-2 Hinge 20-3
Replacing Lower Hinge 20-4
GROUP 15 - SEAT Replacing Ail Three Hinges or
Servicing SeatComponents 15-1 Door 20-5
Removal 15-1 Exterior Panels
Armrest Assembly General Information 20-6
Removal 15-2 Removal
Repair 15-2 Rear Panels 20-6
Installation 15-2 Side Panels 20-7
Cushions and Seat Belts installation 20-7
Removal 15-3 Roof Panels
Repair 1 5-4 Removal
Installation 15-4 Outer Roof 20-8
Horizontal Support Assembly Inner Roof 20-8
Removal 15-4 Installation 20-9
Repair 1 5-6 Glass and Attaching Hardware;
Installation 15-6 Moldings and Seals
Swivel Assembly General Information 20-1
Removal 1 5-6 Removal 20-1
Installation 15-6 Installation 20-12
Vertical Suspension Assembly Control Support with Covers and Cowl
Removal 15-8 General Information 20-13
Repair 1 5-8 Service 20-13
Installation and Adjustment 1 5-8 Headliner and Upholstery
Removal
Front Headliner 20-15
Rear Headliner 20-15
installation 20-15
Radio, Tape Player and Windshield
Wiper Motors 20-15

Operator Station Repair Specifications and Special Tools 90-00*3
Group 00
SPECIFICATIONS
Air Conditioning System
Compressor
Hub and drive plate assembly 0.0002-0.0007 in. mm) press fit to shaft
(0.005-0.018
Plate assembly to pulley clearance 0.022-0.057 in. (0.559-1 .45 mm)
Mainshaft assembly end play 0.0003-0.0013 in. (0.008-0.033 mm)
Oil charge (new or rebuilt) 11 fluid oz. (312 mL) Frigidaire 525 oil
Pulley diameter Approx. 5-5/8 in. (142.8 mm)

Rear head-to-shell nuts 24-26 ft-lbs (32-35 Ntn) (3.2-3.5 kgm)
Refrigerant valve retaining cap screw 25 ft-lbs (34Nm) (3.4 kgm)
Hub and drive plate iocknut 14-25 ft-lbs (19-34 Nm) (1.9-3.4 kgm)
Oil drain plug 10-15 ft-lbs (14-20 Nm) (1 .4-2.0 kgm)
High pressure relief 10-14 ft-lbs (14-19 Nm) (1-4-1-9 kgm)
Compressor Drive Belt
Size 1/2 in. (12.7 mm)
Tension
New belt 130-140 lbs. (578-622 N)
After run in 85-94 lbs. (378-423 N)

90-00-4 Specifications and Special Tools Operator Station Repair
Hose and Tubing Flare Connection Torques
Aluminum or
Metal Tube Thread and Steel Tubing** Copper Tubing* Nominal Torque
Outside Diameter Fitting Size Torque Torque Wrench Span
ft-lbs (Nm) (kgm) ft-ibs (Nm) (kgm)
1/4 7/16 10-35 (14-47) (1.4-4.7) 5-7 (7-9) (.7-.9) 5/8 in.
3/8 5/8 30-35 (41-47) (4.1-4.7) 11-13 (15-18) (1.5-1.8) 3/4 in.
1/2 3/4 30-35 (41-47) (4.1-4.7) 11-13 (15-18) (1.5-1,8) 7/8 in.
5/8 7/8 30-35 (41-47) (4.1-4.7) 18-21 (24-29) (2.4-2.9) 1-1/16 In.
3/4 1-1/16 30-35 (41-47) (4.1-4.7) 23-28 (31-38) (3.1-3.8) 1-1/4 in.
a connection is made with steel to aluminum or copper, use the tower torque
*//
specification,
*Use steef tubing torques only when both ends of connection are steeL
Hose and Tubing O-Ring Connection Torques

Metal Tube Thread and Torque
Outside Diameter Fitting Size ft-lbs(Nm) (kgm)
1/4 7/16 10-15 (14-20) (1.4-2)

3/8 5/8 10-15 (14-20) (1.4-2)
1/2 3/4 24-29 (33-39) (3.3-3.9)
5/8 7/8 26-31 (35-42) (3.5-4.2)
3/4 1-1/16 30-35 (41-47) (4.1-4.7)
CAP SCREW TORQUE CHART ft-lbs (Nm) (kgm) *The types of bolts and cap screws are identified by
head markings as follows:
Three Six
Plain Head: regular machine bolts and cap screws.
Diameter Plain Head* Radial Dashes* Radial Dashes*
3-Dash Head: tempered steel high-strength bolts
1/4 6 (8) (.8) 10 (14) (1,4) 14 (19) (1.9) and cap screws.
5/16 13 (18) (1.8) 20 (27) (2.7) 30 (41) (4.1) 6-Dash Head: tempered steef extra high-strength
3/8 23 (32) (3.2) 35 (47) 50
(4.7) (68) (6.8) bolts and cap screws.
7/16 35 (47) (4.7) 55 (75) (7.5) 80 (108) (10.8)
1/2 55
**Machine bolts and cap screws 7/8-inch and larger
(75) (7.5) 85(115) (11.5) 120 (163) (16.3)
9/16 75 (102) (10.2) 130 (176) (17.6) 175 (237)
are sometimes formed hot rather than cofd which
(23.7) t
5/8 105 (142) (14.2) 170(230) (23) 240 (325) (32.5) accounts for the iower torque.
3/4 185 (244) (24.4) 300 (407) (40.7) 425 (576) (57.6)
7/8 **160 (217) (21.7) 445 (603) (60.3) 685 (925) (92.5)
1 **250 (339) (33.9) 670 (908) (90.8) 1030 (1396) (139.6)

Operator Station Repair Specifications and Special Tools 90-00-5
SPECIAL TOOLS
Air Conditioning *D-18012KD SEAL KIT
)
A^-2014D D2014A
Tools B2014B E2014C
C2014E
*D-18013KD PULLEY PULLER
F2015A H2015C
G2015D
*D-18014KD CLUTCH SERVICE KIT
1 2016F K2016A
J2016B
*D-18015KD BEARING SERVICE SET
L2017B M2017A
*D-1ft016KD CLUTCH HOLDING WRENCH
N2018
*D-18017KD SNAP RING PLIERS SET
O2020B P2020A
*D-1flOZ7KD CERAMIC SEAL SEAT REMOVER
Q2120
*D-18026KD SEAL SLEEVE PROTECTOR
Fig. 1-Toof$ For Servicing Air R 2121 U
1001 Puller
Conditioning Compressor SJDST-26-4B V D-010O6AA Bench
T^JDST-26-4A Holding Fixture
*Order from Service Tools Inc., Box 314, Owatonna

MN 55060.
>
90-00*6 Specifications and Special Tools Operator Station Repair
<
Operator Station Repair Air Condtioning System 90-05-1
Group 05
)
AIR CONDITIONING SYSTEM
REFRIGERANT COUPLINGS
R 31735
ATubing Adapter EGasket Seal H O-Ring

BO-Ring F Lock Nut IValve and Sleeve Assembly
C Poppet Valve Assembly G Union Nut and JO-Ring
D Body Body Assembly KTubing Adapter
Fig. 1 -Exploded View of Refrigerant Coupling
GENERAL INFORMATION Repair

For information on how the couplings function, refer If coupling leaks, replace the coupling half (male or
to page 290-05-14 in this manual. female, or both) and O-rings (B) and (J)- Valve as-
semblies (C) and (I) are not serviced separately from
SERVICE bodies. However, seal (E) is serviced separately.
Disassembly Assembly
1. Remove the male coupling half by removing the 1. Install O-rings on both adapters.
lock nut (F, Fig. 1) which fastens the coupling to the
2. Lubricate O-rings with compressor oil (525 vis-
mounting bracket on side frame brace or compressor
cosity) to prevent them from scuffing or tearing when
bracket.
coupling body is threaded on adapter.
2. Unscrew the body (D) with poppet valve assem- 3. Insert poppet valve assembly (C) into body (D).
bly (C) from the adapter (A).
4. Tighten body on adapter (A) until there is metal-
to- metal contact, and then tighten body an additional
3. Remove the O-ring (B).
1/8 in. (3 mm).
4. Remove the female coupling half by unscrewing 5. Lubricate O-ring (H) liberally with compressor oil.
the union nut and body assembly (G) from the adapter
6. Insert vafve and sleeve assembly (1) into body
<K).
(G).
5. Remove O-ring (J). 7. Tighten body on adapter (K) until there is metal-
to-metal contact, and then tighten body an additional
1/8 in. (3 mm).
>

90-05-2 Air Conditioning System Operator Station Repair
COMPRESSOR
REMOVAL A compressor that has an internal leak (discharge to {
suction side), will require replacement or rebuilding.
External leaks can usually be corrected by installing a
new shaft seal assembly (page 90-05-4).
Major repairs or testing should be done only by a
qualified refrigeration serviceman who has the neces-
sary tools and equipment.
Leak Testing Compressor

After the compressor has been removed from the
tractor, perform a volumetric efficiency test. This test
will determine the condition of internal components
(excluding shaft seal assembly). After completing a
volumetric efficiency test, perform a shaft seal leak test
to check for external refrigerant leaks. The shaft seal
leak test should again be performed after installation of
A Superheat Switch D Mounting Screw a new shaft seal assembly, to check for proper in*
Wiring Lead EAdjusting Screw stallation.
BCover Plate Screw FValve
Volumetric Efficiency Test
O-Compressor Clutch Wire
At least 1 oz. (30 mL) of oil should be present in
Fig. 2-Compressor Mounting
compressor before performing volumetric efficiency
If the compressor is operable, operate for 10 min- test. Tip compressor side-to-side and front-to-rear be-
utes by running engine at 2000 rpm with temperature fore mounting in vise.
control set for maximum cooling and blower speed on 1. Mount compressor in a vise with oil reservoir up.
high position, before removing compressor. This 2. Inspect outside of compressor for damage.
allows the refrigerant oil to be circulated in the system 3. Rotate clutch hub by hand with suction and dis-
and more nearly gives the correct quantity of oil in the charge ports open. If compressor does not rotate sat-
compressor. isfactorily, replace compressor.
Shut off engine and discharge refrigerant from sys-
tem as instructed in DISCHARGING THE SYSTEM.
NOTE: When removing the compressor, it will be
necessary to discharge the complete system.
1. Disconnect 1he wiring lead from the superheat
shutoff switch (A, Rg. 2).
A CAUTION: High pressure may still exist at

the discharge fitting. If this pressure is re-
leased too rapidly, there may be a considerable
discharge of refrigerant and oil.
2. Slowly loosen the refrigerant valve cover plate
retaining cap screw (B).
3. Remove the refrigerant valves (F) from com-
pressor.
4. Cover compressor openings immediately with R 31756
cover plate to protect O-rings and prevent entry of
moisture and dirt into compressor. A Low Pressure Gauge B High Pressure Gauge
5. Disconnect compressor clutch coil wires (C) and Vaive Closed Valve Open
remove the compressor drive belt C Speed Handle
Fig. 3-Testing Compressor For internal Leaks
6. Remove the compressor from the mounting
bracket. 4. Install D-18032KD Test Plate over suction and
7. Drain and measure oil from compressor. discharge ports (Fig. 3).
The compressor should be tested for leaks before 5. Connect manifold low pressure gauge hose to
starting disassembly. Refer to LEAK TESTING COM- discharge adapter fitting (one closest to super heat i
PRESSOR (below). shut-off switch) and connect high pressure gauge hose
to other adapter fitting.

Operator Station Repair Air Conditioning System 90-05-3
NOTE: Low pressure gauge hose is connected to 3. Open valve on R-12 container and pressurize
discharge adapter so that pressure reading taken dur- compressor to can pressure, or 60 psi (4.0 bar) (4.0
ing test can be more easiiy read, kg/cm s ) minimum.
6. Rotate compressor approximately 25 times with 4. Check for leakage from shaft seal and compres-
refrigerant valves open. sor end plate. If there is end plate leakage, replace
compressor. If there is shaft seal leakage, replace
7. Close low pressure gauge valve (A) and open shaft seal assembly.
high pressure gauge valve (B).
5. Close R-12 valve and bleed pressure from com-
8. With a 9/16 in. socket and a speed handle (C), pressor before removing adapter test plate.
rotate the compressor clutch hub ten revolutions at a
rate of one revolution per second (1 rps). Before installing compressor, be sure the compres-
sor contains the correct amount of oil. See the infor-
9. Pressure gauge should read 60 psi (4.0 bar) (4.0 mation given in CHECKING AND ADDING COM-
kg/cm 2 ) or above. A pressure reading of less than 60 PRESSOR OIL, page 90-05-12.
psi (4.0 bar) (4.0 kg/cm s ) indicates one or more suction
and/or discharge valves leaking, an internal leak, or an IMPORTANT: Compressors kept on hand for
inoperative valve. The compressor should be replaced stock purposes should be charged with refriger-
under these conditions. ant, whenever the refrigerant charge is lost. Keep
compressor openings capped until installation, to
10. If compressor is serviceable, perform shaft sea! prevent moisture and foreign material from enter-
leak test. ing compressor.
Shaft Seal Leak Test
3 25123N
A RefrigerantContainer CHigh Pressure Gauge

B Low Pressure Gauge Valve Open
Valve Open D-O-18032KD Test
Plate
Rg. 4-Testing Compressor For External Leaks
1. With adapter test plate and manifold pressure
gauge hoses attached to the compressor connect a 15

02. (450 g) can of R-12 (A, Fig. 4) to charging hose of
manifold.
2. Open both manifold pressure gauge valves (B

> and C).

COMPRESSOR CLUTCH AND SHAFT SEAL ASSEMBLY

(
R28610N
AShaft Seal EFelt Seal HCoil and Coil

BSeal Seat FPulley Bearing Housing Assembly
CPulley Front Shield I Felt Seal
DHub and Drive GPulley Bearing J
Rubber Gasket
Plate Assembly
Fig. 5~Cross-Section of Compressor Clutch Assembly

.
Disassembly 4. Use KD-2018 Clutch Holding Wrench (A, Fig. 7)

to hold the clutch hub while removing the hub and drive
plate lock nut from the compressor shaft.
A Retaining Ring B Spacer

Fig. B-Retaining Ring and Spacer
5. Remove hub drive plate retainer ring (A, Fig. 8)

and spacer (B).
ACompressor C Dust Cover

B D-01006AA Bench Holding Fixture
^'^''''iX/;:. 'Vy-'V
:
Hg. 6-Compressor Dust Cover
1 Mount the compressor vertically in a D-01006AA

(JDM-16) Bench Holding Fixture (Fig. 6).
2. Remove the three dust cover attaching screws.
3. Pull off dust cover (C).
mmwtisg.
:VrV-.. '";-!; ^
A Hub and Drive Plate B Hub Puller
Fig. 9-Removjng Hub and Drive Ptate
6. Use KD-2016B Hub Puller (B, Fig. 9) to remove

the hub and drive plate assembly (A).
A^CIutch Holding B 9/16-inch Thin
> Wrench WaiJ Socket 7. Remove hub pulling tool.
Fig. 7-Removing Lock Nut

Disassembly Continued
8. Remove hub and key from shaft.
(
NOTE: If no further disassembly is required, refer to
assembly instructions p. 90-05-11.
Fig. 12-Shaft Seal Seat Retaining Ring
12. Remove the shaft seal seat retainer ring (Fig.

Fig. 10-Bearing Seal Housing 12) from inside of compressor neck.
9. Use a punch to dent bearing sea! housing (Fig.

10) for removal. Remove housing.
AFelt Seal BSeal Retainer ASeal Seat Remover B Ceramic Seal Seat
Fig, 11 -Seal Retainer Fig. 13-Removing Shaft Seal Seat
10. Carefully pry out seal retainer (B, Fig. 11). IMPORTANT: When KD-2120 Re-
tightening
moval Tool inside of ceramic seal do not use
seat,
11. Remove felt seal (A).
excessive force. Over-tightening may cause ce-
IMPORTANT: Thoroughly clean inside of com- ramic seal seat to shatter.
pressor neck with compressed air before continu-
ing to disassemble,
13. Remove the ceramic seal seat (B, Fig. 13) using <
the KD-2120 Removal Tool (A).

A Shaft Sea! Assembly BSeal Removal Tool A Retaining Ring B Pulley Bearing
Fig. 14-Removing Shaft Seal Assembly Ftg. 16-Pufley Bearing Retaining Ring
14. Insert KD-2014B Seal Installation and Removal 17. Remove the pulley assembly retainer ring (A t
Too! (B, Fig. 14) into compressor neck. Press down on Fig. 16).
tool and twist clockwise to engage shaft sea! (A).
15. Remove shaft seal assembly by pulling straight

out from shaft (Fig. 14}.
Fig. 15-Ceramic Seat Seat O-Ring
Fig. 17-Remaving Puffey and Bearing

16. Remove the ceramic seal seat O-ring (Fig. 15)
from the interior of the compressor by using KD-2014C
18. Use KD-2015 and 2015C Puller Assembly (Fig.
O-ring removal tool.
17) to remove the pulley and bearing from the com-
pressor neck.
NOTE: if no further disassembly is required, refer to
assembly instructions p. 90-05-9.
> 19. Remove bearing using KD-2017A Driver,

Disassembly Continued Assembly

IMPORTANT: If bearing is to be replaced, be 1. Check rubber gasket, and replace if not in good (
sure to use a John Deere bearing. This bearing has condition.
a special seal to keep out dust and dirt.
20. Remove left seal from around compressor neck. 2. Install gasket on compressor.
3. Position clutch coil on compressor head casting

so the electrical terminals correspond with the mark
made previously on the compressor body.
IMPORTANT: Make sure clutch coil dowels (B,

Fig. 19) are correctly seated on compressor head
casting.
4. Replace the coil retaining ring with the flat side of

ring facing coil,
5. Install felt seal over retaining ring.
if installing the same pulley and hub drive piate

assembly, be sure to clean the contact faces of each
unit. Check surfaces for warpage caused by overheat-
Fig. 18-Coit Retaining Ring
ing. Replace those parts that show evidence of war-
page, or are badly worn.
21. Remove coil retaining ring (Fig, 18),
Note position of wiring terminals on coil housing in

relation to compressor body. Mark location if desired,
to insure correct installation.
and Bearing
Fig. 20-/nstalting Pulley with
ACoil Housing C Rubber Gasket KD-201TA and B Tool
B Dowel
6. Use KD-2017A and B Installation Tool to drive
Fig. 19-Removing Coif Housing
pulley and bearing assembly onto compressor neck
(Fig- 20).
22. Remove coil housing assembly (A, Fig. 19) and i
rubber gasket (C),
TM-1181 (Feb~79) Litho in U.S.A. Tractors - 4040 and 4240

7. Check pulley for free rotation.
8. Install pulley snap ring retainer.
AShaft Seal BSeal Installation Tool

Assembly CSeal Protector
Fig. ^-Installing Shaft Seal Assembly
AO-Ring
B Washers
13. Place KD-2121 Seal Protector (C, Fig. 22) over
Fig. 21 -Installing Seal Seat O-Ring end of compressor shaft (with thumb screw removed).
9. Coat seal seat O-ring (A, Fig. 21) with clean 14. Coat new O-ring and face of seal assembly (A)
compressor oil, and place over shaft of KD-2014E Tool with clean compressor oil.
between the two washers (B).
15. Install seal using KD-2014B Tool (B).
1 0. Pull O-ring tight and hold against tool exactly as
shown in Fig. 21. 1 6. Make sure seal is properly positioned by having
the flats of the seal assembly aligned with flats on
11. Insert tool into compressor neck, and push compressor shaft.
down firmly with a jiggling motion to allow O-ring to
snap into groove. 17. Release KD-2014B Tool from seal assembly by
twisting tool slightly counterclockwise.
12. Carefully remove KD-2014E Tool so as not to
dislodge O-ring. 18. Coat face and outside edge of new seal seat
with clean compressor oil, and install seal seat using
KD-2120Tool.
NOTE: Make sure that seal seat O-ring is not dis-

lodged, and that seal seat is making good contact with
the O-ring.
19. Install seal seat retainer ring with flat side

against the seal seat.
20. Place retainer ring in bore of compressor neck

with snap ring pliers.
>

Assembly Continued
21. Complete installation by using KD-2014D Tool (
to help force the retainer ring into the groove. Do not
use a hammer to drive in retaining ring.
22. Remove excess oil from inside the compressor

neck with a clean cloth.
NOTE: Before installing the remaining parts, the

compressor should be tested for leakage of refrigerant
(See Shaft Seaf Leak Test p. 90-05-3.)
23. Install a new felt seal by rolling the material into

a cylinder, overlapping the ends, and placing seal in
the interior of compressor neck.
24. Carefully position seal so that the ends butt

together.
A Puller B Bearing Seal Housing Installation Tool
Fig 24-lnstaiUng Bearing Seal Housing

t
27. Place a new bearing seal housing over the

pulley bearing bore.
28. Press in bearing seal housing until it bottoms
against the bearing using the JDST-26-4A Installation
Tool (B, Fig. 24) and a conventional jaw-type puller
similar to D-01205AA puller (A).
NOTE: Be sure the bearing is bottomed by turning
screw until it is difficult to turn.
ASeal Retainer CJDST-26-4B

B Driver Installation Tool
Fig. 23-instaJiing Bearing Seal Retainer
25. With felt seal properly positioned, insert a new

pulley bearing seal retainer (A, Fig. 23} into bore of
compressor neck,
26. Using JDST-26-4B Installation Tool (C) and

Driver (B) drive shield in until it bottoms on outside end
of neck,
NOTE: The outer face of the seal retainer which

contacts the bearing seaf housing has a Teflon coating.
Therefore, no lubricant of any kind should be used on
A Bearing Seal Housing BBearing Seal Housing
this surface.
Installation Tool i
Fig. 25-Bearing Seat Housing installed

32. Screw KD-2016B Installing Tool (A, Fig. 27)

onto threaded end of compressor shaft approximately
three full turns.
hub and drive plate (B) on compressor

33. Press
shaft by holding hex.
end of tool with a wrench in one
hand and using a wrench in the other hand to turn the
hex. nut.
34. Continue to press hub and drive plate until there

is 0.032 in. (0.81 mm) clearance between the drive
plate and pulley. (Use the 0.032 in. (0.81 mm) feeler
gauge provided as part of tool 2016F.)
35. Remove KD-2016B Installation Tool.
ABearing Front Shield B Shaft Shoulder C Key 36. Make certain the key has remained in place by
looking into drive plate hub.
Fig. 26-Drive Key Position
29. Position key (C, Fig. 26) so that it will protrude 37. Install hub spacer washer.
about 3/16 in. (5 mm) from shoulder of compressor
shaft (B). 38. Secure spacer with retainer ring (fiat side of ring
.30. Align hub and drive plate assembly (with key) in facing spacer).
shaft.
31. Position assembly in compressor front end 39. Install a new retaining nut on compressor shaft
casting. with the thin side of nut next to the spacer.
IMPORTANT: Do not drive or pound on hub of
drive plate assembly or on end of compressor 40. Tighten nut to 15 ft-lbs (20 Nm) (2 kgm). (Use
shaft. Use the proper tools to prevent possible KD-2018 Clutch Holding Wrench to hold clutch from
shifting of swash plate position (keyed to main turning while tightening nut.)
shaft), which might cause compressor damage.
41. Check the gap between the drive plate and
pulley for specified cfearance of 0.022-0.057 in. (0.56-
1.45 mm).
J?2S*ZS
> A Hub Installing Tool B Hub and Drive Plate

Fig. 27'instaiiing Hub and Drive Plate

90-05*12 Air Conditioning System Operator Station Repair
Checking And Adding When Servicing Compressor

Compressor Oil
1. Place compressor in a horizontal position with (
the drain plug downward.
General Information
The compressor oil flows throughout the system with 2. Remove the drain plug and while tipping the
the refrigerent when the system is operating, lubricat- compressor back and forth and rotating the compres-
ing the compressor parts, in general, it is not neces- sor shaft, drain the oil.
sary to question the oil level in the system unless there
is evidence of a significant loss of refrigerant (hence, a Measure the
3. oil in a bottle or container that is
significant loss of oil) from: graduated in fluid ounces (or milliliters).
1. Broken hose 4. Discard the oil
2. Severe leak at hose fitting 5. If more than 3 fluid ounces (89 mL) was drained
from the compressor, add 6.5 oz, (192 mL) of new oil
3. Leaking compressor seals back into the compressor.
4. Coflision or upset damage to system compo- 6. If3 fluid ounces (89 mL) or less was drained, add
nents. 8 fluid ounces (237 mL) of new oil to the compressor.
If the compressor or one of the other major system

When installing a new or rebuilt compressor that has
components (condenser or evaporator) has been re- a full charge of oil ounces [312 mL]), drain the
(11 fluid
moved for servicing, the oil level should be checked. oil and save it. Place the required amount of oil that
To check the oil level in the system, the compressor was saved back into the compressor in the amount
has to be removed from the engine. When oil is re- instructed in Steps 5 and 6.
quired, pour 525 viscosity refrigerant oil into the oil
drain tube of compressor. When a compressor that has been over-
installing
hauled (and has not been filled with a full charge of oil),
IMPORTANT: Use care when checking and add 1 extra ounce (28 mL) to the amount given in steps
addingoil. Too much oil In the system will reduce 5 and 6.
maximum cooling capacity. Too little oil will result
in poor lubrication of the compressor leading to 7. Install compressor (see COMPRESSOR IN-
early compressor failure. STALLATION; page 90-05-13).

When Servicing System Components 1. Install compressor on tractor.

Other Than Compressor
2. Connect the magnetic clutch control wiring.
When replacing system components, the
other
compressor wili also have to be removed. Follow in-
3. Install compressor drive belt and tighten, using a
structions given above for checking compressor oil and
belt tension gauge, to 130-140 lbs. (578-622 N) on a
add the foJfowing amounts of oil for each listed com-
ponent being replaced:
new beft, or 85-94 fbs. (378-423 N) after run in.
Evaporator 15 fluid oz. (45 ml_)

immediately after run in (approx. 10 minutes) check
Condenser 1.0 fluid oz. (30 mL)
tension. If tension is within specification, no adjustment
is necessary. If tension is not within specification, wait

NOTE: If the complete system was purged with
10 minutes; loosen belts and tension to specifications.
components in place, the amount of oil lost is consid-
Tension front belt only.
ered to be negligible.
any component has been removed, the oil drained

k CAUTION: New compressors are charged
If
and the component individually flushed the amount of

** with a mixture of nitrogen, Refrigerant-12,
oil listed above for that component should be added to

and 11 fluid oz. (312 mL) or Frigidaire 525 viscosity
oil. If the cover plate is removed too rapidly, oil will
the compressor.
be blown out with the sudden release of pressure.
If the complete system was disassembled and all
and components
When installing an exchanged or rebuilt compres-
lines compressor) were
(including the
individually drained of oil and flushed, the full charge of
sor, SLOWLY remove the cover plate from the com-
pressor valve fittings to bleed off any pressure that may
oil (11 fluid oz. [312 mL]) should be added to the
exist in the compressor.
compressor when system is reassembled.
Coat the compressor manifold O-ring packings with

COMPRESSOR INSTALLATION compressor oil and install refrigerant valves on com-
Before installing compressor, be sure the compres- pressor. Tighten cover plate screw to 25 tWbs (34 N-m)
sor contains the correct amount of oil. See the infor- torque.
mation given in CHECKING AND ADDING COM-
PRESSOR OIL, page 90-05-12. IMPORTANT: Prevent dirt or moisture from en-
tering thecompressor manifold assembly. Gauge
IMPORTANT: Compressors kept on hand for port caps should be in place.
stock purposes should be charged with refriger-
ant, whenever the refrigerant charge is lost* Keep Be sure to flush the complete system if com-
compressor openings capped until installation, to pressor failed internally due to broken parts or
prevent moisture and foreign material from enter- seizure. Refer to FLUSHING THE SYSTEM, page
ing compressor. 290-10-22.
NOTE: Before installing compressor, rotate the If was discharged and opened up for
the compressor
compressor shaft 4 or 5 times. This permits proper service, the system must be evacuated and recharged.
lubrication of compressor seal over all its surface. Be Refer to CHARGING THE SYSTEM, page 290-10-25.
sure to remove ail excess oil from the outside surface
of the compressor to prevent oif being thrown onto the
magnetic clutch.

.
CONDENSER, RECEIVER-DRYER, AND EVAPORATOR

CONDENSER 4. Remove oil cooler-condenser.
General Information 5. Measure the oil from condenser to know how

much will be required when repair has been made.
The condenser is mounted directly in front of the
radiator. Airis drawn through the condenser by the
6. Cap or plug condenser and hose fittings.
engine fan, permitting heat exchange to take place.
Repair
Be sure condenser core is not plugged with
that the
dirt or trash, or excessive heat and pressure may build 1. Remove the caps or plugs from openings. If
up, causing system to not function properly. contamination is evident in condenser, flush system.
Removal 2. Examine condenser core for possible restrictions

or sources of trouble. The fins should be straight and
Depressurize the air conditioning system as in-
free of dirt and trash.
structed in DISCHARGING THE SYSTEM, page 290-
10-22.
3. Cap the outlet connection and install a
Schrader-type service valve in the inlet opening.
4. Place refrigerant container in a pail of water

heated to a maximum of 125F (51.5C) which gives a
pressure of 167.5 psi (12 bar).
5. Connect refrigerant supply to the Schrader valve.
6. Open refrigerant container valve and test con-

denser for leaks witha leak detector (see LEAK
TESTING, page 290-10-26). if the aluminum con-
denser core leaks, replace with a new one.
7. Plug or cap openings until ready to install.
Installation
Reverse the removal steps. Use a torque chart

(Group 00, this section) as a guide for tightening con-
nections on pipes and hoses.
AInlet and Outlet B Oil Cooler Hoses

NOTE: If the condenser was repaired or replaced
Hoses CCap Screw witha new one, pour 2 fluid oz. (56 mL) of oil into
condenser. If there were any major leaks in the system,
Fig. 28-Removing Condenser (Typical refer to CHECKING AND ADDING COMPRESSOR
Installation)
OIL, (page 90-05-12).
1 Disconnect the condenser inlet and outlet hoses Purge system with R-12 or dry nitrogen.
(A, Fig. 28).
Evacuate and charge the system.

2. Disconnect the oil cooler hoses (B, Fig. 28).
3. Remove cap screw (C).

.
RECEIVER-DRYER 2. Disconnect the tnfet and outlet fittings on re-

ceiver-dryer (B, Fig. 30).
)
3. Remove the receiver-dryer ciamp (A) and re-
move assembly. Cap or plug openings.
4. Plug lines to prevent contamination.
Repair
The receiver-dryer assembly is not repairable. To
service a malfunctioning unit, replace with a new one.
Whenever the system is opened up for service and
the receiver-dryer two years old or older replace the

is T
receiver-dryer. When the system is opened up for

service and the receiver-dryer is less than two years
old, do not replace receiver-dryer unless contamina-
tion is found in system.
A InletFrom D Outlet To
Condenser Expansion Valve Always install other system components before in-
B Desiccant E Pick-Up Tube a new receiver-dryer. This will help keep the
stalling
CSight-Glass F RIter Pad receiver-dryer from absorbing additional moisture prior
Fig. 29-Cross-Section of Receiver-Dryer to evacuation.
General Information Installation
Fig. 29 shows the receiver-dryer in cross-section. 1 Reverse the removal procedure for installing unit.
To obtain information on how this unit works, see page
u
290-05-16. NOTE: Install with the top" label at the top (12:00)
position.
Removal
2. Refer to torque chart in Group 00 for tightening
Depressurize the system as instructed
1. in DIS-
refrigerant pipes,
CHARGING THE SYSTEM, page 290-10-22.
IMPORTANT: Be sure to keep new receiver-
dryer capped until ready to Install. Install receiver-
dryer last.
3. Purge system with R-12 or dry nitrogen.
4. Evacuate and charge system (page 290-10-24

and 25).
A Clamp B Receiver-Dryer
Fig. 30-Receiver-Dryer Removal
>

.
90*05-16 Air Conditioning System Operator Station Repair
EVAPORATOR 7. Remove insulation from expansion valve (B).
General Information 8. Disconnect sensing bulb, evaporator inlet and (

outlet fittings (C).
The evaporator constructed of aluminum and
is
greatly resembles an ordinary cooling system radiator. 9. Disconnect expansion valve equalizer line fitting
Refrigerant travels through tubes located within the (E).
core.
10. Remove sensing tube (F) from evaporator core.
To obtain maximum cooling efficiency, the refriger-
Note location, so that it can be reinstalled in same
ant must remain in the evaporator for a sufficient length
place,
of time to completely vaporize. Too little or too much
refrigerant entering the evaporator will limit refrigerant IMPORTANT: The tube connecting the bulb to
capacity to absorb heat. the expansion valve contains a low pressure gas.
The regulatory controls for the evaporator are the To avoid improper valve action, do not kink or
expansion valve and the thermostatic temperature pinch the tube, or dent the bulb.
control s witch
11. Remove evaporator core mounting screws (G,
Fig. 31), and lift out core.
Removal
12. Cap openings.
Depressurize the system as explained
1. in Dis-
charging The System, page 290-10-22.
Repair
2. Remove the two cap screws from the top and
three cap screws at front of roof. If contamination is evident in system, flush compo-
Raise roof, and remove the cover-to-housing
3. nents (page 290-10-22).
sheet metal screws.
Accessible minor leaks may be repaired, but the
evaporator should be replaced if there is a restriction or
a major leak in the core. The core should be tested with
at least 50 psi (3 bar) when testing for leaks.
Installation
Before installing evaporator, check the condensate

drain tray (which is an integral part of the inner roof and
directly under the evaporator) to make sure that it is
clean and that the outlets on both ends are not

plugged.
Fig. 31 -Evaporator and Heater
4. Partially drain cooling system.

5. Remove heater hoses from heater core.
6. Remove insulation from sensing bulb (D, Fig.
R 25129N
31).
A Inner Roof D Bushing

B Hose and Clamp E Packing
C Tube
Fig. 32-Condensate Drain Tube and Hose

A drain hose (B, Fig. 32) at each end of the drain tray NOTE: If the evaporator was repaired or replaced
is routed down through the hollow front members of the new one, pour 1. 5 fluid oz.
with a (45 mL) of oil into the
body to remove the condensate water to the outside. evaporator. If there were any major leaks in the sys-
Each hose is clamped at the upper end to a tube (C) tem, refer to CHECKING AND ADDING COMPRES-
that is interlocked with a bushing (D) and sealed to the SOR OIL (page 90-05-121
condensate tray (inner roof) with rubber packing (E).
10. Purge system with R-12 or dry nitrogen.
Access to the drain tube and hose assembly is
obtained by removing the switch panel bezel and rear 11. Evacuate and charge system (page 290-10-24
headliner from inside the body. (See Group 20 of this and 290-10-25).
section for further information.)
12. Leak check system,
condensate water leaks around rubber packing,
If
break out the tube and remove bushing with packing- 13. Thoroughly wrap expansion valve, sensing
Install new packing on bushing and insert into hole- bulb, and adjoining section of the inlet refrigeration
Slip a new tube into bushing, pushing in firmly until it pipe (Portion within compartment) with insulation tape
locks in bushing. to prevent condensate drip.
1. Inspect drain hose for cracking, splitting, or any

other form of deterioration and replace as required. REGULATORY CONTROLS
2. Be sure split hoses on top of body frame front EXPANSION VALVE
members are in place to protect the drain hoses from
General Information
chafing.
For information on how the expansion valve works,
Route drain hose over split hose, but under foam
3. see page 290-05-16.
blocks which are just above the split hose,
Removal
Route drain hose down through body front
4.
1. Depressurize the system as instructed in Dis-
members and clamp the upper end securely to the
charging The System, page 290-10-22.
drain tube. Make small loop in drain hose and band
loop to retain water (trap).
5. install rubber plug at bottom of posts,
6. Remove caps from evaporator core openings

and reverse the removal instructions.
NOTE: Expansion valve sensing bulb, evaporator

outlet pipeand temperature sensing tube have to be
clean and free from corrosion. Good contact is neces-
sary for proper operation.
7. temperature control switch sensing tube in

Insert
Fig. 33-Roof Mounting Screws
evaporator atsame location as when removed. (See
page 90-05-20.)
three screws at front of roof (Fig. 33).
8. Connect hoses and fill cooling system.
3. Raise roof, and remove the cover-to- ho using

9. Bleed air from system if necessary. See "Instal-
sheet metal screws.
lation" on page 90-10-2 of this section.
Use care when tightening parts. Refer to the torque

chart in Group 25 when necessary.

Removal Continued General Information

4. Remove the insulation from sensing bulb and The purpose of the temperature control switch (A,
expansion valve. Fig. 31 shows the insulation re- Fig. 34) is to regulate the temperature of the refrigerant
moved. in the evaporator corresponding to the control knob
setting selected by the operator. See page 290-05-10
5. Disconnect sensing bulb (D, Fig. 31). for information on how the switch operates.
6. Disconnect expansion valve (B) inlet and outlet Removal

fittings.
7. Disconnect equalizer line fittings (E).
2. Remove sensing tube from evaporator core (Fig.
31).
8. Plug or cap openings after removing valve and
bulb.
3. Remove the control panel retaining screws.
IMPORTANT: If valve seems to have been

operating properly, be careful not to kink or pinch 4. Remove control knob from switch.
the tube connecting the sensing bulb to the valve

body when removing the unit.
Repair
Since there are no external adjustments, an im-
properly working expansion valve must be replaced by
a new one.
Installation
Before installing valve, remove the caps from open-

ings and check screen in valve inlet for foreign materi-
al. If is present, remove the screen and
foreign material
clean. screen is clogged, replace receiver-dryer. Do
If
ATemperature Control Switch B Retaining Nut
not allow contamination to enter valve. Reverse the
removal steps. Fig. 35-Temperature Control Switch Removal
TEMPERATURE CONTROL SWITCH 5. Unscrew switch retaining nut (B, Fig. 35).
6. Disconnect wiring and remove switch (A).
Testing
The temperature control switch is not designed to be
repaired as such. However, it should be tested for
proper operation.
1. Using an ohmmeter, attach leads to control

switch terminals.
2. Fill a container with ice, water, and some rock

R 31758
salt.
ATemperature Control Switch BSensing Tube

3. Insert a thermometer into the water.
Fig. 34-Temperature Control Switch
4. Set knob on temperature control switch to max-
imum cooling (turn clockwise). (

.
5. Insert sensing tube into container. COMPRESSOR RELIEF VALVE

6. After one minute, observe reading on ohmmeter. General Information
7. Ohmmeter should read no continuity (contacts

open).
p i|^|
:
f
8. Remove sensing tube and hold in hand while
r ;::*i::- <
observing ohmmeter.
9. Ohmmeter should register continuity (contacts

" -^ ""^tH? "Hrej^ ". =
closed). :
Jf! -
:
.
^. .îfent^dttt:? :^^^.;;^--p^^^ :| :
:t;^ k ..
:
jgf S ;| ^^gjg^N;. ,,
^^^-^
: --pppt^'" ^^^
the switch does not operate properly, replace
_
1
--^=
10.
:
^^^^^
;:..: _ .... :: . : ...
If t
with a new one.

'
TT
nllliilllillll m^^mm^;,.. li.... :; ; :.; H
fR i^Mmm^^m^^:::::\:. SaO^BSSEBriK
NOTE: Switches are preset to correctly regulate the
temperature in the evaporator. Fig. 36-Compressor Relief Valve
Installation The compressor relief valve (Fig. 36) is located in

the rear head of compressor. To obtain information on
The sensing tube should be inserted vertically be- how this valve works, see page 290-05-17.
tween and second refrigerant tubes into the evap-
first
orator core 15 in. (381 mm) from the left hand side. Removal
Insert the tube the full depth of core.
If frosting of the evaporator core occurs (generally in

A
CAUTION: High pressure may still exist at
the discharge fitting. If this pressure is re-
leased too rapidly, there may be considerable dis-
high humidity areas), move the tube towards the ex-
pansion valve, which on the left end of the core. This
is charge of refrigerant and oil.
means that the tube will be moved towards the frosted

1. Discharge the refrigerant from compressor (page
area of the core, since the expansion valve end of the
core is the coldest end. 290-10-22).
Inserting the sensing tube into a colder area of the 2. Slowly remove the valve (Fig. 36) from com-
pressor in case some high pressure still remains.
core cause the contact points to open sooner, thus
will
retarding frost on the evaporator core. In low humidity

areas, it may be desirable to move the sensing tube Repair
toward the right hand side of the evaporator, especially The valve is not designed to be repaired. If the valve
ifthe system cycles too frequently. does not operate properly or has been damaged, re-
place with a new one.
IMPORTANT: Do not pinch or kink the sensing
tube. If necessary to reshape tube to fit into core, Before replacing valve, make sure that there is not a
avoid making too sharp a bend. malfunction somewhere else in the system.
Reverse the removal steps. Installation
1 install valve on compressor.
2. Add refrigerant as required (page 290-10-23).

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Air Conditioning System Operator Station Repair 90*05-21
AIR INTAKE SYSTEM

PRESSURIZER BLOWERS AND SWITCH
General Information 4. Disconnect wiring connectors and lift out assem-
bly.
The pressurizer blowers draw fresh outside air
The mounting base fastened to rubber cushions
is
through the air intake openings in cab roof, pulling the
using bolts with self-locking nuts. To gain access to the
air through the air intake filter, evaporator and heater
mounting bolts, first remove the air louver bezel (which
cores, and discharge the conditioned air inside the
is secured with 14 screws) from inside the body. Bolt
SOUND-GARD body.
heads will then be in direct view.
The pressurizer blowers have to be in operation 5. Blowers may be removed from the motor shaft on
before the air conditioning system will function. Gen- all models after first removing the spring retainer clips.
erally speaking, the blowers should be in operation

most of the time, not only to direct cooled or heated air Blower Removal
into the cab, but to prevent dirt or dust from entering
around panels and doors, by pressurizing the inside
SOUND-GARD body (Serial No. 167014- )

air.
three screws from front of roof.
On Tractors with SOUND-GARD body (Serial No. 2. Raise roof, and remove the cover-to-housing
167014- a three speed, single blower motor
) sheet metal screws.
was adopted. The following information covers both
early and late models.
Blower Removal
SOUND-GARD body (Serial No. -167013)

three screws from front of roof.
2. Raise roof, and remove the cover-to-housing

sheet metal screws.
A-Clips C Blower Retaining Clips
BScrews
Fig. 39-Blower Assembly
3. Remove the four screws (A, Fig. 39) securing

upper half of housing to lower half.
4. Remove the eight clips (B), and lift off upper half
of housing.
5. Disconnect blower motor wiring connectors. The
blower motor with blowers can now be lifted from lower
half of housing.
6. To remove a blower from the drive shaft, remove
retainer clip (C) and slide blower from shaft.
A Retainer Clip CScrews Repair

BBlower Housing DMounting Base
The blower motors and switch are not repairable. If
Fig.38-Blowers and Housings (Shown Attached
the motor or switch fail to perform satisfactorily, the
to Mounting Base For illustration Purposes)
part should be replaced.
The blower and motor assembly (Fig. 38) may be
removed without removing the mounting base (D) Installation
since the blower housings (B) are individually replace-
Place assembly in position and reverse removal
able.
steps.
> 3. Remove the four housing-to-mounting base
screws and the four motor mounting screws (C).

90-05*22 Operator Station Repair Air Conditioning System
Blower Switch Removal Loosen the knobs (A, Fig. 41) to open the filter
access door.
1. To remove blower switch, remove the air louver
bezel retaining screws and bezel (if not done pre-

viously).
2. Remove switch control knob.

A Foam Recirculating C Access Door
Filter D Filter Element
B Safety Catch
Fig. 42-Air Filter Element
Depress the safety catch (B, Fig. 42) at the front of

A Retaining Nut B Blower Switch
the door and remove the door (C) and filter (D).
Fig. 40-Blower Switch Removal
3. Unscrew switch retaining nut (A, Fig. 40).

Service
4. Disconnect wiring and remove switch (B). Clean the filters by one of the following methods:
Repair A. Tapping
The blower motors and switch are not repairable. If Tap filter gently on a flat surface dirty side down.
the motor or switch fail to perform satisfactorily, the
part must be replaced. B. Compressed Air
Installation
Direct compressed air (100 psi maximum) (7 bar)
(7 kg/cm 2 ) through filter.
Place assembly in position and reverse removal
steps. C. Water Washing
AIR FILTERS 1. Soak filter in warm water and R36757 John
Deere Cleaner for 15 minutes.
Removal
2. Rinse until clean (maximum water pressure -
40 psi (3 bar) (3 kg/cm 2 ).
3. Air dry - do not use compressed air.
Replace filter if ruptured, or if not cleanable.
NOTE: The recirculating filter MUST be kept clean

AAccess Knobs B Safety Catch or cooling efficiency will be reduced considerably.
Bg. 41 -Access Door
Installation
Carefully place filter element on door and install

door. Tighten knobs securely.

AIR FILTERS Service

Clean the filters by one of the following methods:
Removal
A. Tapping
Tap filter gently on aflat surface dirty side down.
B. Compressed Air
Direct compressed air (100 psi maximum) (7 bar)

(7 kg/cm 2 ) through filter.
AAccess Knobs BSafety Catch
C. Water Washing
Fig. 38-Access Door
1. Soak filter in warm water and R36757 John
Deere Cleaner for 15 minutes.
Loosen the knobs (A, Fig. 38) to open the filter
access door.
2. Rinse until clean (maximum water pressure -
40 psi) (3 bar) (3 kg/cm 2 ).
3. Air dry - do not use compressed air.
Replace filter if ruptured, or if not cleanable.
NOTE: The recirculating filter MUST be kept clean
or cooling efficiency will be reduced considerably.
Installation
AFoam Recirculating CAccess Door Carefully place filter element on door and install
Filter DFilter Element door. Tighten knobs securely.
BSafety Catch
Fig. 39-Air Fitter Element
Depress the safety catch (B, Fig. 39) at the front of

the doorand remove the door (C) and filter (D).
TM-1181 (Sept-77) Litho in U.SA. Tractors - 4040 and 4240


Operator Station Repair Heating System 90-10-1
Group 10
HEATING SYSTEM
SYSTEM COMPONENTS
HEATER VALVE Repair
General Information The valve is not designed to be repaired internally. If
the valve fails to shut the coolant

completely or off
otherwise fails to perform properly, replace with a new
one. Be sure the heater boses are correctly connected
to the engine. If hoses are reversed, a satisfactory
heater valve will not operate properly, and may be
permanently damaged.
Installation
1. Reverse the removal steps, making sure the
hose clamps properly seal hoses to prevent leaking.

2. Connect the heater core outlet (upper front
corner) hose to the valve inlet (long leg). The return
Fig. 1-Heater Valve

hose connects to the valve outlet (short leg).
3. Fill cooling system.
The heater valve shown ina device for
Fig. 1 is 4. Start engine and check for proper operation.
controlling engine coolant circulation in the heater
core. Opening the valve allows coolant to circulate HEATER CORE
through the core, while the pressurizer blowers draw in
air through the heater core to give the desired heating General Information
effect. The heater core (A, Fig. 2), is combined with the air
The valve is designed so that the coolant flows from conditioning evaporator core and is similar to a cooling
1
the heater core outlet to the top (long "leg ') of valve system radiator.
and out the bottom (short "leg") of valve.The quantity The pressurizer blowers draw air through the heater
of coolant flowing through the valve depends upon the core and blow the air through the air outlet panel into
control setting, varying from no flow through maximum body.
flow. Coolant enters the heater core at the lower rear
A
direct-mounted control knob on the cab console fitting, flows through the core and out the outlet fitting at
regulates the valve. upper front corner.
Removal Removal
1. Drain a portion of the cooling system, and re- Follow evaporator "Removal" steps page 90-05-16
move control knob. to remove heater core.
three at front of roof. Repair
Raise roof and remove the cover-to-housing
3. T
sheet metal screws. The heater core should be tested for leaks whenever
a repairis made. Cap or plug the outlet and apply air
4. Disconnect valve inlet and outlet hoses.
5. Remove the cap screws attaching the heater
pressure at 15 psi (1 bar) (1 kg/cm 2 to the inlet )
valve to the mounting bracket. opening to test. the core cannot be satisfactorily
If
6. Remove valve.
repaired, replace with a new one.
Fins should be straight and free from obstructions.

90-10-2 Heating System Operator Station Repair
Installation HEATER BLOWERS

1. Connect supply hose (with white stripe) to the Forced circulation of the heated air is accomplished
heater core inlet at lower rear corner. by the pressurizer blowers. (Refer to page 90-05-22),
2. Connect outlet hose to heater valve inlet (long
leg).
HEATER PIPES AND HOSES
Carefully inspect the heater system pipes and hoses
3. Tighten hose clamps securely.
(Fig, 2) for possible sources of trouble whenever a
4. Fill the cooling system as required. repair is made on the system. All connections should
be checked for prior leakage. Hoses that are frayed, or
5. Start the engine and run long enough to make
otherwise appear questionable, should be replaced.
sure that all the air has been purged from the system.
If airremains in the system, loosen one of the hoses

at the heater valve and allow the air to escape. Tighten
the hose clamp and finish fining system to correct level.
R 28631N
ACombination Heater Evaporator Core D Return To Water Punv
BHeater Valve E Return Hose

C Supply From Engine Block FSupply Hose
Fig. 2-Heating System Hose and Pipe Installation

Operator Station Repair Seat 90-15-1
Group 15
SEAT
PERSONAL POSTURE SEAT
iiiiii
:
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ASuspension Assembly CCushions and Seat Belts

B Seat Support Assembly D Armrest Assembly
Fig. 1-Personal Posture Seat Assembly
SERVICING SEAT COMPONENTS To service the armrest assembly or cushions, re-

move the four cap screws securing cushion to seat
The Personal Posture Seat comprised of the
is
support. To service seat support or suspension as-
suspension assembly (A), seat support assembly (B),
sembly, first remove cushions and armrest assembly;
cushions and seat belts (C), and armrest assembly (D).
then remove suspension and seat support from
It is mounted in the Sound-Gard Body with four cap
Sound-Gard Body.
screws which secure the seat base (suspension sup-
port) to the rear panel.
>

: .
90-15-2 Seat Operator Station Repair
ARMREST ASSEMBLY 4. Remove armrest cushion (D) from armrest.
5. Drive out link pivot pins (A) from armrest and I

Removal
remove links (C).
6. If necessary, remove latch plate from front link by

removing the round-headed retaining bolt.
Repair
Inspect parts for wear, replacing as needed. Proper
operation should be the determining factor for parts
replacement.
Installation
1 Reassemble armrest parts, referring to Fig. 3 and

4.
2. Install armrests on cushion supports.
3. Raise and lower armrest to make sure that links

pivot without binding.
AArmrests CScrews
BLink DCushion Support
Fig. 2-Armrests
1. Remove seat belts and take out the special

screws (C, Fig, 2).
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ArPivot Pin Cushion

B Button and Cup E Latch Key
CLi nk F Latch Plate R 27060N
Fig, 3-Armrest Disassembly Locations

AArmrest Cushion G Pin
2. To disassemble armrests, align cut-out notch in
BArmrest H Front Link
C Latch Key I Latch Plate
upper corner latch plate (F, Fig. 3) with the latch key
DCup JPin
(E), and remove key from armrest. ESpring KRear Link
F Latch Button
3. Unscrew button (B) and remove spring and cup
Fig. 4-Exploded View of Armrest Assembly
from latch key.
i

. . L
CUSHIONS AND SEAT BELTS

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1-
A Pivot Plate C Backrest Cushion

Screws DSeat Belt Attaching
B Support-To- Screw
Backrest Screw E Seat Belts
FPivot Plate
F/jg. 6-Bac*resf Cushion and Seat Beits
7. Separate supports from pivot plates (F, Fig. 6).
ACushion Support CAttaching Screws

BLink
Fig. S-Cushion Support
1. Separate the cushions and armrests from the

seat support
2. Remove the seat belts from the cushion supports

(A, Fig. 5).
3. Disconnect the armrest link (B) from the cushion

support (A). Tim "J "
-'^'Z:^'
4. Remove seat cushion attaching screws (C) from

the cushion support (A).
5. Remove armrests and seat cushion,
6. Remove both screws (B, Fig. 6) which fasten the ALumbar Adjustment Lever F Friction Plate
backrest cushion to the cushion supports. B Bushing G Springs
C Pivot Prate HKnob
DCushion Support I Cover Plate Screws
E Tilt Adjuster Slide J Cover Plate
Fig. 7-Backrest Tiit Mechanism
TM-1181JSep-77) Litho in U.S.A. Tractors - 4040 and 4240

. .
Removal Continued 1 Remove four cap screws securing cushions and

armrest assembly to support assembly, and remove
The backrest tilt mechanism is contained in the
cushion and armrest assembly.
right-hand cushion support (Fig. 7). The left-hand
support is a one-piece casting having no internal parts.
2. Remove four cap screws securing support as-
8. To disassemble tilt mechanism, remove the
sembly to tractor.
screws (t, Fig. 7) and cover plate (J).
9. Unscrew the knob (H) and remove slide (E),
3. Remove the seat rail stops (D, Fig. 8) from end of
friction plate (F), and springs (G).
rails (E).
10. Slip bushing (B) off pivot plate (C).
4. Insert a large screwdriver into slotted shaft (A)

Repair
through hole in support frame.
Inspect support (D), slide (E) and friction plate for
wear. Springs (F) must exert afirm pressure on plate to 5. Push in on screwdriver disengage counter-
to
keep slide in position. Bushing (B) should rotate freely balance shaft latch (see Fig. 8) from notches in brack-
on pivot pin, and not bind in slide. Replace parts if they et, allowing shaft reef spring to unwind.
do not operate properly.
Both seat belts should be in good general condition 6. Disconnect cable (C) from hook in suspension
and operate properly. Always replace a seat belt hav- frame.
ing a questionable condition.
Installation
1. Install cushion supports on backrest cushion

(Fig, 6), and attach seat belts to supports.
2. Fasten seat cushion and armrests to supports
(Fig. 5).
SEAT SUPPORT ASSEMBLY

Removal
A Reel Spring D Latch Handle

and Reel E Counterbalance
B Latch Spring Shaft
CSnap Rings FCable
Ftg. 9-Seat Support Separated From Suspension
7. Slide seat support off suspension assembly. Fig.

9 shows the seat support assembly removed.
A^-Shaft DStops
B Pivot Screw Nut E Rail
Remove
CCable F Position Selector Lever 8. rollers (with shims) from suspension
frame shafts (I, Fig. 22).
Fig, 8-Seat Support Assembly

To facilitate installation, keep the rollers and their 16. Remove the seat latch shaft retaining rings (E)
respective shims together so that less time will be from the inside walls of support frame.
required to adjust the rail-to-roller clearance (page
17. Pull shaft (C) out of seat latch (D) and support
15-10).
frame, and remove latch.
9. Remove snap rings (C, Fig. 9) from both ends of 18. Take out position selector lever screw and re-
counterbalance shaft. move lever (B).
10. Move shaft to the right (in direction opposite Repair

slotted end).
Inspect all parts for wear or damage. Satisfactory
operation should be the determining factor in replace-
11. Remove shaft latch (D), latch spring (B), reel
ment of parts.
spring and reel (A) from shaft.
If counterbalance reel cable needs replacing, be
12. Remove middle snap ring from groove. sure reel spring pin is installed flush with reel on the
cable winding side.
13. Move shaft to left (in direction of slotted end).
Installation
14. support frame as washer
Pull shaft out of hole in
Install seat latch mechanism in reverse order of
and middle snap ring are removed from shaft.
removal. Make sure retaining rings are correctly posi-
tioned in shaft grooves (Fig. 10) and that latch handle
is inserted in slot of seat latch.
1, Install counterbalance assembly in seat support.

Figs. 9 and 1 1 show the relationship of the parts.
A Latch Handle DSeat Latch

B Lever and Screw ERetaining Ring
CSeat Latch Shaft FBracket Notches
Fig. 10-Seat Latch ACounterbafa nee D Counterbalance
Shaft Shaft Latch
15. With the counterbalance assembly removed, BReel Spring and Spring
remove latch handle (A) from support frame. C Reel E Snap Rings and
Washer
Fig. 1 1-Expioded View of Counterbalance

Assembly
>

Installation Continued SUSPENSION ASSEMBLY

2. Install counterbalance shaft (A, Fig. 11) in sup-
port bracket and into latch handle.
Removal (
1. Remove armrest assembly and cushions.
3. Place flat washer and snap ring (E) in shaft.
2. Separate the seat support assembly from the
4. Move enough to install reel (C)
shaft inward far suspension assembly (page 15-4).
and reel spring (B). Reel spring must be installed so
that spring will be compressed as cable is unwound
from the reel.
5. Move the slotted end of shaft into position to

install shaft latch and spring (D) between latch handle
and bracket.
6. Install outer snap rings (E) on shaft.
7. Position rollers with their respective shims on the

suspension frame shafts.
8. Assemble seat support on suspension and install

rail brace (Fig. 8).
9. Check rail-to-roller side play clearance to provide

free rolling of support throughout the full range of travel
with 0.005 to 0.030 in (0.13 to 0.76 mm) side play (See
ARatchet Lever DYoke
page 15-10 for shim adjustment). B Spring Pin EWeight Adjustment
CLock Nuts Screw
10. Connect counterbalance cable to hook on sus- F Cap Screw
pension frame.
Fig. 12-Weight Adjustment Control
11. Insert a long screwdriver into slot in counter-

3. Operate the ratchet lever (A) and turn the weight
balance shaft, and push in until shaft latch is disen-
adjustment screw far enough to permit yoke tab (indi-
gaged from notches in seat support.
cator) to travel to the bottom of slot, which is the lb.
scale reading.
12. Turn counterbalance shaft counter-clockwise
(to tighten spring) until reel spring will pull seat support
4. Disconnect the weight adjustment cable from
from its extreme forward position to its extreme rear-
yoke (D) by unscrewing lock nuts at threaded end of
ward position.
cable.
13. Engage latch in support notch and check

5. Pull end of cable out of yoke.
operation.
14. Place the position selective lever in any one of

the notches in support frame ranging from "short" to
"tall".
15. Center the seat latch in its respective slot in the

suspension frame, and tighten pivot screw nut (B, Fig.
8).
<

The weight adjustment screw and ratchet lever may

be removed after removing the spring pin (B) from end
of screw (E). The ratchet lever is fastened to the weight
adjustment screw with a special self-locking cap screw
(F) and plain washer. Note the washer which is posi-
tioned on the weight adjustment screw next to ratchet
lever.
6, Remove cable (A, Fig. 13) from upper pulley and

from weight adjustment pulley (C).
7. Remove the upper pulley pin (B) and remove

pulley from its clevis.

A Suspension Assembly CArm Assembly
BScrews DShock Absorber
Fig. 14-Arm Assembly Screws
12. Carefully lower the arm assembly while raising

up rear end of suspension frame at the same time.
Doing so permits the upper end of shock absorber (D)
to separate from its mounting (half-circle bulge at rear
of suspension frame). (See Fig. 13).
A Upper Cable DLower Cable

B Upper Pulley Pin EBracket
CWeight Adjustment FWeight Scale
Pulley
Fig. 13-Control Cables and Pulleys
8. Unhook the iower cable (D) from special drive

screw on pulley shaft.
9. Take off one of the pulley shaft mounting brack-

ets (E) and remove retaining rings from end of shaft
with bracket still attached. 5234B$tt
1 0. Remove shaft. A Lower Cable D Link Stop Pin

B Spring EShaft
11. Remove the two screws (B, Fig. 14) which C Shaft Link
secure the arm assembly (C) to the suspension frame Fig, 15-Removing Shock Absorber and Spring
(A).

REMOVAL Continued Replace rubber bushings (D, Fig. 16) if they

16.
13. Move shock absorber and spring assembly (B,

show signs of deterioration or wear. The rubber bush-
ings are positioned in the shock absorber mounting
Fig. 15) upward to disengage the shaft (E) from links
(C).
ring and secured to the shaft with flat washers (F) and
retaining rings (A).
14. Remove shock absorber from suspension

frame and arm. 17. To remove the rubber bushings, pry off the
retaining rings. Slip washers and rubber bushings off
15. Remove cable {A} from shock absorber shaft.
shaft. Remove shaft.
The suspension and arm assemblies pivot on

link
NOTE: If retaining rings are difficult to remove, use
bushings secured to the suspension base and frame a press to compress rubber bushings, as shown in Fig.
(Fig, 19). To separate these parts, simply remove the
17.
attaching screws.
*"
- jjlL -
Jtt
HIP
" '.:::::::
A Retaining Ring C Special Adapter

B Press DWasher
Hft&i%!tm$
Fig. 17-Instaiting Retaining Ring
ARetaining Ring D Rubber Bushings On Shock Absorber Shaft
B Lower Spring Cap EShaft
CÛpper Spring Cap FWashers 18, Construct SpringCompression Tool as shown
in Making Special Tools page 00-6.
Fig. 16-Shock Absorber and Spring Disassembly
Locations

A
'""'<<
A Upper Mounting Ring CLower Mounting Ring

BNuts
Fig. 18-Removmg Spring from Shock Absorber
19. Remove mounting shaft from lower mounting

ring (C, Fig. 18), and insert into upper mounting ring
(A).
R 2706S% !
20. Insert shock absorber and spring in Compres-

sion Tool as shown in Fig. 18, Ftg. 19-Removing Bushing From Suspension Arm
21. Tighten nuts (B), until spring is compressed Examine cables, pulleys, bushings, and races for
enough to allow rotation of mounting ring. wear or damage. Replace any of these parts they are if
worn beyond an acceptable amount, or when they do

22. Unscrew nuts and remove shock absorber from not function properly.
spring.
Installation
Repair
Assemble the upper spring cup,
1. spring, and
Examine spring for general overall condition. A new lower spring cup on shock absorber.
spring has a tension of 650-794 lbs (2890.5-3532.5 N)
when compressed 5.26 in. (133,5 mm). 2. Compress spring (Fig. 18) a sufficient amount to
permit mounting ring to be rotated 1/4 turn,
Replace shock absorber H it does not offer accept-
able resistance to both compression and extension 3. Insert shaft into mounting ring, and install rubber
when held vertically with shock absorber body down. bushings. Using a rubber lubricant on the bushings will
be helpful for installing retaining rings.

Use No. 27487 Driver with No. 27497 (7/8 in.) and
No. 27495 (3/4 in.) Disks (Fig. 19) to remove bushings 4. Install washer and retaining ring on one end of
from suspension arm. shaft.
5. Place end of shaft with ring down on base of

press and install the other washer.
6. Use the special adapter to compress bushing so

retaining ring may be installed. Check assembly to
make sure all parts are correctly installed.
TM-1181 (Sep-77) Litho in U.S. Tractors - 4040 and 4240

Installation Continued 12. Install shaft links (Fig. 15) on arm assembly
pins.
13. Place looped ends of lower cable in outside

grooves of shock absorber shaft.
1 4. Position shock absorber shaft in links with cable
ends secured between link and shaft shoulder (Fig.

15).
15. Raise rear end of suspension frame, and place

shock absorber upper mounting ring in frame.
16. Fasten arm assembly to suspension frame.
R 27069N
17. Install upper pulley in clevis and position upper
ALeft Bracket CWeight Adjustment
cable on weight adjustment pulley (Fig. 14).
BBushings Pulley and Shaft
DRight Bracket
18. Position lower cable over pin on pulley shaft.
Fig. 20-Weight Adjustment Pulley Assembly
19. Position weight adjustment yoke (Fig. 12) in
If the weight adjustment pulley assembly (Fig. 20) suspension support.
was removed from the arm assembly, it should be
installed at this time. 20. Slide the washer (Fig. 21) on screw up against
ratchet lever and connect weight adjustment screw
7. Press bushings (B, Fig. 20) into brackets (A and with ratchet lever to yoke.
D) and install pulley shaft (C). Make sure that pulley is
adjacent to the left-hand bracket. 21. Install spring pin on end of screw.
NOTE: Bushings are self-lubricating, and therefore The ratchet lever should move back and forth with
do not require any lubricant only a light Loosen or tighten the self-locking cap
drag.
screw to achieve the desired lever movement.
8. Mount weight adjustment pulley on arm assem-
bly. 22. Position weight adjustment yoke tab at the ex-
treme left-hand end of slot (0 scale reading).
9. Rotate pulley and observe if it turns freely in
bushings. If binding occurs, disassemble parts, and 23. Insert threaded end of upper cable into yoke,
reassemble before proceeding with the installation. and tighten cable as tight as it will go. Tighten lock
nuts.
10. Assemble suspension arm and link assemblies
to support, using Fig. 21 to aid installation. rollers with their respective shims on the roller
Place
shafts.Mount the seal support assembly on suspen-
1 1 Assemble suspension frame to link assembly.
. sion assembly and install rail brace (Fig. 8), or stops.
Leave arm assembly disconnected from suspension
frame until shock absorber has been installed (see Fig. Check the rail-to-roller side play clearance to pro-
15). vide free roiling of seat support assembly throughout
the full range of travel. Clearance should measure
0.005-0.030 in. (0.13-0.76 mm). Add or subtract shims
between rollers and roller shafts. Shims are available
in 0.010 and 0.020 in. (0.254 and 0.508 mm) sizes.

R284e4U
ASuspension Frame I Spring QPulley

B Race J Shock Absorber RHeaded Pin
C Bushing K Upper Cap S Weight Adjustment Yoke
DSrrim(s) L Shaft T Suspension Arm
E Roller MWire Cable UWire Cable
FShaft Link N Suspension Link VPulley with Shaft
G Bushing 0Suspension Support WBracket
HLower Cap PWeight Adjustment Screw with Ratchet
Fig. 21 -Exploded View of Suspension Assembly

HYDRACUSHIONED SEAT
::
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11 mem
AVertical Suspension Assembly CCushions and Seat Belts
BHorizontal Suspension Assembly DArmrest Assembly
Fig. 22-Hydracushioned Seat Assembly
SERVICING SEAT COMPONENTS Removal

To service the armrest assembly or cushions, re- The Hydracushioned seat is comprised of the
move the four cap screws securing cushion to seat suspension assembly (A, Fig. 22), horizontal
vertical
support. suspension assembly (B), cushions and seat belts (C),
and armrest assembly (D). It is mounted in the
To service horizontal suspension assembly, first re- Sound-Gard Body with six cap screws which secure
move cushions and armrest assembly with support the seat base (suspension support) to the support
from the Sound-Gard Body and then remove the sup- brackets.
port from the cushion and armrest assembly.
To service vertical suspension assembly, first re-

move cushions and armrest assembly with support,
then remove the suspension assembly from the
Sound-Gard Body.

Operator Station Repair Seat 90-15*13
ARMREST ASSEMBLY 4. Remove armrest cushion (C) from armrest.
5. Drive out link pivot pins (I) from armrest and

Removal
remove links (C).
6. If necessary, remove latch plate from front link by

removing the round headed retaining bolt.
Repair
Inspect parts for wear, replacing as needed. Proper
operation should be the determining factor for parts
replacement.
Installation
1. Reassemble armrest parts, referring to Fig. 24

and 25.
2. Install armrests on cushion supports.
3. Raise and lower armrest to make sure that links

pivot without binding.
AArmrests CScrews
B Link DCushion Support
Ftg. 23-Armrests
1. Remove seat belts and take out the special

screws (C, Fig. 23).
APivot Pin DCushion

BButton and Cup ELatch Key
CLink FLatch Plate
R 27Q60N
Fig. 24-Armrest Disassembly Locations
AArmrest Cushion G Pin
2. To disassemble armrests, align cut-out notch in
BArmrest H Front Link
upper corner latch plate (F, Fig. 24) with the latch key
C Latch Key 1 Latch Plate
DCup J Pin
(E), and remove key from armrests. ESpring KRear Link
F Latch Button
3. Unscrew button (B) and remove spring and cup
Fig. 25-Exptoded View of Armrest Assembly
from latch key.

CUSHIONS AND SEAT BELTS

Removal
APivot Plate CBackrest Cushion

Screws DSeat Belt Attaching
BSupport-To- Screw
Backrest Screw ESeat Belts
F Pivot Plate
Fig. 27-Backrest Cushion and Seat Belts
7. Separate supports from pivot plates (F).
ACushion Support CAttaching Screws

BLink
Fig. 26-Cushion Support
1. Separate the cushions and armrests from the

seat support.
2. Remove the seat belts from the cushion supports

(A, Fig. 26).
3. Disconnect the armrest link (B) from the cushion

support (A).
4. Remove seat cushion attaching screws (C) from

the cushion support (A).
5. Remove armrests and seat cushion.
6. Remove both screws (B, Fig. 27) which fasten

ALumbar Adjustment Lever FFriction Plate
the backrest cushion to the cushion supports. B Bushing GSprings
C Pivot Plate HKnob
DCushion Support I Cover Plate Screws
E Tilt Adjuster Slide JCover Plate
Fig. 28-Backrest Tilt Mechanism

Removal Continued
The backrest tilt mechanism is contained in the
right-hand cushion support (Fig. 28). The left-hand
support is a one-piece casting, having no internal
parts.
8. To disassemble tilt mechanism, remove the

screws (I, Fig. 28) and cover plate (J).
9. Unscrew the knob (H) and remove slide (E),

friction plate (F),and springs (G).
10. Slip bushing (B) off pivot plate (C),
Repair ACap Screws
inspect support (D), slide (E) and friction plate for Fig. 29-Seat Removal from Sound-Gard Body
wear. Springs (F) must exert a firm pressure on plate to
keep slide in position. Bushing (B) should rotate freely 2. With the seat in the extreme forward position and
on pivot pin, and not bind in slide. Replace parts as the seat attenuator lock lever locked in position, re-
required. move the rear two cap screws securing the horizontal
Both seat belts should be in good general condition suspension assembly to the vertical suspension as-
and operate properly. Always replace a seat belt hav- sembly. (Not illustrated)
ing a questionable condition.
Installation
1. install cushion supports on backrest cushion

(Fig. 27), and attach seat belts to supports.
2, Fasten seat cushion and armrests to supports

(Fig. 26).
HORIZONTAL SUPPORT ASSEMBLY

Removal
1.With the seat in the extreme rearward position
and the seat attenuator lock lever locked in position,
remove the front two cap screws (A, Fig. 29) securing
the horizontal suspension assembly to the vertical
suspension assembly.
ACap Screws
Fig. 30-Seat with Support Assembly
3. Remove four cap screws (A, Fig, 30) securing the

support assembly to the cushions and armrest as-
sembly.

" .
RemovalContinued 10. Remove the nut (D) attaching the rear seat
cushion support (C) to the shock absorber.
1 1 Disconnect the spring (B) and roller (E) from pin
and remove the rear seat cushion support (C).
A Attenuator Lockout Attaching Screw

B
Lever
Spring
ESpring
F Seat Adjuster Lever
Mmm *'*- -^ -
C Attaching Screw
ANut C Snap Rings
Fig. 31 -Horizontal Suspension Assembly BSeat Rail DAdjuster Slide Assembly
Fig. 33-Seat Rails and Slide Assembly

4. Remove
the attaching screw (C, Fig. 31) secur-
ing the attenuator lockout lever (A).
12. Remove nuts (A, Fig. 33) securing shock ab-
5. Disconnect the attenuator lockout lever spring sorber support to adjuster slide assembly (D).
(B) and remove lever (A). 13. Remove seat rail.
14. To remove the bearing assembly, the snap

6. Remove
the attaching screw (D) securing the
rings (C) must be removed.
seat adjuster lever (F).
15. Remove adjuster slide assembly (D).
7. Disconnect the adjuster lever spring (E) and re- The seat adjuster slide assembly is replaceable
move lever (F). only as an assembly.
I :mzm HJ8432'f
:
ARetaining Rings CBearing

ARetaining Ring ERollers BFelt Washers DAdapter
BSpring FSpring
CRear Seat Cushion GFront Seat Cushion Fig. 34-Exploded View of Bearing Assembly
Support Support
DNut 16, Remove retaining ring (A, Fig. 34) from either
end of adapter (D) and remove felt washers (B) and
Fig. 32-Support Disassembly Locations
bearing (C).
8. Remove retaining ring (A, Fig. 32).
9. Remove the spring (F) and roller (E) from pin and
remove the front seat cushion support (G).

Repair 3. Remove the cotter pin (A, Fig. 36) and headed
pin (B) securing the hydraulic piston rod to the sus-
Inspect all parts for wear or damage. Replace if seat
pension assembly.
does not function properly.
4. Remove the retaining ring (C) from the seat
Installation position lever.
For assembly of seat support, reverse the removal 5. Remove the capscrew securing the seat position
procedure, page 15. lever to the suspension assembly.
6. Remove six cap screws (A, Fig. 37) (three across

VERTICAL SUSPENSION ASSEMBLY
the front and three across the rear) securing the sus-
Removal pension assembly to the support brackets.
1. Remove cushion and armrest assembly with
support from the Sound-Gard Body (See page 90-15-

15).
AScrews
||J|i.||n|
Fig. 35-Cover Panel
Fig. 37-Removal of Vertical Suspension
2. Remove the three screws (A, Fig. 35) attaching
the cover panel to the seat. A CAUTION: To prevent pinching of fingers
4& between the suspension frame, prop sus-
pension open with a block of wood (C, Fig. 38).
ACotter Pin CRetaining Ring %M3tS:

B-Headed Pin
ACap Screws D Lower Plate
Fig. 36-Removing Vertical Suspension Assembly BTop Plate EAttaching Screws
CBlock of Wood
Fig. 38-Disassembly of Suspension Assembly

.
Removal Continued
7. Remove the two cap screws (A, Fig. 38) securing
the front of the top plate (B) to the suspension frame.
8. To remove the top plate (B), lift the front up and

slide the plate away from you.
9. Turning the suspension assembly over, remove

the attaching screws (E) at the front of the lower plate
(D) and remove the plate like the top plate was re-
moved.
10. To separate the suspension frame, remove the

two cap screws at the center of the suspension.
"Hj-liiiiliiiiiill-riiilllljlilil-ijiij* "'
: :: ''
^' :
|:-iMi:-
:
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: :
: ;;!!

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=
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S4^^^ ii^teiy!!lsijK!::.i:i. :
r ==:.;!=! "r= '=îi|pljjjjJSîsiii!!in!i?;li!T '
!!!
Fig. 40-tnstaIIing Bushing in Suspension Frame

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";-f^RF^llîÊ:i#J j^PPS^HIIIIpiE^^^::^ "": "

- i i I . r r^tf^=Bi- ...::..
To remove bushings from suspension frame, use
IpBliHj
No. 27487 Driver with No. 27493 (5/8") and No. 27492
'"y*- (9/16") Disks. To install new bushings use No. 27493
""I:: V :
'
.:::i;,lllV " : T *\vW
"jjj
F " U (5/8") and No. 27495 (3/4") Disks.
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* ;:;;jj;::ia^^,^;; J!'
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;;;::;

ASpring Washer CRace For assembly of vertical suspension, reverse the
BSlider DBushing removal procedure, page 17.
Fig. 39-Verticaf Suspension Assembly When assembling the seat position lever, be sure
the tangs of the special washer are positioned over the
Repair
pin on the lever.
Examine sliders, spring washers, bushings, and
races for wear or damage. Replace any of these parts Adjust the seat position lever spring screw to
friction
if they do not function properly. provide 18 in.-lbs. (2.03 Nm) (0.2 kgm) drag measured
at the grip end of lever.

DELUXE SEAT
ASuspension Assembly
BSeat Support Assembly
CCushions and Seat Belts
Fig. 41 -Deluxe Seat Assembly
GENERAL INFORMATION To service the cushions, remove the four cap screws
securing seat cushions to seat support and two cap
The Deluxe Seat is comprised of the suspension
screws securing seat back to rear seat back support.
assembly (A), seat support assembly (B), and cush-
ions and seat belts (C). It is mounted in the body with
four cap screws which secure the seat base (suspen-
sion support to the rear panel.)
^ To service seat support or suspension assembly,
remQve cushions; then remQve suspensjon an(j
seat support from body.
>

.
SEAT SUPPORT ASSEMBLY 9. To ease installation, keep the rollers and their
respective shims together so that less time will be
Removal required to adjust the rail-to-roller clearance (page
15-24).
1. Remove the four cap screws securing seat
cushions to seat support.
2. Remove the two cap screws securing seat back

support to the rear seat support and remove cushions.
3. Remove four cap screws securing support as-

sembly to tractor.
ALatch Spring CSnap Ring

BReel Spring and Reel DLatch Handle
Fig. 43-Seat Support Separated from Suspension
10. Remove snap ring (C, Fig. 43) from slotted end
of counterbalance shaft.
ACounterbalance Shaft 1 1 Move shaft to right (in direction opposite slotted

end).
Fig. 42-Seat Support Assembly
12. Remove latch spring (A), reel spring and reel

4. Insert a large screwdriver into slot in counterbal-
(B) from shaft.
ance shaft (A, Fig. 42).
13. Remove middle snap ring from groove.

5. Push in on screwdriver disengage counterbal-
to
ance shaft latch from notches in bracket and turn in a
1 4. Pull shaft out of hole in support frame as washer
clockwise direction to allow spring to unwind.
and middle snap ring are removed.
6. Disconnect cable from hook in suspension frame.
7. Slide seat support off of suspension assembly.

Fig. 43 shows the seat support assembly removed.
8. Remove rollers (with shims) from suspension

frame shaft.

1. Install counterbalance assembly in seat support.

Fig. 43 and 45 show the relationship of the parts.
$284?N
A Latch Handle D Retaining Rings

B Lever and Screw ESeat Latch ACounterbalance Shaft D Counterbalance Shaft
C Seat Lxrtch Shaft B Reel Spring Latch and Spring
C Reel E Snap Rings and
Fig. 44-$eat Latch Washer
Fig. 45-ExpkxSed View of Counterbalance Assembly

15. With the counterbalance assembly removed,
remove iatch handle (A, Fig. 44) from support frame.
2. Install counterbalance shaft (A, Fig. 45) in sup-
16. Remove the
seat latch shaft retaining rings (D) port bracket and into latch handle.
from the inside walls of support frame.
17. Pull shaft (C) out of seat latch (E) and support 3. Place flat washer and snap ring (E) in shaft.
frame and remove latch.

4. Move shaft inward far enough to install reel (C)
18. Take out position selector fever screw, and re- and reel spring (B). Reel spring must be installed so
move lever (B). that spring will be compressed as cable is unwound
from the reel
Repair
Inspect all parts for wear or damage. Satisfactory 5. Move the slotted end of shaft into position to
operation should be the determining factor in replace-

install shaft latch and spring (D) between iatch handle
ment of parts.
and bracket.
If counterbalance reel cable needs replacing, be 6. Install outer snap rings (E) on shaft.
sure reel spring pin is installed flush with reel on the
cable winding side. 7. Position rollers with their respective shims on the
suspension frame shafts.
Installation
install seat latch mechanism in reverse order of 8. Assemble seat support on suspension and install
removal. Make sure retaining rings are correctly posi-

rail brace (Fig, 45).
tioned in shaft grooves (Fig. 44} and that latch handle

is inserted in slot of seat latch.

.
9. Check rail-to-roller side play clearance to provide
free rolling of support throughout the full range of travel
with 0.005 to 0.030 in. (0.13 to 0.76 mm) side play
(page 15-24).
10. Connect counterbalance cable to hook on sus-

pension frame.
11. Insert a long screwdriver into slot in counter-

balance shaft, and push in until shaft latch is disen-
gaged from notches in seat support.
12. Turn counterbalance shaft counter-clockwise

(to tighten spring) until reel spring wili pull seat support
from its extreme forward position to its extreme rear-
ward position.
13. Engage latch in support notch and check

operation.
ASuspension Frame DShock Absorber
14.Place the position selective lever in any one of BCap Screws E^Shaft
the notches in support frame ranging from "short to
11 CArm Assembly FShaft Link
"tall".
Fig. 46-Suspension Assembly
1 5. Center the seat latch in its respective slot in the

3. Remove the two screws (B) which secure the
suspension frame, and tighten pivot screw nut (B, Fig.
arm assembly (C) to the suspension frame (A).
44).
4. Carefully lower the arm assembly white raising

SUSPENSION ASSEMBLY up rear end of suspension frame at the same time.
Removal Doing so permits the upper end of shock absorber to
separate from its mounting (half-circle bulge at rear of
1 Remove cushions.
suspension frame.)
2. Separate the seat support assembly from the

5. Move shock absorber and spring assembly (D)
suspension assembly (page 15-20).
upward to disengage the shaft (E) from links (F).
6. Remove shock absorber from suspension frame

and arm.
The suspension link and arm assemblies pivot on

bushings secured to the suspension base and frame
(Fig. 51). To separate these parts, simply remove the
attaching screws.

.
iliiilill
ARetaining Ring CSpecial Adapter

B Press DWasher
t4îfe
Fig. 48-lnstaliing Retaining Ring
ARetainingRing DRubber Bushings On Shock Absorber Shaft
BLower Spring Cap EWashers
CUpper Spring Cap
Construct Spring Compression Tooi as
9. shown in
Fig. 47-Shock Absorber and Spring Disassembly Making Special Tools page 00-6.
Locations
7. Replace rubber bushings (D, Fig. 47) they show

if
signs of deterioration or wear. The rubber bushings are

positioned in shock absorber mounting ring and se-
cured to the shaft with fiat washers (E) and retaining
rings (A).
8. To remove the rubber bushings, pry off the re-

taining rings. Slip washers and rubber bushings off
shaft. Remove shaft.

284? 08 . ..-...,,. >.,
NOTE: ff retaining rings are difficult to remove, use

ALower Mounting Ring CNuts
a press to compress rubber bushings, as shown in Fig.
BUpper Mounting Ring
48.
Fig. 49-Removing Spring from Shock Absorber
10. Remove mounting shaft from lower mounting

ring (A, Fig. 49), and insert into upper mounting ring
(B).
1 1 insert shock absorber and spring in Compres-

sion Tool as shown in Fig. 49.
12. Tighten nuts (C) until spring is compressed

enough to allow rotation of mounting ring.
> 13. Unscrew nuts and remove shock absorber from

spring.

.
Repair 4. Install washer and retaining ring on one end of

shaft.
Examine spring for general overall condition. A new i
spring has a tension of 650-794 lbs. (2890.5-3532.5 N)
5. Place end of shaft with ring down on base of
when compressed 5.26 in. (133.5 mm).
press and install the other washer.
Replace shock absorber if it does not offer accept-

able resistance to both compression and extension
6. Use the special adapter to compress bushing so
when held vertically with shock absorber
retaining ring may be installed. Check assembly to
body down.
make sure all parts are correctly installed.
7. Assemble suspension arm and link assemblies to

support, using Fig. 51 to aid installation.
8. Assemble suspension frame to link assembly.

Leave arm assembly disconnected from suspension
frame until shock absorber has been installed (see Fig.
46).
9. Install shaft links (Fig. 46) on arm assembly pins.
10. Raise rear end of suspension frame, and place

shock absorber upper mounting ring in frame.
1 1 Fasten arm assembly to suspension frame.
12. Place rollers with their respective shims on the

roller shafts.
i:H. zrmmr'
13. Mount the seat support assembly on suspen-
Fig. 50-Removing Bushing from Suspension Arm sion assembly.
Use No. 27487 Driver with No. 27497 (7/8 in.) and Place
rollers with their respective shims on the roller
No. 27495 (3/4 in.) Disks (Fig. 50) to remove bushings shafts.Mount the seat support assembly on suspen-
from suspension arm. sion assembly and install rail brace (Fig. 41), or stops.
Examine cables, pulleys, bushings, and races for Adjust clearance as follows:
wear or damage. Replace any of these parts if they are
worn badly or operate poorly. Check the raii-to-roller side play clearance to pro-
vide free rolling of seat support assembly throughout
Installation the full range of travel. Clearance should measure
0.005-0.030 in. (0.13-0.76 mm). Add or subtract shims

1. Assemble the upper spring cup, spring, and
between rollers and roller shafts. Shims are available
lower spring cup on shock absorber.
in 0.010 and 0.020 in. (0.254 and 0.508 mm) sizes.
2. Compress spring (Fig. 49) a sufficient amount to

permit mounting ring to be rotated 1/4 turn.
3. Insert shaft into mounting ring, and install rubber

bushings. Using a rubber lubricant on the bushings will
be helpful for installing retaining rings.
<

ft 28540N
^%
A Upper Cap GWasher LShaft Link
B Spring HRetaining Ring MAdjusting Yoke
C Shock Absorber I Race N Spring Pin
DLower Cap JBushing OAdjusting Screw
E Lower Shaft KArm P Seat Suspension Support
F Rubber Bushing OShim{s)
Fig, 51 -Exploded View of Suspension Assembly


Operator Station Repair Miscellaneous Components 90*20-1
Group 20
MISCELLANEOUS COMPONENTS
SOUND-GARD BODY FRAME
R 270S0N
Fig, 1-SOUND-GARD Body Frame
GENERAL INFORMATION REPAIR

The SOUND-GARD body frame (Fig. 1) is basically
a 4-post ROLL-GARD with additional members welded
to it, forming an integral operator enclosure framework.
A CAUTION: A tractor roll-over may place a
severe stress on the ROLL-GARD struc-
ture. Therefore, reuse of the SOUND-GARD body is
not recommended if its structural members have
Not only does the body frame form a base for been bent, buckled, or stretched.
mounting the air conditioning, heating, and other com- When making a repair on the body frame, no
fort components, but it also has a primary function of welding, grinding, drilling or cutting of any type
providing roll-over protection for the operator. should be done directly on the ROLL-GARD struc-
tural members with the one exception of welding
For information on removing the SOUND-GARD on new door hinges. Doing so, may weaken the
body from the tractor, see Section 10. members sufficiently to limit their effectiveness in
protecting the operator if a rollover or upset should
occur.
Follow the instructions outlined in the Direction
I
which is supplied with the replacement door
hinges for fastening hinge to the body frame.

.
90-20-2 Miscellaneous Components Operator Station Repair
BODY DOOR AND ROOF PANELS

General Information Door Handle and Latch
The door (Fig. 2) swings on two large hinges having
one-half of the hinge welded to the body side post, and
the other half bolted to the door frame. A door latch and
door stop assembly are mounted on the inside section
ofdoor frames. The left hand electric windshield wiper
motor is mounted on the upper door frame.
Removal
Door
A Door Handle and Spacer

BDoor Handle Arm Cap Screw
CCap Screws
Fig. 3-Door Handle and Latch
1 Remove the two screws which secure the outer

door handle and spacer (A, Fig. 3) to the operators
door.
2. Remove cap screw (B) from clamp.
R34608
3. Pull out door handle and spacer.
AHinge Pins BWiper Motor 4. Remove the three cap screws (C) securing latch
and inner door handle to door.
Fig. 2-Door
5. Remove latch and inner door handle assembly.

1. Disconnect wiring from wiper motor (B, Fig. 2).
2. Disconnect pin from door stop bar.
3. Drive spring pins out of door hinge pins (A), and

remove hinge pins.
4. Carefully remove door from body.

. "
Operator Station Repair Miscellaneous Components 90-20-3
Door Stop NOTE: Use this procedure if removing outer roof

only, A different procedure is recommended when
) removing both outer and inner roof panels. See "inner
Roof Removal.
1. Disconnect the battery ground cable.
2. Open the outer roof.
3. Disconnect front and rear flasher warning lamp

wiring leads (E, Fig. 5).
4. Disconnect radio antenna lead (F).
5. Remove the roof support-to-outer roof bracket

attaching screw (G).
6. Lift off outer roof.
Inner Roof Removal
2. Drain cooling system.
3. Discharge air conditioning system.

A Headed Pin BCap Screws
4. Remove air bezel and body filter from inside
Fig. 4-Door Stop
SOUND-GARD body.
1 Disconnect pin (A, Fig. 4) which fastens the door
5. Remove knobs and mounting hardware from
stop bar to the bracket on body center post.
switches and controls.
2. Remove two cap screws securing door stop to
door (B). 6. Open outer roof and disconnect front and rear
3. Remove door stop. warning lamp wiring leads (E, Fig. 5) and ground wires.
Roof Panels 7. Disconnect radio antenna lead (F).
Outer Roof Removal 8. Remove roof-to-bracket attaching screw (G) and

lift off outer roof.
9. Remove sealing tape and attaching screws from

pressurizer housing cover and remove cover.
10. Disconnect air conditioning lines (H, Fig. 5) and
heater hoses.
11. Disconnect electrical connections from main

wiring harness.
12. Drill pop rivets from inner roof panel using a

3/16 in. drill bit.
13. Raise front of inner roof up enough to reach in

and disconnect the left-hand wiper motor wiring from
switch and also remove the evaporator and condenser
drain tray hoses.
14. Remove inner roof with all components.
ft 270841
AOuter Roof EWiring Leads
BInner Roof F RadioAntenna
C Rood Lamp GAttaching Screw
D Roof Support HAir Conditioning Lines
Fig. 5-Removing Roof Panels

Installation
A Pressurizing Housing (
Panel (left-hand)
Binsulation
C Blind Rivet (57 used)
D Pressurizing Housing
Panel (front)
E Pressurizing Housing
Panel (right-hand)
F Screen
GInner Roof
HBlind Rivet (15 used)
I Backing Plate
(heater valve)
J Nut Retainer
KSquare Nut
LWear Plate
MRear Backing Plate
(pressurizer housing)
NHanger
OAir Filter Baffle
(door opening)
P Air Filter Well
Baffle (upper rear)
Q Air Filter Well
Baffle (rear)
R Blind Rivet
R 27085N
Fig. 6-lnner Roof Component Parts (Two Piece Roof Shown)
Prior to installing inner roof panel, properly clean the

body frame roof mounting surfaces. Remove old
sealant and scrape or wire brush the frame members
to remove rust, scale, or other types 6f deterioration, if
present. Retouch cleaned areas with paint.
If two piece roof, remove existing pressurizing

panels (A, D, and E, Fig. 6) if serviceable, and install on
new roof panel.
Transfer ali components from old roof to new. Route

hoses and secure components except for blower
motor. Set blower motor in place only, do not attach.
Apply R46663 Sealant (A, Fig. 7) to the top of body

frame in a band or strip as shown in illustration. Sealant
should be placed in the approximate center of the
frame members. Apply liberal amounts at (5.59 mm)
R28632N
0.22 in. step (B) located at the extreme front, and to a AR46663 Sealant CSpacer
circular area adjacent to the roof support spacers (C). BStep
Fig. 7-Location of Sealant
\

.
Set inner roof panel on body frame. Leave front

1. NOTE: Heater hose with white stripe is supply
of inner roof propped up enough to reach in and hose.
> reconnect drain tray hoses and left-hand wiper motor
wiring.
9. Install pressurizer housing cover and install new
sealing tape over attaching screws and inner roof
2. Reconnect all component wiring and mount pane!.
switches loosely in place.
10. Mount outer roof on hinges and install support
3. Connect battery ground cable and test all com- peg. Leave roof propped up.
ponents for proper operation.
1 1 Reposition radio antenna wire and tape to in-
4. If all components function properly, install filter side of outer roof.
body and tighten switch mounting hardware.
12. Charge air conditioning system (page 290-05-
5. Remove blower motor assembly and rivet new 11).
roof into place.
13. Fill cooling system using proper amount of
6. Install blower motor, air bezel and control knobs. anti-freeze.
7. Mount rear flood lamps with outer roof hinges 14. Be sure to bleed all air from cooling system
and ground wires. (page 90-10-2) and check for leaks. -
8. Install air conditioning lines and heater hoses. 15. Check air conditioning system for leaks.
A Bond Rivet
B Roof and Brackets
C Front Bracket
DSpring
E Roof Support Rod
FWiper Motor Cover
GSpring Nut
H Insulation
I Cover-To-Evaporator Seal
J Cover Side Seal
KInsulation
L Rear Cover Seal
M Pressurizer Housing Cover
NRoof Support (right-hand)
O Rear Pivot Bracket
PRoof Support (left-hand)
-~x
^
<&
%. "-
Fig. 8-Outer Roof Component Parts

GLASS AND ATTACHING HARDWARE;

MOLDINGS AND SEALS (
R 27088N
ASide Window GSide Window Upper Molding

6Upper Door Window H Side Window Molding Strap
CLower Door Window I Rear Window
D Upper Right-Hand Front Window JBolting Strap
ELower Right-Hand Front Window K Upper Rear Window Molding
FBolting Strap L Rear Window Molding Strap
Fig. 9-Glass and Attaching Hardware
GENERAL INFORMATION Side and rear windows use flat glass which is hinged
at the top so that the window can be opened when
All glass used in the SOUND-GARD body is a
desired. Window latches are used to hold the window
tempered safety plate type glass, which has been
closed against rubber seals, or permit it to open within
tinted to reduce glare. Both curved and fiat glass is
limits of the latch slot.
used.
The curved glass

CAUTION: Always use care when handling
(Fig. 9) at the front of body is
glass to prevent personal injury.
retained with special rubber moldings. These moldings
have two interlocking lips that holdihe glass in place.
<

. .
Operator Station Repair Miscellaneous Components 90-20*7
REMOVAL 3. Cut off excess seal material.
4. Install curved glass moldings with the two inter-

locking lips toward the outside of body.
5. Press molding into place, and make sure that the

ends fit tightly together.
6. Lubricate moldings with a liquid soap to help

make installation of glass easier.
7. Install glass into its groove in molding, and

"work" molding to help position glass.
ARoller BMolding Up CJDST-29 Tool

Fig. 10-Positioning Molding Lips for Curved Glass Removal
1. Remove
curved glass from its molding by first
JDST-29 Tool (C, Fig. 1 0) into seam
inserting prong of
of molding and pry out the inner lip (B).
2. Position roller (A) of tool on the side of seam

toward the glass, and push the tool to unlock the lips.
A Roller BMolding Lip

3. Press in on glass to keep it in place, and pry
glass out of molding at one of the corners. Fig. 11 -Positioning Molding Lips for
Curved Glass Installation
4. Grasp the glass firmly with both hands and re-

move from body. 8. Starting at one corner, interlock lips (B, Fig. 11)
by using JDST-29 Tool.
5. Remove side and rear windows by first discon-
9. Insert prong of too! into seam with roller (A) on
necting the window latch from the latch bracket.
side of seam away from the glass, and push tool to
force lips into position.
6. Remove the machine screws and bushings.
10. Install side and rear windows to body.
7. Carefully remove glass.

1 1 Insert screw and bushing into hole in glass with
the flanged end of bushing toward the head of screw.
INSTALLATION
12. Tighten screws securely.
Before installing glass, check moldings and seals for
their general condition. Replace if worn or deteriorated. 13. Connect window latch to latch bracket.
14. Check window operation.

1 When replacing seals, thoroughly remove traces
of old seal from metal trim.
2. Install new seals using AR49923 Adhesive.

>

CONTROL SUPPORT WITH COVERS AND COWL
R 2709 IN
AUft-Hand Cowl FControl Support Cover

BCowl Insulation GCenter Bulkhead Insulation
CControl Support HCowl Rear Cover
DInsulation I Cover Insulation
ERight-Hand Cowl
Fig. 12-ControI Support and Related Parts
GENERAL INFORMATION Eventually, the insulation (B, D, G and I, Fig. 12)

may require replacement. Install new insulation with
The control support is bolted to the Sound-Gard
adhesive only after removing all the old insulation, and
Body at the floor. While not a part of the body, it is
properly preparing the attaching surfaces. The insula-
usually removed along with the body whenever it is
tion on be installed with
front of bulkhead (D) should
removed from the tractor. (See Section 10, for Sound-
the topskin side facing forward (away from body).
Gard Body removal.)
Insulation is also used on inside surfaces of control
support at bottom next to floor. This insulation is not
SERVICE
shown in Fig. 12.
Seldom will there be a need for service on the
control support itself. However, there may become a
need for service of components mounted in the control
support. If so, refer to the appropriate section of this
manual for specific service information on these parts.

..
HEADLINER AND UPHOLSTERY

I
AFront Headliner
BTrim Stud (10 used)
CRear Headliner
OLamp Housing
ETapping Screw
F^Spring Nut
R 27092N d>^4
Fig. 13-Headliner
REMOVAL 3. Remove the two trim studs at front.
The is made in two pieces; a front section

headliner
The air outlet bezel also has to be removed if the
(A, Fig. 13)and a rear section (C). It is held in place
front headliner was not taken off.
with moldings, bezels, and trim studs (B).
Upholstery pads are removed by pulling them loose

Front Headliner
from the body panels when the retaining moldings
1 To remove the front headliner, remove the radio. have been removed.
2. Remove the air outlet bezel. INSTALLATION

Mount dome lamp and dome lamp support on rear
3. Take out the trim studs and remove the front
headliner before installingon roof. Headliner installa-
headliner.
tion is done in reverse order of removal.
Rear Headliner body panels are dean and free of

Make sure all
1 Remove retaining moldings from sides and rear. foreign material before installing upholstery pads.
Bond pads body panels with AR49923 Adhesive.
to
2. Remove the air filter door. Smooth out pads and install retaining moldings.
RADIO, TAPE PLAYER, AND WINDSHIELD WIPER MOTORS

For service information on these components, refer to Section 40 in this manual.

<
<

1
Miscellaneous Options Specifications 95-00-1
I
Section 95
MISCELLANEOUS OPTIONS
(Not Used In U.S. and Canada)
Page Psge
GROUP 00 SPECIFICATIONS
- GROUP 60 AUXILIARY TRAILER BRAKES
-
Mechanical Hand Brake 95-00-2 How Works

the Trailer Brake Valve 95-60-
Auxiliary Trailer Brakes 95-00-2 Brake Valve Removal 95-60-2
Inspection 95-60-3
GROUP 50 - MECHANICAL HAND BRAKE Installation 95-60-3
General information 95-50-1 Testing Brake Valve Assembly 95-60-6
Removal 95-50-5
Inspection 95-50-5
Installation 95-50-5
>

95-00-2 Specifications Miscellaneous Options
Group 00
(
SPECIFICATIONS
SPECIFICATIONS
Mechanical Hand Brake
Brake Shaft Needle Bearing Seat O.D 2.249-2.250 in. (57.13-57.15 mm)
Brake Shaft Ball Bearing Seat O.D 2.362-2.363 in. (59.99-60.01 mm)
Friction Disk Thickness 0.160-0.165 in. ( 4.06- 4.19 mm)
Separator Plate Thickness 0.245-0.255 in. ( 6.22- 6.48 mm)
Cap Screw Torque Specifications
Brake Cover to Brake Housing 35 ft-lbs (50 N-m)

Brake Housing to Transmission Case 35 ft-lbs (50 N-m)
Auxiliary Trailer Brakes
Control Valve Spool O.D 0.473-0.474 in. (12.01-12.04 mm)

Valve Housing Bore I.D 0.473-0.474 in. (12.01-12.04 mm)
Spring Free Length Working Load
Pressure Spring 1.04 in 0.59 in. at 49-58 lbs.

(26.5 mm) (15 mm at 210-260 N)
Operating Test
Load right-hand pedal with operating

pressure with this load* Approx. 67 lbs (300 N) pressure
2130 psi (150 bar)
*During a period of approx. 10 seconds, there should be no back pressure or sinking of brake pedal.
<
TM-1181 (Jun-80) LithO in U.S.A. Tractors - 4040 and 4240

Miscellaneous Options Mechanical Hand Brake 95-50-1
Group 50
MECHANICAL HAND BRAKE
R35033
Fig. 1 -Mechanical Hand Brake
GENERAL INFORMATION
The mechanical hand brake used as a backup
is To activate the brake, pull up on the hand lever,
braking system.The kit consists a hand brake lever
of which moves the brake arm upward. This will cause the
in the operator's station, a brake housing with friction actuating disk to move out, causing the stationary
disks and separator plates, an actuating disk assem- separator plates to lock up with the rotating friction
bly, and actuating linkage. disks. This will result in the tractor coming to a stop.
The brake may be actuated in emergencies while

the tractor is moving or used as a parking brake. This
brake is driven off the front of the differential drive
shaft, with the gears and brake disks in continual
rotation anytime the tractor is moving.
>

95-50-2 Mechanical Hand Brake Miscellaneous Options
AHandle
BBushing
C Boot
DSpring Pin
E Pawl
FSpring Pin
GBrake Rod Guide
HSpring (2 used)
I Machine Screw
J Clip
KSnap Action Switch
LLock Washer
M Hex Nut
R34977 NCap Screw (2 used)
0 Bushing (2 used)
PWasher (2 used)
Fig. 2-Auxiliary Hand Brake Linkage

R34978
A Hand Brake Rod MLink

BSpring Pin NHeaded Pin
C Spring OBrake Arm
DWasher P Cap Screw and Lock Washer
E Clevis with Bushing QWoodruff Key
F Plate ROil Seal
GSpring Pin S Thrust Washer (2 used)
H Headed Pin T Clutch Housing
I Special Washer U Retaining Ring
JSpecial Washer V Operating Shaft
K Spring Pin WYoke
LCotter Pin
Fig. 3-Auxiliary Hand Brake Linkage

R34979
ANeedle Bearing LRetaining Ring (4 used) WWire

BBrake Shaft MOperating Yoke Pin X Special Cap Screw (3 used)
C Ball Bearing N Disk Link Pin YWasher (3 used)
D Bearing Cup OOperating Yoke Z Spacer (3 used)
EThrust Washer PBrake Actuating Link (2 used) AASecondary Brake Housing
FDifferential Drive Shaft QDowel Pin (4 used) BBClutch Housing
G0.010 in. Steel Shim RSnap Ring CCGasket
H Brake Drive Gear SActuating Disk DDTransmission Case
I Plate Retainer TSeparator Plate (5 used) EE Brake Driven Gear
J Special Cap Screw (2 used) UFriction Disk (7 used) FFSnap Ring

K Special Cap Screw VBrake Housing Cover
Fig. 4-AuxHiary Hand Brake Parts

REMOVAL INSTALLATION
1. Refer to Section 10, Group 20 for separating the 1. if replacing needle bearing (A), press it into
clutch housing from the transmission case. transmission case bore until it is flush with bearing
bore.
2. Remove
the three cap screws (X, Fig, 4), at-
taching cover (V) on brake housing (AA). 2. install brake shaft (B), ball bearing (C) and snap
ring (FF).
3. Remove cover (V) and three spacers (Z).

3. Install gear (EE) and snap ring (R).
4. Remove friction disks (U), separator plates (T)

and actuating disk assembly (S) from brake shaft (B). 4. Install brake parts into brake housing (AA) in the
following order:
5. Remove four cap screws (K) attaching housing
(AA) to transmission case. Remove housing. a. Install one disk (U), one separator plate (T), and
one more disk into brake housing first.
6. Remove snap ring (R) and slide gear (EE) from

brake shaft, b. install actuating disk assembly (S).
7. necessary, remove snap ring (FF), ball bearing

If c. Install remaining disks and separator plates al-
(C), brake shaft (B) and needle bearing (A). ternately, starting and ending with disk.
8. Refer to Figures 2, 3, and 4 as a guide to remove 5. Align separator plates (T) so spacer (2) is posi-
remaining parts. tioned in notches of plates.
INSPECTION 6. Tighten brake housing cover (V) to 35 ft-Ibs (50

N-m) torque.
Inspect friction disks and separator plates for
1.
wear. Make sure grooved pattern of friction disk fac-

7. Install a piece of 1 6 gauge wire through the brake
ings is not worn or rubbed off. Be sure the disks and
the following sequence:
housing cover screws in
plates are within the following specifications:
a. Install wire through the upper R.H. screw and

Plate Specifications
secure in a knot.
(5 used) 0.245-0.255 in. (6.22-6.48 mm)
b. Proceed to lower center screw and then up
Disk Specifications
through the upper L.H. screw and secure in a
0.160-0.165 (4.06-4.19 mm) knot.
(7 used) in.
2. Check friction disk splines for broken teeth. c. Cut off any excess wire.
3. Inspect braking surfaces of actuating disks (S, IMPORTANT: To provide clearance for the
Fig. 4), housing (AA) and cover (V) for scoring or other
PTO drive gear, wire cannot run horizontally
damage. Replace if necessary. between upper R.H. and L.H. screws.
4. Check needle bearing (A, Fig. 4) and ball bearing 8. Refer to Fig. 3 for assembling the brake linkage
(C) for serviceability. assembly.
damage and 9. if replacing oil seal (R, Fig. 3), press sea! into
5. Check brake shaft (B) for wear, for
clutch housing with sealing lips facing inward. Coat
broken teeth. Replace if necessary.
sealing lips with lubricant
10. Provide 0.02 in. (0.5 mm) end play between

brake arm (O) and washer (S).
>

*
Miscellaneous Options Auxiliary Trailer Brakes 95-60-1
Group 60
I
AUXILIARY TRAILER BRAKES
.-j 3
L55587A
1Control Line from Transmission Case 5Va\ve Cap 8 Bleed Orifice

2 Pressure Line to Quik-Coupler 6Spool 9 Pressure Spring
3 Return and Leak-Off Line 7Spool Return and Leak-Off 10Spring Cap
4 Pressure Line from Rockshaft Housing Orifice 11Valve Body
Fig. 1 -Brake Valve, Sectional View
HOW THE TRAILER BRAKE VALVE WORKS

With the engine running, oilunder system pressure When the braking operation is completed, pressure
is forced through pressure brake
line (4, Fig. 1), into oil no longer flows through control line (1) to overcome
valve body (11), where it is blocked by spool (6) which spring pressure. Spring (9) moves the spool again to
is in neutral position. the left into neutral position.
When the tractor power brakes are applied, oil from

Thus, return and leak-off orifice (7) is again con-
the brake pressure oil passes through line (1,
circuit
nected to passage in valve body leading to pressure oil
Fig. 1) to the left of spool (6), pushing spool to the right
line (2). Oil can now return into the transmission case
after overcoming pressure of spring (9). The return and
via pressure line (2), spoof (6) and return and leak-off
leak-off orifice (7) is now closed while passage leading
line (3).
to pressure oil line (2) of Quik-Coupler is opened. Oil
under pressure in the valve body can now pass
through pressure line (2) and Quik-Coupler to the
hydraulic trailer brakes.
>

95-60-2 Auxiliary Trailer Brake Miscellaneous Options
BRAKE VALVE REMOVAL

(
Fig. 4-Removing Valve Housing
4. Remove the brake valve housing bracket from

the selective control valve.
Fig. 2-Removing Return Oil Line
1. Relieve hydraulic pressure.
2. Remove the return oil line from brake valve

housing.
R35038
ACap Screw (2 used) GWashers (4 used)

BValve Cover H Pressure Spring
CO-Ring 1 Snap Ring
DValve Body j O-Ring
ESpool KSpring Cap
FBleed Screw L Brake Valve Assembly
Fig. 5-Brake Valve Assembly
5. Turn spring cap (K, Fig. 5) out of valve body (D).
6. Pull spool (E) with spring (H), washers (G) and

snap ring (I) out of valve body.
mwm IP-: 7. Remove snap

ers (G) from spool (E).
ring (I), spring (H) and both wash-
Fig. 3-Removing Pilot and Pressure Oil Lines

8. Unscrew both cap screws (A) from valve body
(D) and remove valve cover (B).
3. Remove pilot oil line.
4. Remove pressure oil line.
<

INSPECTION INSTALLATION
Check spool and valve body for scoring or other
damage.
The spool and valve body are not separately re-

placeable because they are selectively fitted at the
factory. If either needs replacement, the complete
control valve assembly must be replaced.
Check afl other parts and replace where necessary.
Discard O-rings and replace with new ones.
Check tension of pressure spring (H, Fig. 5). It

should be 0.59 in. at 49-58 lbs. (15 mm at 210-260 N).
R80137L1
A Valve Housing C Connector

B O-Ring D45 Elbow
Fig. 7-Instalfing Brake Valve Connector
1. On 4040 Tractor: Install connector (C, Fig. 7),

O-ring (B), and 45 elbow (D) in valve housing (A).
On 4240 Tractor: Install connector (C) and O-ring

(B) only in valve housing (A).
R80137K2
A Coupler
B Brake Valve Housing
Fig. 6-Brake Valve Housing
1. The coupler (A, Fig, 6) is replaceable as individ-

ual parts or as an assembly.
R80137J1
A Bracket C Cap Screw (2 used)

B Valve Housing DWasher (2 used)
Fig. 8-Mounting Valve Housing to Bracket (4240 Shown)
2. install valve housing (B, Fig. 8) to bracket (A). Do

not tighten screws yet.
NOTE: On 4040 Tractor, flip the vaive housing (B)

over right to left.
>

95-60-4 Auxiliary Trailer Brke Miscellaneous Options
R35023
1 Valve Assembly 13Return Oil Line 25 Connector (4040 and 4240)

2 Bracket 14 Aluminum Washer Elbow {4040 only)
45 Swivel
3Cap Screw (2 used) 15 Reducing Connector
26 Pressure Oil Line
4Lock Washer (2 used) 16O-Ring 27 Connector (4040 and 4240)
5Cap Screw (2 used) 17 Plug 903 Swivel Eibow (4040 only)
6 Washer (2 used) 18Clamp 28O-Ring
7 Washer (2 used) 19 Pilot OiJ Line 29Special Adapter
8 Lock Washer (2 used) 20 Special Connector 30Seal
9 Nut (2 used) 21 Nut 31 Nut
10O- Ring (3 used) 22 O- Ring 32 Coupler Plug
HÊIbow (3 used) 23 Cap Screw 33 Coupler Receptacle
12Ciamp (4240 only) 24 Washer
Rg. 9-Trailer Brake Valve and Hose Routing Diagram
TM-1181 (Jun-SO) Litho in USA. Tractors - 4040 and 4240

INSTALLATION Continued 6. Install two 90 elbows (A, Fig. 1 1) and Orings in
each end of the valve housing.

I
"SIS:/ %:> (B
if
life
'>
RS0137K1
Fig. 12-lnstaiimg LH. Brake Connector
A Valve Housing D Coupler
BNut E Bracket 10. Install special connector (20, Fig. 9), nut (21),
C Nut and O-ring LH. side of transmission case.
(22) into the
Fig. 10-installing Coupler to Valve Housing
3. fnstaff coupler (D, Fig. 10) through bracket (E)

and start nut (B) on coupler threads.
NOTE: On 4040 Tractors, use offset bracket
4. Tighten coupler (D) into valve housing special

adapter until it bottoms on seal.
5. Tighten both nuts (B and C) to hold coupler

against bracket (E).
-" i
Fig. 13-lnstalling Brake Valve to Selective

Control Valve
11. Install the brake vafve and bracket to selective

control valve.
</
Fig. 11 -Installing Valve Housing Elbows
>

95-60-6 Auxiliary Trailer Brakes Miscellaneous Options
15. Install return oil line from the LH. side (R.H.
side of 4040) of valve assembly to the load control arm
adjusting hole plug elbow. (
16. On 4240 Tractors: Install clamp securing return

oil line to brake valve.
17. Make sure ail fittings are tight; then, start tractor
to check for leaks.
is
A CAUTION: Care should be taken to only
crack the brake valve plug because the oil
at system pressure.
18. Bleed the LH. brakes by carefully loosening

plug on front of brake valve assembly. Bleed brakes
until all air has escaped.
TESTING BRAKE VALVE ASSEMBLY

Fig. 14-Installing Brake Valve Lines
1. Use an adapter to connect a pressure gauge
(measuring range 0-2250 psi [0-250 bar]) to coupler

12. Install pressure oil line between rockshaft fitting
plug (32, Fig. 9).
and front of brake valve.
2. Start engine.
13. Install from R.H. side (LH. side
the pilot oil line
of 4040) of valve assembly to the LH. brake feed
3. Pressure gauge should not register any pres-
connector.
sure.
14. Clamp the pilot line to selective control valve

4. Press down on left-hand brake pedal with ap-
lower mounting screw.
proximately 67 lbs (300 N) force. The gauge should
immediately show a pressure of approximately 2130
psi (150 bar). Within a period of 10 seconds, the brake
pedal should neither sag nor should a back pressure
be observed.
Fig. 15Installing Return Oil Line
<

Engine Operation and Diagnosis Specifications and Special Tools 220-00-1
Section 220
ENGINE OPERATION AND DIAGNOSIS
Specifications 220-00-1 Checking Camshaft-Oil Pump Gear
Special Tools 220-00-1 Backlash 220-10-3
GROUP System Operation
05 - Checking Valve Lift 220-10-3
Cooling System 220-05-4 Checking Valve Clearance 220*1 0-4
Lubrication System 220-05-2 Checking Crankshaft End Play 220-1 0-5
GROUP 10 - System Tests and Diagnosis Checking Damper Run-out 220-1 0-5
Dynamometer Test 220-1 0-1 Checking Oil Pressure 220-1 0-5
Engine-PTO Speed Relationship 220-10-1 Testing Cooling System 220-1 0-6
Instructions for Engine Break-In 220-10-2 Diagnosing Engine Malfunctions 220-10-6
Testing Compression Pressure 220-10-2
Group 00
SPECIFICATIONS
Engine pressure
oil 40 to 50 psi (2.75 to 3.75 bar) (3.80 to 3.86 kg/cm 2 )
Compression pressure 370 to 400 psi (25.5 to 27.6 bar) (24.9 to 27.0 kg/cm 2 )
at 200 to 250 rpm

Radiator leakage test 18 psi (1 .24 bar) (1 .26 kg/cm 2)
Valve lift
Intake valves 0.412 to 0.442 in. (1 0.5 to 1 1 .2 mm)

Exhaust valves 0.413 to 0.443 in. (1 0.5 to 1 1 .3 mm)
Valve Clearance
Intake valves 0.01 8 mm)
in. (0.5
Exhaust valves 0.028 mm)
in. (0.7
Crankshaft end play (New part) 0.0015 to 0.015 in. (0.04 to 0.4 mm)
Damper radial run-out 0.040 in. (1 .0 mm) maximum
SPECIAL TOOLS
TOOL NUMBER USE
AD-14547BA Used for testing compression
Motor'rte Tester* pressure.
BD-14557BA
Adapter*
'
S. tMM
Fig. 1 -Compression Test Equipment
AD-1 Fitting* Used for testing oil pressure.

B19-HP Hose and
FittingAssembly*
CD-20 Gauge*
mmm
Fig. 2-Oti Pressure Test Equipment
*Order from Service Tools, Box 314, Owatonna, MN 55060
TM-1181 (Feb~79) Litho in USA. Tractors - 4040 and 4240

220-00-2 Specifications and Special Tools Engine Operation and Diagnosis
TOOL NUMBER USE
(
0-051 04ST Pressure Used for testing radiator
Pump*
Fig. 3-Radiator Test Equipment
JDE-109Gear Used for checking camshaft

Backlash oil pump gear backl&sh.
Indicator*
E28499N
Fig. 4-Gear Backlash Indicator
*Order from Service Tools, Box 314, Owatonna, MN 55060
<

Engine Operation and Diagnosis System Operation 220-05-1
Group 05
SYSTEM OPERATION
COOLING SYSTEM
R2S302
ARadiator EWater Pump HWater Manifold

615 psi cap FCylinder Block Main Cooling Gallery I Thermostats
COverflow Valve GEngine Oil Cooler JWater Bypass Pipe
D7 psi cap
Fig. UEngine Cooling System
The dual pressure cooling system consists of a gallery (F) on the left-hand side of the engine. Coolant
radiator (A, Fig. 1),water pump (E), two thermostats from the gallery circulates through the block to cool
(I), and water manifold (H). block and cylinder liners, then flows into the cylinder
Two pressurizing caps with different opening pres- head. From the cylinder head, the coolant passes into
sures are connected to a coolant overflow valve (C) the water manifold (H) and thermostat housing.
mounted in the front of the radiator. At coolant tem- If the thermostats are closed (as during warm-up
peratures of 222F (105C) and below, the system is periods) coolant is directed back to the pump through
pressurized by the 7 psi (0.48 bar) (0.49 kg/cm 2 ) cap the bypass pipe be recirculated. This provides a
(J) to
(D). Between 222F (105C) and 228F (109C) the faster and more uniform warm-up.
overflow valve closes, stopping overflow from the 7 psi If the thermostats are open (engine at normal
(0.48 bar) (0.49 kg/cm 2 ) cap and allowing the 15 psi operating temperature) coolant flows back through the
(1.03 bar) (1.05 kg/cm2 cap (B) to pressurize the
) thermostats to the top of the radiator.
system. The engine oil cooler (G), located in the matin gal-
The pump draws coolant from the bottom of the lery, receives its cooling capacities from the coolant
radiator (A) and discharges it into the main coolant flow around it.
>

220-05-2 System Operation Engine Operation and Diagnosis
LUBRICATION SYSTEM
(
R29303
AEngine Oil Cooler EOil Pressure Regulating Valve I Piston Cooling Orifices
BOil Cooler Bypass Valve F Main Bearings J Piston Pin and Bushing
COil Filter GConnecting Rod Bearings 1 Engine Pressure
Oil
DFilter Bypass Valve HCamshaft Bushings Pan Oil Oil
Fig. 2-Engine Lubrication System Shown with Camshaft-Driven Pump

Oil
The engine lubrication system consists of a gear- engine oil pressure regulating valve (E) into the engine
driven positive displacement pump, oil cooler, oil filter, oilgallery in the cylinder block. Oil is then distributed,
cooler bypass valves, oil pressure regulating valve and under pressure, to each main bearing fillet to lubricate
filter bypass valve. main bearings (F).
NOTE: 4240 Engines having Serial No. (160280- from the piston cooling orifices (I) lubricates the
Oil
) were equipped with a crankshaft-driven oil piston pin and bushing (J) through a hole in the con-
pump, shown in Fig. 3. necting rod.
Cross-drilled passages in the crankshaft distribute
Oil is pumped from the oil pan by the engine oil oilfrom the main bearing journals to the connecting rod
pump through the engine oil cooler (H, Fig. 2) around journals to lubricate connecting rod bearings (G).
the cooler bypass valve (B) into the engine oil fil-
oil Numbers 1, 3, 5, and 7 main bearing fillets are also
ter (C). Passing through the filter, the oil continues camshaft bushings (H). A
drilled to lubricate the four
around the filter bypass valve (D) and in front of the drilled passage from the rear camshaft bushing
through the cylinder block and cylinder head provides
<
lubrication to the rocker arm shaft.

Engine Operation and Test System Operation 220-05-3
R62962
AEngine Oil Cooler E

Oil Pressure Regulating Valve IPiston Cooling Orifices
BOil Cooler Bypass Valve FMain Bearings JPiston Pin and Bushing
COil FiHer GConnecting Rod Bearings {I Engine Oil Pressure
D Filter Bypass Valve HCamshaft Bushings mm Oil Pan Oil
Fig. 3-Engine Lubrication System Shown with Crankshaft-Driven OH Pump

NOTE: Description of the lubrication system on engines equipped with a crankshaft-driven oil pump (Fig. 3) is given
on opposite page.
>

220-05-4 System Operation Engine Operation and Diagnosis
<
<

.
Engine Operation and Diagnosis System Tests and Diagnosis 220-10-1
Group 10
SYSTEM TESTS AND DIAGNOSIS
DYNAMOMETER TEST
If possible, test the engine on a dynamometer before
it tuned. This test gives the horse power output and
is
fuel consumption of the engine as it is. This will help

determine if a tune-up can restore the engine or
whether an overhaul is needed.
Good performance by the engine depends on these

basic things:
1. An adequate supply of dean air and fuel.
2. Good compression.
Proper valve and injection pump timing for good

3.
combustion.
4. Proper air and fuel temperatures.
Make the dynamometer test as follows:

Fig. 1 -Dynamometer Test
1 Connect the engine to the dynamometer using
the manufacturers instructions (Fig. 1). 4. Gradually increase the load on the engine until its
speed is reduced to 2200 rpm.

2. Operate the engine at one-half load until the
coolant and crankcase oil temperature are up to nor- 5. Read the horsepower on the dynamometer.
mal.
6. Compare the reading taken with the following
3. Run engine at fast idle (2400 rpm). chart.
ENGINE-PTO SPEED RELATIONSHIP

4040
Engine RPM PTO Speed Rated PTO Horsepower
2200 (full load) 1000 (Syncro-Range and 90*

Quad-Range)
1011 (Power Shift)
4240
Engine RPM PTO Speed Rated PTO Horsepower
2200 (full load) 1000 (Syncro-Range and 110*

Quad-Range)
1011 (Power Shifft)
*Factory observed test.
>

.
220-10-2 System Tests and Diagnosis Engine Operation and Diagnosis
INSTRUCTIONS FOR ENGINE BREAK-IN

Use a dynamometer to perform the following break-in procedure, if necessary, engine break-in can be performed <
without adynamometer if under controlled operating conditions.
Fill engine crankcase with Torq-Gard Supreme 10W-20 oil to proper level for use during the break-in operation.
TIME LOAD ENGINE SPEED REMARKS

5 Minutes No Load 800 RPM Check
5 Minutes No Load 1500 to 2000 RPM oil pressure,
5 Minutes 1/4 Load 1900 to 2200 RPM coolant
10 Minutes 1/2 Load 1900 to 2200 RPM temperature
10 Minutes 1/2 to 3/4 Load 1900 to 2200 RPM and leakage.
10 Minutes 3/4 to Full Load 2200 RPM
After break-in, run engine 1 to 2 minutes at 1500 RPM, No Load before shut-down. Loosen, then retighten
cylinder head cap screws per specified sequence (p. 20-10-9 and p. 20-10-10). Loosen, then retighten rocker arm
shaft clamps to 45 to 65 fMbs. (61 to QQ Nm) (6.1 to 8.8 kgm). Check and reset valve clearance to specifications.
During the first 100 hours of operation, avoid over-toads, excessive idling, and no-load operations. Do NOT use
foot throttle. After 100 hours, drain crankcase oil and change oil filter. Fill crankcase with oil of proper viscosity and
service classifications.
TESTING COMPRESSION PRESSURE 4. Attach test gauge to adapter.
NOTE: Before beginning test insure that batteries 5. Pull out engine stop knob.
are fuiiy charged.
IMPORTANT: Thoroughly clean area around in* 6. Close fuel shut-off valve.
jection nozzles*
1 Remove fuel pressure and fuel leak-off lines from in a new engine the compression should be ap-
injection nozzles. proximately as follows:
2. Remove injection nozzles.
Cranking Speed Compression pressure
200-250 rpm 370-400 psi (25.5 to 27.2 bar)
(26 to28 kg/cm 2 )*
^Pressure given was taken at 1000 feet above sea
level. A 3.6% reduction in gauge pressure will result for
each additional 1000 feet of altitude.

if pressure is much lower than shown, remove
gauge and apply oil to the ring area of piston through
injection nozzle hole. Do not use too much oil. Do not
get on the valves.
oil
Test compression again. If pressure is higher, worn

or stuck piston rings are indicated, if the pressure is still
low, it is possible that valves are worn or sticking.

It is very important that ail cylinder pressures be
approximately There should be less than 25 psi

alike.
Fig. 2'Testing Compression Pressure (1 .72 bar) (1 .75 kg/cm 2 ) difference between cylinder
pressures.
3. Install proper adapter (Fig. 2) in injection nozzle
bore.

Checking Camshaft-Oil Pump Gear 1. Install gauge (D) on engine block using the two
Backlash cap screws provided (A, Fig. 4).
NOTE: Before measuring backlash, the engine

2. Align the pointer over the center mark on gauge
must be at normal operating temperature.
and tighten pointer (B).
Installing Gauge
NOTE: It is extremely important that the pointer is
1 . Remove speed-hour meter drive housing located
tight before determining backlash measurement.
on rear right-hand side of engine block.
3. Place fingers on hex portion of the pointer (C),
R 2661 2N
3 w
BJ
and move the pointer back and forth by hand.
IMPORTANT: Do
move the pointer.
not use excessive force to
ARing CGrind Material as Required

NOTE: If the total movement of the pointer is 5
BPointer marks or more, check camshaft oil pump drive gear
and gear on oil pump for a step wear pattern on teeth of
Fig. 3-Ring with Pointer
gears.
2. Screw together Pointer and Ring from JDE-109
Backlash Indicator Tool (Fig. 3) Checking Valve Lift
3. Install ring with pointer on top flange of engine on Measuring valve lift can give an indication of wear to
pump drive gear. cam lobes, cam followers, and push rods.
NOTE; If interference exists between the cylinder

1. Set valve clearance to specifications as pre-
block and the ring, grind some material from ring (Fig.
viously indicated.
3). Do not tighten pointer.
Checking Backlash
Fig. 5-Checking Valve Lift
2. Place dial indicator on rotator (Fig. 5).

R 2661 3N
3. Manually turn engine in running direction with

ACap Screws DGauge JDE-81 Engine Rotation Tool.
BCenter Alignment EEngine Oil Pump
CHex Part of Pointer Drive Gear
> Fig. 4-in$taJHng JDE-109 Gear Backlash
Indicator

Checking Valve Lift(Continued) Valve Clearance Specifications

4. After rocker
dial indicator
arm contacts valve stem, observe
reading as valve is moved to full open.
Intake Valves 0.018 in. (0.5 mm) <
Exhaust Valves 0.028 in. (0.7 mm)
Valve Lift Specifications
FRONT OF ENGINE *-
intake Valves 0.412 to 0.442

. in. (10.5 to 11.2 mm)
Exhaust Valves 0.413 to 0.443 in. (10.5 to 11.3 mm)
Checking Valve Clearance
NO. 1 TDC COMPRESSION STROKE
R1318? NO. 6 TDC COMPRESSION STROKE
Fig. 7-Valve Clearance Adjustment
';.!:**<
A-^JDE-81 Engine Rotation Too! Set
Fig. 6-Setting "TDC"
1. Use JDE-81 Engine Rotation Tool Set (A, Fig. 6)

to position No. 1 piston at TDC of its compression
stroke.
2. Turn flywheel until rotation tool timing pin en-

gages timing hole in flywheel and both valves on No. 1
cylinder are in the up position. (Rocker arms loose).
Fig. 8-Checking Valve Clearance
3. Adjust valve clearance on No. 1 , 3, and 5 exhaust

valves and No. 1, 2, and 4 intake valves (Fig. 8).
4. Rotate flywheel 360 degrees until No. 6 piston is
at "TDC" of its compression stroke, and tool timing pin

engages flywheel hole.
5. Adjust valve clearance on No. 2, 4, and 6 exhaust

valves and No. 3, 5, and 6 intake valves to the specifi-
cations listed above. i

Checking Crankshaft End Play NOTE: Engine should be run for approximately five
minutes before checking damper run-out The damper
Use the following procedure to check crankshaft end
assembly becomes more concentric after warmed up.
play before removing crankshaft:
1. Thoroughly clean outer edge of damper pulley
1. Completely depress and release the clutch
(A, Fig. 10) so an accurate indicator reading may be
pedal.
made.
2. Attach a dial indicator base (B) to side frame and
position indicator contact point on damper.
3. Use JDE-81 Engine Rotation Tool Set to rotate
crankshaft, while observing indicator read out. If run-
out of damper exceeds 0.040 in. (1 mm), replace
damper.
CHECKING OIL PRESSURE
iiiiPir
Fig. 9-Checking Crankshaft End Play
2. Place a dial indicator on crankshaft pulley or

Fig. 11 -Main Gallery Pipe Plug
damper (Fig. 9).
IMPORTANT: Use care not to distort the timing
1 . Remove pipe plug from main oil gallery (Fig. 1 1 ).
gear cover or damage the bearing inserts when
prying. Do not pry on rubber damper at rear of :
lPt:-
:
^M:ggBP:MBMl
pulley.
3. Pry between the pulley and timing gear cover
(Fig. 9).
CRANKSHAFT END PLAY SPECIFICATIONS

New part end play 0.0015 to 0.015 in.
(New
Maximum end
thrust bearing)
play acceptable 0.0150
(0.04 to 0.4
in. (0.38
mm)
mm)
**iyzm
Checking Damper Run-out
"\M^liM.^^^^^mJî:
* ' :
[
+Jr \ ;
=
^~^zr^
.-,, ^y^fji
ppHJ^-oy- -
::: ;
__ ^y
'S: -:
V
_. :
* - =^_ j
LJWIHi^ ;-*' ;.:^ -*1

Fig. 12-Checking Oil Pressure
ADamper Edge BIndicator Base

2. install pressure gauge (Fig. 12).
Fig. 10-Checking Damper Run-out
3. Warm up engine and run at 1900 RPM.

CHECKING OIL PRESSUREContinued DIAGNOSING ENGINE MALFUNCTIONS

4. Oil pressure should be 40 to 50 psi (2.75 to 3.79
Will Not Start
bar) (2.80 to 3.86 kg/cm2).
Fuel System Malfunction See Section 30
NOTE: To adjust oil remove regulating
pressure, Empty fuel tank
valve spring at filter base and add washers to increase Fuel shut off cable not pushed in
oil pressure and subtract washers to decrease oil Improper fuel
pressure. Plugged fuel filter
Fuel shut off at tank
IMPORTANT: Do not use more than a total of
five washers. Electrical System Malfunction See Section 40
Corroded or loose battery connections
TESTING COOLING SYSTEM Weak battery
1. Remove hood.
Engine Runs Irregularly or Misses
2. Visually check the radiator for leaks or damage. Basic Engine Problem See Section 20 Group
Improper valve clearance 10
Low compression 10 and 15
Engine overheating 20 and 25
Valves sticking or burned .... 10
Worn camshaft lobes .... 10
Detonation 10 and 15

Low fuel supply
Restricted fuel line or filter
Air in fuel
Incorrect injection pump timing
Plugged or defective injection nozzle
Faulty injection pump
Faulty fuel pump
25fc Frequent Stalling

Fig. 13-Testing Cooling System Operator Error
Engine not at operating temperature
3. Remove the 7 psi (0.5 bar) (0.5 kg/cm 2) cap to
overflow valve hose from overflow valve. Restricted fuel lines
Faulty fuel pump
4. Inserta 5/16 in. cap screw in end of hose and Plugged fuel filter
tighten hose clamp over cap screw to seal hose. Vent on fuel tank cap obstructed
Dirty or faulty injectors
5. Remove the 15 psi (1.03 bar) (1.05 kg/ cm 2 )
radiator cap. Lack of Power
6. Attach D-051 04ST Pressure Pump to 15 psi (1 .03

Basic Engine Problem See Section 20 Group
2
bar) (1.05 kg/cm ) filler neck.
Engine overheating 20 and 25
Incorrect valve clearance 10
7. Use pump to apply 18 psi (1 .24 bar) (1 .26 kg/ cm 2
)
Blown cylinder head gasket 10
compressed air to system.
Worn camshaft lobes 10
Burned, warped, pitted or sticking
8. Check engine, radiator and hoses for coolant
valves 10
leaks.
Weak valve springs 10 i

5
Engine Operation and Diagnosis System Tests and Diagnosis 220-1 0-7
Service problem Excessive Fuel Consumption

Dirty or obstructed air cleaners
Improper fuel
Plugged fuel filters
Faulty injection nozzles
Leaks in fuel system
Restricted exhaust system
Restricted air cleaners
Plugged fuel tank vent
Faulty injection pump timing
Power Train Malfunction See Section 50 Improper valve clearance
Clutch Slipping
Engine Overheats
Service Problem
See Section 10
Improper grade of fuel

Loose or broken fan belt 30 Fuel System Malfunction See Section 30
Faulty thermostats 30 Excessive fuel delivery
Defective radiator pressure cap 30 Faulty injection nozzles
Faulty water pump 30 Restricted air cleaners

Service Problem See Section 10 Improper injection pump timing
Low coolant level
Crankcase oil level low White Exhaust Smoke
Engine overloaded
Improper fuel
Excessive fuel delivery
Improper injection pump timing
improper fuel
Excessive Oil Consumption
Basic Engine ProblemSee Section 20 Group Slow Acceleration
Worn valve guides or valve stems 10
Oil control rings worn or broken 15
Faulty injection pump
Worn or scored liners or pistons 15
Piston ring gaps not staggered 15
Excessive main or connecting rod
Detonation
bearing clearance 15 and 20

Service Problem See Section 10 Fuel System Malfunction See Section 30
Crankcase oil too thin Oil picked up by intake air stream
Oil level too high Faulty injection nozzles
Stuck ether applicator
Low Oil Pressure
Abnormal Engine Noise

Stuck or improper regulating valve
Basic Engine Problem See Section 20
adjustment 25 Low engine oil level
Excessive main and connecting rod Excessive valve clearance
bearing clearance 15 and 20 Worn cam followers
Plugged oil pump intake screen 25 Bent push rods
Leakage at internal oil passages 25 Worn rocker arm shafts
Faulty oil pump 25 Worn main or connecting rod bearings
Service Problem See Section 10 Foreign material combustion chamber
in
Low oil level Worn piston pin bushings and pins

improper viscosity of oil Scored piston
incorrect engine timing
High Oil Pressure Excessive crankshaft end play
> Loose main or connecting rod bearing caps

Basic Engine Problem See Section 20
Camshaft oil pump drive gear worn or broken
Stuck or improperly adjusted regulating valve


Fuel/Air Operation and Tests Specifications and Special Tools 230-00-1
Section 230
FUEL/AIR OPERATION AND TESTS
Page Page
GROUP 00 - SPECIFICATIONS AND GROUP 10DIESEL FUEL SYSTEM
-
SPECIAL TOOLS How The System Works 10-3

Specifications Diagnosing System Malfunctions 10-4
Air Intake System 00-2 Fuel Pump 1 0-6
Diesel Fuel System 00-2 Fuel Filter 10-6
Control Linkage 00-2 Bleeding Fuel System 10-7
Special Tools 00-3 Fuel Injection Pump
General Information 10-8
GROUP 05 AIR INTAKE SYSTEM
- Automatic Speed Advance 10-8
How The System Works 05-1 Adjustments 10-8
Diagnosing System Malfunctions 05-2 Fuel Injection Nozzles
Air Cleaner 05-3 Genera! Information 10-10
Restriction Indicator How The Fuel Injection
Switch 05-3 Nozzle Works 10-11
Diagnosing Malfunctions 10-12
GROUP 15 - CONTROL LINKAGE

Speed Control Linkage 15-1
Foot Throttle Linkage 15-3
Diesel Fuel Shut-Off Control 15-4
>

230-00-2 Specifications and Special Tools Fuel/Air Operation and Tests
Group 00 \
SPECIFICATIONS
Air Intake System
Item Specifications
AIR CLEANER
Air intake vacuum at 2200 engine rpm (full load) with
clean filter elements
With extension
4040 Tractor 8 in. (20 mbar) water
4240 Tractor 9.5 in. (24 mbar) water
INTAKE MANIFOLD
Intake manifoicMo-cyiinder head cap screws 35 fMbs (47 Nm) (4.7 kgm)
ETHER STARTING AID

Spray nozzle orifice 0.020 in. (0,51 mm)
Voltage to energize solenoid 4 volts
Diesel Fuel System

Item Specification
FUEL TANK
Capacity
4040 Tractors 37 U.S. gal. (140 L)
4240 Tractors 46 U.S. gaL (174 L)
FUEL PUMP
Normal operating pressure at idle speed 3.5-4.5 psi (0.2-0.3 bar) (0.2-0.3 kg/cm 2 )
FUEL INJECTION PUMP

Timing to engine TDC
Slow idle speed 780-820 rpm
Speed Advance
Check point (at full toad) 9 + 1/2 by 2100 rpm
Total advance movement 9 1/2
j
Control Linkage
Hem Specification

Force to move hand throttle 8 lbs. (35 N)
Slow idle speed : 780-820 rpm
Foot throttle pedal position at fast idle 1/4-in. (6 mm) above floor mat
DIESEL FUEL SHUT-OFF CONTROL
Fuel shut-off lever and cable Lever fully downward in run position;
slack removed from cable
<

Fuef/Air Operation and Tests Specifications and Special Tools 230-00*3
SPECIAL TOOLS
Air Cleaner TOOL USE
*D05022ST Gauge Measuring air intake restriction

(Formerly JDST-11) (Group 05)
.
T^K
?*m ikm
Fig. 1 -Water Vacuum Gauge
Injection Pump and Speed TOOL USE

Control Linkage
AJDE-28 Speed Indicator Obtain accurate engine rpm
Adapter* reading (use with tachometer)
B D-05011-STHand Checking injection pump and

Tachometer* speed control linkage speed
adjustments
R 26813N
Fig. 2-Tools For Checking Speeds

No. 19918 Timing Window* Checking degrees of advance
R 29064N
Fig. 3~No. 19918 Timing Window
USE
No. JDF-21-2Speed Checking degrees
Advance Gauge* of advance
RG2603
Fig. 4-No. JDF-21-2 Speed Advance Gauge
> *Order from Service Tools, Box 314, Owatonna, MN 55060.

230-00-4 Specifications and Special Tools Fuel/Air Operation and Tests
TOOL USE i
'
''-T'"-i&L
AJDE-81-1
: '
- >
Engine Checking injection pump tim-

Rotation Tool* ing
BJDE-81-4 Timing Pin* Checking injection pump tim-

ing
R 26134N
Fig, 5-Toots Required for Checking Timing
AJDF-18-1* To adjust speed advance on

4240 Tractor.
BJDF-18-2*
R 31262
Fig. 6-Speed Advance Adjusting Tools
*Order from Service Tools, P.O. Box 314, Owatonna, MN 55060
<

Fuel/Air Operation and Tests Air Intake System 230-05-1
Group 05
AIR INTAKE SYSTEM
R 29065N
AAir Stack CAir Intake Pipe

BAir Cleaner DIntake Manifold
Fig, UAir intake System (6404D and 6466D Engines)
HOW THE SYSTEM WORKS This dust-laden air enters the system through the air
stack (A) and is filtered in the air cleaner (B).
Outside air is drawn into the air intake system (Fig.
1 ) by engine suction.
Clean air travels through the air intake pipe (C) to
the intake manifold (D) of the engine.
>
TM-1181 (Sep-77) Litho in U.S.A. Tractors 4040 and 4240

230*05-2 Air Intake System Fuel/Air Operation and Tests
DIAGNOSING SYSTEM MALFUNCTIONS

The following is a guide for diagnosing air intake take system components, refer to the headings which
system malfunctions. For specific diagnosis of air in* cover complete servicing.
POSSIBLE SUGGESTED
PROBLEM CAUSE REMEDY
Engine Emits Excessive

Black Smoke Air cleaner element is restricted Ciean or replace elements (Section 30,
Group 05)
Engine Does Not

Develop Full Power Air cleaner is restricted Clean or replace elements (Section 30,
Group 05)
TM-1181 (Sep-77) Utho in U.S. A. Tractors - 4040 and 4240

Fuel/Air Operation and Tests Air Intake System 230-05-3
AIR CLEANER RESTRICTION INDICATOR SWITCH

How The Air Cleaner Works How The Switch Works
R 29074N
AAir Inlet DSecondary (Safety)

BDust Outlet Element
CPrimary Element EAir Outlet
Fig. 2-Air Flow Through Air Cleaner ARestriction Indicator BWiring Connector
Switch
Dust-laden air enters the air cleaner inlet (A, Fig. 2),
Fig. 3-Restriction Indicator Switch
and is forced into a high-speed centrifugal motion.
A restriction indicator switch (A, Fig. 3) is located on

Most of the dust settles out of the air (before it enters
the air intake pipe, just above the air cleaner outlet
the filter elements) and falls to the bottom of the air
connection. The purpose of the switch is to warn the
cleaner body. It is expelled to the outside of the air
operator whenever there is excessive restriction
cleaner (B) through a rubber valve, which automatically
present in the air cleaner, indicating that the air cleaner
ejects the dust and keeps it from accumulating inside
filter elements probably require servicing.
the air cleaner body.
Whenever the vacuum restriction in the air cleaner

As the intake drawn through the primary ele-
air is
reaches 24-26 in. (59.7-64.7 mbar) of water, an elec-
ment (C) and a secondary (safety) element (D), the trical connection (B) on the switch activates an indica-
remaining dust particles are retained in the primary tor lamp on the dash.
element to permit only clean air to enter the intake
manifold. Operation of the restriction indicator switch should
be checked whenever a tune-up or overhaul has been
The safety element retains the dust that would oth- performed on the engine, or whenever it is suspected
erwise pass into the engine if the primary element not operating properly.
that the switch is
should rupture.
Testing Switch Operation
See Section 30, Group 05 for service information.
To test the restriction indicator switch operation, or
todetermine the amount of restriction in the air intake
system, follow these steps:
1. Run the engine and bring to operating tempera-

ture.
2. Remove left-hand side shield and grille screen.

On 4240 Tractor, also remove air stack extension,
muffler, and hood.
\ 3. Disconnect wiring connector (B, Fig. 3) from

switch (A). Unscrew switch from connection on pipe.

230-05-4 Air Intake System Fuel/Air Operation and Tests
NOTE: The JDST- 1 1 vacuum gauge is calibrated in
inches of water. A water manometer calibrated in
inches of water may also be used* t

Check indicator lamp on dash to make sure that it
6.
is good. Electrical connections must be clean and
sound.
7. air filter elements in air cleaner (Fig.

install clean
2). If theelements are not clean, either install new
filter
elements, or clean the existing ones. Refer to the

tractor operator's manual for element cleaning instruc-
tions.
8. Operate the engine at full load. Use a piece of

sheet metal or cardboard to gradually cover the air
cleaner opening.
9. Note action of indicator lamp in relation to the

reading on JDST- 11 gauge or manometer. Compare
ASwitch C-^JDST-11 Gauge
with the following specifications:
BWiring Connector DPipe Fittings
Fig. 4-Testing Air Intake System Restriction Air intake vacuum at 2200 rpm (full load)
and with clean filter elements:
<(
4. install T" and pipe fittings (D, Fig. 4) on pipe. Wrth Extension
4040 Tractor 8 in. (20 mbar)
5. Screw JDST-1 1 one end of "T\
gauge (C) into 4240 Tractor 9.5 in. (24 mbar)
Gauge has 1/4 in. pipe thread. Connect switch (1 /8 in. Maximum permitted
pipe thread) to other end of 'T\ and attach wiring reading 25 in. (62.3 mbar)
connector to switch, as shown. Restriction to energize
lamp 24-26 in. (60.0-60.5 mbar)
If the restriction indicator switch is defective, replace

it with a new one.
After completing the switch operation test, discon-

nect the wiring connector.
Remove gauge and switch from "T" fitting. Take off
pipe fittings.
Install restriction indicator switch in fitting on air
intake pipe.
install hood, /muffler, air stack extension, grille
screens, and side shields.

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Fuel/Air Operation and Tests Diesel Fuel System 230-10-3
HOW THE SYSTEM WORKS

The fuel pump (B, Fig. 1) draws fuel from the tank incorporated into the fuel system is a means of
(A) and pressurizes it to 3.5-4.5 psi (0,25-0.30 bar) returning excess (or unused) fuel back to the fuel tank.
(0.25-0.30 kg/cm 2 ) at idle speed. This pressure per- Excess fuel comes from two sources:
mits the fuel to flow through the filter (C) and charge
the transfer pump (D) of the injection pump (E). (1) Injection PumpA quantity of fuel greater than
that required by the engine is supplied to the injection
With the transfer pump charged with fuel by the fuel pump.
pump, the injection pump plungers pressurize the
fuel
to about 6000 psi (412 bar) (422 kg/cm 2). Delivery (2) Injection Nozzles A small amount of fuel seeps
pipes (F) are used to route this high pressure fuel to the past the nozzle valve for lubrication purposes.
injection nozzles (G).
To get the excess fuel back to the tank, a return line
Fuel entering the injection nozzle at 6000 psi (412 (H) from the injection pump is connected to the front
bar) (422 kg/cm 2 easily overcomes the 3200 psi (221
) end of the nozzle leak-off pipe (I). Fuel from both
bar) (232 kg/cm
2
pressure on 4040 Tractors or 3600
)
sources is then returned to the tank by a return pipe (H)
2 end
psi (248 bar) (254 kg/cm pressure on 4240 Tractors
)
connected to the front of the leak-off pipe.
required to open the nozzle valve. When the nozzle
valve opens, fuel is forced out through the orifices in
the nozzle tip and atomizes as it enters the combustion

chamber.

230-10-4 Diesel Fuel System Fuel/Air Operation and Tests
DIAGNOSING SYSTEM MALFUNCTIONS

The following is a guide for diagnosing fuel system components, refer to the groups which cover complete
malfunctions. For specific diagnosis of fuel system servicing.
FUEL SYSTEM
DIAGNOSING MALFUNCTIONS CHART
POSSIBLE SUGGESTED
Fuel Not Reaching

Injection Nozzles Fuel clogged
filter Replace fuel filter (this group)
Fuel clogged or restricted
line Clean lines as required
Fuel too heavy at low temperatures Use correct grade of fuel (see machine
OM)
Air in system Correct problem and bleed fuel system
(this group)
Fuel tank valve shut off Open fuel tank valve
Low fuel pump pressure Check fuel lines for restrictions
Engine Starts Hard or

Won't Start Fuel too heavy at low temperatures Use correct grade of fuel (see machine
OM)
Injection nozzles faulty or sticking Repair (Section 30, Group 1 0)
incorrect timing Adjust timing (this group)
Injection pump is faulty Repair (Section 30, Group 10)
Water in fuel Drain water from fuel, Install new filters
(this group)
Fuel filter clogged Replace fuel filter (this group)
Injection pump return fuel line or
fittings restricted Clean lines as required
Low cetane fuel Use correct grade of fuel (see machine
OM)
Engine Starts and Stops Air in system Correct problem and bleed fuel system
(this group)
Fuel filter dogged Replace fuel filter (this group)
Fuel lines clogged or restricted Clean lines as required
Water in fuel Drain water from fuel. Install new filters
(this group)
Erratic Engine Operation Fuel filter clogged Replace fuel filter (this group)
Fuel too heavy at low temperatures Use correct grade of fuel (see machine
OM)
Injection nozzles faulty or sticking Repair (Section 30, Group 10)
Fuel lines clogged or restricted Clean as required
Incorrect timing Adjust timing (this group)
Governor faulty Repair (Section 30, Group 10)
Water in fuel Drain water from fuel, Install new filters
(this group)
OM)
Injection nozzle return lines clogged Clean lines as required
Speed advance faulty Repair (Section 30, Group 10)

FUEL SYSTEM
DIAGNOSING MALFUNCTIONS CHART- -Continued
POSSIBLE SUGGESTED
Black Smoke Injection nozzles faulty or sticking Repair (Section 30, Group 1 0)
Injection pump timing is incorrect Adjust timing (this group)
OM)
Over-fueling Repair and adjust (Section 30, Group
10)

Blue or White Smoke Cranking speed too low Check batteries and electrical system
(Section 240)
Injection pump timing is incorrect Adjust timing (this group)
Excessive wear in liners and/or
piston rings stuck Repair (Section 20)
Incorrect cetane fuel for ambient
temperature Use correct grade of fuel (See
machine OM)
Engine running too "cold" Check thermostat (Section 20, Group
30)
Engine Idles Poorly Injection nozzles faulty or sticking Repair (Section 30, Group 10)
Pump slow idle speed not correctly
adjusted Adjust slow idle speed (this group)
Fuel lines clogged or restricted Clean as required
Water in fuel Drain water from fuel. Install new filters
(this group)
Injection pump return lines or fittings
restricted Clean as required
Injection nozzle return lines clogged Clean as required
OM)
Injection pump housing not full of fuel Restriction or faulty transfer pump
Engine Does Not Develop
Fuel Power Low cetane fuel Use correct grade of fuel (see machine
OM)
Injection pump or governor faulty Repair (Section 30, Group 10)
Fuel filter clogged Replace fuel filter (this group)
Injection nozzle return lines clogged Clean as required
injection pump return fuel line or
fittings are restricted Clean as required
Water in fuel (or gasoline in fuel) Drain water or replace with clean fuel.
Install new filters (this group)
Incorrect fast idle speed Adjust speed (this group)
Injection pump housing not full of fuel Restriction or faulty transfer pump
>

FUEL PUMP How The Fuel Filter Works

General Information (
Fuel flows from the fuel tank at gravity pressure to
the inlet side of the diaphragm-type pump. This pump
increases the fuel pressure to 3-1/2 to 4-1/2 psi

(0.25-0.30 bar) (0.25-0.30 kg/cm 2) at idle speed, and
forces fuel through the filter to the injection pump.
The fuel pump is operated by an eccentric lobe on

the engine camshaft.
Diagnosing Malfunctions
Before replacing the pump when fuel does not flow
(or only a small amount flows), check the following
sources that would limit pump performance:
Fuel shut off at tank.

Hand primer left in the upward position. R 26812N
Clogged fuel line.
Loose or damaged fuel line connections. AInlet EFirst Stage Filtering
BOutlet Media
If correction of these conditions does not provide a CAir Vent FDrain
satisfactory flow of fuel, the pump is defective and must
DSecond Stage GSediment Bowl
Filtering Media f Supply Pump Pressure
be replaced (see Group 10, Section 30).
Fig. 3-Fuef Flow Through Fitter
FUEL FILTER
Fuel enters the filter at (A, Fig. 3) and flows through
General Information a first stage filtering media (E) and a second stage
media (D) before flowing through outlet (B) to
filtering
A fuel filter (B, Fig. 4) is used to prevent dirty fuel
The filtering media is housed in the
the injection pump.
from reaching the injection pump and injection nozzles.
glass sediment bowl (G) and expoxied to the bowl as
one assembly.
The filter element will require occasional replace-
ment to maintain an adequate flow of fuel to the
Since water and other contaminants may settle to
injection pump. The frequency of this service will vary
the bottom of the sediment bowl, a drain plug (F) is
according to the cleanliness of available fuel and the
provided to permit their removal.
care used in storage.
An air vent (C) enables air in the fuel system to be

expelled to the outside through filter when bleed plug
(A, Fig. 4) is removed.

Replacing Filter After changing the element, install drain plug in filter
body.
Open the fuel shut-off valve and bleed the filter.
(See "Bleeding Fuel System" on next page.)
ABleed Plug CRetaining Spring

BFilter Element DDrain Plug
Fig. 4-Fuel Filter

R29052K
AFinger Tabs CFuel Filter Body
To change the filterelement (B, Fig. 4), close the BSpring Pin
fuel shut-off valve at bottom of fuel tank.
Element
Fig. deinstalling Filter
Remove drain plug (D) and drain filter.

BLEEDING FUEL SYSTEM
Release the
pull off element.
filter element retaining spring (C) and
A CAUTION: Escaping diesel fuel under
pressure can have sufficient force to pen-
trate the skin, causing serious personal injury.
NOTE: The spring may be released by pressing Before disconnecting lines be sure to relieve all
inward on the outside finger tab (A, Fig. 5) until the top pressure. Before applying pressure to the system,
hook of the spring can be disengaged. Disengage the be sure all connections are tight and that lines,
top hook by pulling upward on the inside finger tab.
pipes and hoses are not damaged. Fuel escaping
from a very small hole can be almost invisible. Use
Before a new filter element, inspect the
installing
a piece of cardboard or wood, rather than hands, to
filter body where element makes contact. These loca-
search for suspected leaks.
tions must be completely void of dirt or other conta-
minants. If contaminants are found, clean carefully. If injured by escaping fuel, see a doctor at once.
IMPORTANT: Any dirt lodged in the spring pin medical treatment is not administered immediately.
groove or end of the spring pin by cleaning
at the
efforts will be washed into the injection system and Whenever the fuel system has been opened up for
may result in severe damage to the injection pump service (lines disconnected or filters removed), it will be
or nozzles. necessary to bleed the air from system.
Push new element over the spring pin (B). Hook the
bottom end of retaining spring first, then hook the top
end.
>

230-10-8 Diesel Fuel System Fuet/Air Operation and Tests
BLEEDING FUEL SYSTEM Continued

\
RZ14Z1
A Cam Ring E Advance Piston

BAnnulus F Head Locating Screw
Fig. 6-Hand Primer C Plug G Hydraulic Head
DAdjusting Screw H Rotor
Loosen bleed plug on fuel fijter (A, Fig. 4), and Fig. 7-Avtomatic Speed Advance
operate hand primer (Fig. 6) on fuel pump until most of (Advance Used on 4040 Tractor Illustrated)
the air bubbles are expelled from the filter.

As engine speed increases, movement of the the
cam ring (A t Fig. 7) also maximum of 9
increases to a
Push hand primer back (toward engine) as far as it
degrees. As engine speed decreases, the cam ring is
will go. Tighten filter bleed plug.
forced to return to a retarded position.
Movement of the cam ring is accomplished hydrau-
NOTE: lithe engine will not
neces-
start, it may be lically,using fuel under pressure from the transfer
sary to loosen the fuel pipes at the injection nozzles to
pump. Fuel is directed to an advance piston (E) which
bleed the air from system. With the hand throttle in
rotates the cam ring against the direction of rotor (H)
slow idle position and the engine fuel shut-off control
rotation.Counteracting piston movement is a spring
knob pushed all the way in, turn the engine with the
that preloaded by an adjusting screw (D), called a
is
starter until fuel without air flows from the loose fuel
"trimmer" screw.
pipe connections. Tighten the connections.
NOTE: The illustration and information given above
pertains to the advance system used on 6404D en-
FUEL INJECTION PUMP gines (4040 Tractor). The advance system used on
6466D engines (4240 Tractor) is called a Servo-Ad-
General Information vance. simitar in that fuel pressure from
It is the
The fuel injection pump used on
4040 and 4240the transfer pump is used to move
advance piston, but
the
tractors is a Roosa Master, Model DM-4. This pump is differs in that a pilot piston (located in advance piston
twin cylinder, distributor-type, having an automatic bore) covers or uncovers ports to move the cam ring.
speed advance, and a manual fuel shut-off control. Thus pump timing is advanced or retarded. A trimmer
t
screw is used to provide adjustment of the advance.

For information on how a DM-Series injection pump Trimmer screw is located between pump body and
operates, refer to TM-1064, "Fuel injection Equip- cylinder block on 4240 Tractor.
ment Roosa Master".
Adjustments
Automatic Speed Advance Speed Advance (4040 Tractor)
How The Speed Advance Works Before adjusting the speed advance, be sure the
injection pump is correctly static-timed. See "Installa-
The purpose speed advance (Fig.
of the automatic tion", page 30-10-6.
7) is to insure optimum combustion for maximum Disconnect the tachometer drive cable from engine
power at higher engine speeds. This is done by ad- and install JDE-28 adapter. Connect an accurate ta-
vancing or retarding the start of fuel delivery in re- chometer to the adapter. Refer to page 230-00-3.
sponse to changes in engine speed. Remove the timing hole cover (E, Fig. 10) and install
No. 19918 timing window (B) or JDF-21-2 Speed Ad- i
vance Gauge (Fig. 8). Refer to "SPECIAL TOOLS,"
page 230-00-3.
Installing the JDF-21-2 Speed Advance Gauge
A Base DScrews
B Gauge Body E Pump End of Pointer
CGasket FTiming Line on Cam
Fig. 8-lnstalling JDF-21-2 Gauge
AInner Scale D Pointer Tip

B Outer Scale E"Zero" Line
a. Mount base marked "21734" on gauge body C Long Degree Line
(B) using screws provided.
Fig. 9-"Zeroing" JDF-21 Gauge
NOTE: Current production base is marked "DM
b. Mount gauge assembly on pump using gasket
DB2" instead of "21 734. " This base is part of JDF-21-2
Speed Advance Gauge. See "Special Tools," page (C) and screws (D) provided. Tighten screws securely.
230-00-3.
c. Engage pump end of pointer (E) with groove
in cam The pointer is spring loaded to maintain
ring (F).
engagement.
d. Loosen lock nuts on back of gauge and slide

inner scale (A, Fig. 9) so one of the longest degree
lines (C) aligns with pointer tip (D). At the same time,
alignone of the "zeros" (E) on the outer scale (B) with
long degree line and pointer. Tighten lock nuts.
>

Speed Advance (4240 Tractor)
Before adjusting the speed advance, be sure the

<
injection pump is correctly static-timed. See "Installa-
tion", page 30-10-6.
Disconnect the tachometer drive cable from engine

and install JDE-28 adapter. Connect an accurate ta-
chometer to the adapter. Refer to page 230-00-3,
Remove the timing hole cover (E Fig. 10) and install

7
No, 19918 timing window (B) or JDF-21-2 Speed Ad-

vance Gauge. Refer to "SPECIAL TOOLS," page
230-00-3,
For installation of the JDF-21-2 refer to page 230-

10-9.
Start the engine and bring to operating temperature.
ACam Ring DAdjusting Screw

BTiming Window ETiming Hole Cover Remove the sealing wire from the side of injection
C Lock Nut FSeal Cap pump.
Fig. 1Q-Adjusting Speed Advance (4040 Tractor) NOTE: Speed control rod may be removed to facil-
itate adjustment of speed advance.
Start the engine and bring to operating temperature.
Remove the sealing wire and seaf cap (F, Fig. 10)
from the side of injection pump. Loosen the lock nut
and turn the advance adjusting screw (D) out to retard,
and in to advance. Each mark on the timing window
represents 2 degrees. Each mark on the speed ad-
vance gauge represents one quarter (1 /4) of a degree.
Adjust the speed advance to the specified setting at
2100 rpm given in the table below.
Degrees Advance
Engine RPM Full Load No Load
2100 (Check) 9 1/2

Total Advance
Movement 1/2 9 1/2
After adjusting the speed advance, tighten the lock A-^JDF-18-2 Tool C-^JDF-18-1 Tool
nut, and install seal cap and sealing wire. B End Plug Lock Nut DTrimmer Screw
Lock Nut
Remove timing window, and install timing hole
Fig. 1 1 -Loosening Trimmer Screw Lock Nut (4240 Tractor)
cover.
(Pump removed for illustrative purposes)
If the automatic speed advance cannot be adjusted

Place JDF-1 8-2 Tool (A, Fig. on spring slide lock
1 1 )
to specifications, remove the pump from tractor, and
nut (B). Place JDF-1 8-1 Too! (C) on trimmer screw lock
repair (page 30-10-5).
nut (D). Loosen trimmer screw lock nut, making sure
spring slide lock nut does not come loose. Remove
both tools.
<

Adjustments Continued Fast Idle Speed
AJDF-18-2 Tool
Fig. 12-Adjusting Speed Advance (4240 Tractor)

(Pump removed for illustrative purposes)
Place Allen head end of JDF-18-2 Toof (A, Fig. 12}

into trimmer screw (B). While holding trimmer screw
lock nut with JDF-18-1 Tool, turn trimmer screw out to AThrottle Lever D JDE-26 Adapter
advance and in to retard. Each mark on the timing & Fast Idle Screw E Hand Tachometer
window represents 2 degrees. Each mark on the speed C Lock Nut F Slow idle Screw
advance gauge represents one quarter (1/4) of a de-
Fig. 13-Checking Pump Fast idle Speed
gree. Adjust the speed advance to the specified setting
at 2100 rpm given in the table below.
To check the fast idle speed, disconnect the ta-
Degrees Advance
Engine RPM Futf Load No Load chometer drive cable and install JDE-28 Speed
2100 (Check) 9 1/2 Adapter (D, Fig. 13).
Total Advance
Movement 9 1/2 9 1/2
With the engine running, move the throttle iever (A)
forward so that the fast idle stop screw (B) is against its
speed advance, tighten the lock

After adjusting the stop. Use an accurate tachometer similar to D-05011-
nut, and instaff seaf cap and sealing wire. ST Indicator (E) and JDE-28 Speed Adapter for mea-
Remove timing window, and install timing hole suring the fast idle speed. The fast idle speed should
cover. be 2380-2420 rpm. Always stop engine before making
If the automatic speed advance cannot be adjusted any adjustments.
to specifications, remove the pump from tractor, and
repair (page 30-10-5). Tighten lock nut (C) securely when fast fd/e speed is
correctly set.
Pump Idle Speeds
Move pump shut-off lever all the way forward
against its stop in "run" position. Operate engine until it
is thoroughly warmed up.
A
"^
CAUTION: To avoid possible personal in-
jury, do not make any adjustments while
engine is running.
Disconnect speed control rod from injection pump.

>

Slow Idle Speed

With the engine running, move the throttle lever (A, I
Fig. 13} rearward, so that slow idle screw (F) is against
its stop. Check slow idle speed using same method as
checking fast Idfe speed described on preceding page.

Correct setting is 780-820 rpnn.
Tighten Jock nut (C) securely when fast idle speed is

correctJy set. Connect tachometer drive cable and
speed control rod.
Refer to Group 15 of this section to obtain informa-

tion on adjustment of the speed control linkage.
A KDEL Nozzle Holder B DLLA NozzJe
FUEL INJECTION NOZZLES Fig. 14-Modef KDEL 21 mm Injection Nozzle
General Information
Correct alignment of the nozzle assembly with its
The KDEL 21mm injection nozzle (Fig. 14) consists holder is essentia! in order that the atomized fuel will be
of the nozzle holder (A) and the DLLA nozzle (B). sprayed combustion chamber at the angle and
into the
location intended by design. KDEL holders use an
Notice Fig. 15. The nozzle valve (J) is held on its intermediate plate (F) with dowel pins (E) on, both sides
seat by a spring (L). Shims (M) are used to regulate the to insure alignment.
nozzle opening pressure.
A retaining nut (G) is used to fasten the nozzle
The nozzle and valve are fitted together by pre-
(I)
assembly to the holder body. The diameter of the
cision lapping. These parts are referred to as a nozzle holder body is 21 mm, and from this dimension the fuel
assembly, and are not serviced separately. injection nozzles are known as 21 mm nozzles.
AFuel Inlet GNozzle Retaining Nut M Shims

B Leak-Off Connection HWasher N Gland Nut
CO-Ring I Nozzle 0 Snap Ring
D Snap Ring J Valve P Edge-Type Fitter
E Dowel Pin K Spring Seat QNozzle Holder
F Intermediate Plate LSpring R Fuel Passage
Fig. 15-Cross-Sectional View of KDBL-21 mm Injection Nozzle
<
TM-1181 (Jun-80) Litho in U.S.A, Tractors - 4040 and 4240

An edge-type filter (P) is placed in the fuel inlet of

nozzle holder. Its purpose is to prevent coarse, foreign
particles from damaging the nozzle assembly or plug-
ging the orifices. Finer particles pass through the filter
without harm. The filter is not removable.
To provide a seal between the injection nozzle and

the engine cylinder head, a steel washer (H) is used at
the base of the nozzle retaining nut.
The fuel injection nozzle is fastened to the engine

cylinder head by a gland nut (N). See Fig. 16. The
gland nut also functions as a jack screw to raise the
injection nozzle out of cylinder head during removal.
How The Fuel Injection

Nozzle Works
The injection pump pressurizes the fuel to about
6000 psi (412 bar) (422 kg/cm 2 on the Roosa Master )
DM-4 pump. Fuel pipes (A, Fig. 16) deliver the fuel to
the injection nozzle.
Fuel enters the injection nozzle inlet (B), and passes

through the edge-type filter (C). Coarse foreign par-
ticles are retained by the filter.
A passage (D) routes fuel through the nozzle holder

to the nozzle valve (E). The nozzle valve is lifted
instantly off its seat by the high pressure inlet fuel

acting on an annulus in the valve.
NOTE: Since the nozzle valve opening pressure of

E28420N
a used injection nozzle 3200 psi (221
is set to open at
2
bar) (232 kg/cm ) pressure on 4040 Tractors and 3600
psi (248 bar) (254 kg/cm 2) on 4240 Tractors, the inlet
A Fuel Delivery Pipe G Nozzle Valve Spring
B Fuel Inlet H Leak-Off Connector
fuel pressure easily overcomes the resistance of the C Edge-Type Filter I Leak-Off Pipe
nozzle valve spring (G). D Fuel Passage J Engine Cylinder Head
E Nozzle Valve I
High Pressure Fuel
When the nozzle valve opens, a definite quantity of F Orifices | Return Fuel
fuel(determined by the injection pump output) is forced

Fig. 1$-Fuel Flow Through A KDEL Injection Nozzle
out through orifices (F), The fuel becomes finely at-
omized as it is sprayed into the combustion chamber at
This increase in volume available for the fuel causes
high velocity.
the pressure within the delivery pipe to drop suddenly
to about 500 psi (30 bar) (30 kg/cm 2 ). When this
As soon as the "charge" of fuel has been delivered happens, the nozzle valve closes abruptly because of
by the injection pump plunger, the pump delivery valve
the heavy spring tension exerted on it.
closes. The nozzle valve then closes instantly to stop
fuel delivery and prevent after-dribble. stays closed It
The nozzle assembly is lubricated by a small
until opened at the next delivery stroke. amount of fuel which seeps between the lapped sur-
faces of the nozzle and valve which accumulates
NOTE: The injection pump delivery valve has a around the spring (G, Fig. 16).
''retraction piston", which is part of the delivery valve.

The leakage fuel is routed out the nozzle holder
Its function is to provide additional volume for the fuel
through a leak-off connector (H) and returned back to
> in the delivery pipe when the delivery valve closes.
the fuel tank by means of a leak-off pipe (I).

Diagnosing Malfunctions occur on the 21 mm nozzles. Only possible defects

related to these nozzles are listed. Failures in other
Fuel injection nozzles are usually removed from the
components of the fuel injection system are listed
i
engine when there is a noticeable loss of power or
under their respective headings in this group.
excessive smoking.
Refer to Section 30, Group 10 for repair information.

Listed below are various malfunctions which may
FUEL INJECTION NOZZLE

DIAGNOSING MALFUNCTIONS CHART
POSSIBLE SUGGESTED
Engine Has Low

Horsepower Nozzle orifices plugged Repair (Section 30, Group 10)
Incorrect nozzle valve opening
pressure Adjust (Section 30, Group 10}
Broken or damaged parts Repair as required (Section 30, Group
10)
a. Broken nozzle vatve spring
b. Cracked or split nozzle tip
a Cracked or split nozzle body
d. Interna! leak
Wrong nozzle and valve in holder Install correct nozzle assembly (Section
30, Group 10)
Nozzle loose in cylinder head Make sure R64840 steel washer is in-
stalled on tip end of injection nozzle.
Tighten to specified torque (Section
30, Group 00).
Engine Emits Too Much

Smoke Nozzle orifices plugged Repair (Section 30, Group 10)
Broken or damaged parts Repair as required (Section 30, Group
10)
a. Broken nozzle valve spring
b. Cracked or split nozzle tip
c. Cracked or split nozzle body
d. Internal leak
Wrong nozzle and valve in holder Install correct nozzle assembly (Section
30, Group 10)
Worn nozzle valve seat Replace nozzle assembly (Section 30,
Group 10)

Fuel/Air Operation and Tests Control Linkage 230-15-1
CONTROL LINKAGE
Group 15

(Without Foot Throttle)
R29063K
ALever D VerticalControl Rod F Turnbucfcfe

B Lever Screw
Friction Spring ECable or Rear GFront Control Rod
CLever Stop Screw and Jam Nut Control Rod HThrottle Lever
Rg. 1-Speed Control Linkage (Without Foot Throttle)
NOTE: For information on removal, repair, and installation of the speed control linkage,
refer to Page 30-15-1.
TM-1181 (Sep-77) Utho in US. A, Tractors - 4040 and 4240

230-15-2 Control Linkage Fuel/Air Operation and Tests
SPEED CONTROL LINKAGE Continued

Adjustments NOTE: Lengthening rod an additional 1-1/2 turns
insures that the stop screw on pump throttle lever (H)
IMPORTANT: Before adjusting the speed con- will make positive contact with its stop.
trol linkage,be sure that the injection pump fast
and slow idle speeds are correct. See "Adjust-
ments" on pages 10-9 to 10-10 of this section for
instructions on adjusting the injection pump idle
speeds.
Bring engine to operating temperature. Use the fol-
lowing procedure to adjust the speed control linkage:
AJDE-28 Speed Adapter BHand Tachometer

Fig. 3-Checking Stow Idle Speed For Correct
Speed Control Linkage Adjustment
4. Move the speed control lever rearward until the

slow idle speed is reached. Use D-05011-ST hand
tachometer (B, Fig. 3) or other suitable indicator to
determine exact speed.
Adjust stop screw (C, Fig. 1) so that head of screw

just contacts the speed control lever at slow idle.
B Friction Spring Screw C Lever
Tighten lock nut on screw.
Ftg. 2-Disconnecting Linkage And Removing
Speed Control L&ver NOTE: When the speed control fever position is
speed will be the
correctly adjusted for slow idle, the
1. Adjust the speed control lever friction spring same as on the injection pump before the
that set
screw (B, Fig. 2) until a8 lb. (35 N) force at the end of speed control rod was connected. Instructions for set-
the lever is required to move the speed control lever. ting the pump slow idle speed are given on page
230-10-10.
2.Disconnect the tachometer drive cable and install
JDE-28 Speed Adapter (A, Fig, 3), 5. Recheck fast and slow idle speeds. Readjust if
required.
3. Move the speed control lever forward until the
lever stops. Adjust the turnbuckle (G, Fig. 1) until the 6. Remove JDE-28 Speed Adapter and connect
stop screw on pump throttle lever (H) contacts the fast tachometer drive cable.
idle stop.Rotate turnbuckle an additional 1-1/2 turns
(to lengthen rod). This gives about 1/4-in. (6 mm)
override on injection pump throttle lever spring.

Fuel/Air Operation and Tests Control Linkage 230-15-3
R26913N
AVertical Control Rod D Inner Arm H Pedal

BOuter Arm EArm Shaft I Pedaf Arm
CRear Control Rod FShaft Arm J Pedal Support
GSpring
Fig. 4-Foot Throttle Linkage
NOTE: For information on removal, repair and installation of the foot throttle linkage,
refer to Page 30-15-4.
Adjustment floor. Clearance should be 1/4-ia (6 mm).
To check the foot throttle linkage adjustment, move

If clearance is not correct, adjust yoke on rear con-
the hand speed control lever all the way forward to the
trol rod (C, Fig. 4). Tighten lock nut on yoke when
fast idle position.
adjustment is completed.
Check clearance between bottom of foot pedaf and
TM-1181 (Sep-77) Utho in USLA Tractors - 4040 and 4240\

230-15-4 Control Linkage Fuel/Air Operation and Tests
DIESEL FUEL SHUT-OFF CONTROL

A manually operated cable control (Hg 5) operates
T
the shut-off lever on the injection pump.
To adjust the fuel shut-off control cable, loosen the

lock screw on pump shut-off lever (A). With the
(B)
cable control knob pushed all the way in, rotate pump
shut-off lever forward as far as it will go. Remove slack
in cable and tighten lock screw.
A Pump Shut-Off B Lock Screw

Lever
Fig. 5-Dieset Fuel Shut-Off Control

Electrical Operation and Tests Specifications and Special Tools 240-00-1
Section 240
ELECTRICAL OPERATION AND TESTS
Page Page
GROUP 00SPECIFICATIONS AND GROUP 20 LIGHTING CIRCUITS
SPECIAL TOOLS General Information 240-20-1
General Information 240-00-2 Flood Lamps 240-20-3
Charging Circuit 240-00-3 Head Lamps and Tail Lamps 240-20-4
Lighting Circuits 240-00-3 Turn Signals and Warning Lamps 240-20-4
Instrument and Accessory Circuits 240-00-4 Light Switch 240-20-5
Power Front-Wheel Drive 240-00-5 Instrument, Indicator, and Console
Special Tools 240-00-6 Lamps 240-20-5
Dome Lamp 240-20-6
GROUP 05 GENERAL INFORMATION Bu/b Replacement 240-20-6
AND DIAGRAMS
General Diagnosis 240-05-1 GROUP 25 INSTRUMENT AND
Precautions 240-05-6 ACCESSORY CIRCUITS
Electrical Diagnostic Kit 240-05-6 Instrument Cluster 240-25-1
Wiring Diagrams 240-05-8 Accessories 240-25-4
Circuit Breakers 240-05-20 Additional Accessories 240-25-1
SOUND-GARD Body Relay 240-05-21
GROUP 30 POWER FRONT-WHEEL DRIVE
GROUP 06 ELECTRICAL SYSTEM How the System Works 240-30-1
DIAGNOSIS Electrical Tests 240-30-3
Electrical Diagnosis Kit 240-06-1 Syncro-Range Transmission Switches . . 240-30-9
Electrical System Diagnosis 240-06-2
GROUP 35 REMOTE ELECTRICAL CIRCUITS
GROUP 10CHARGING SYSTEM Electrical Remote Control 240-35-1
General Information 240-10-1 Outlet Socket 240-35-4
How the System Works 240-10-1
Precautions 240-1 0-4
GROUP 15 STARTING CIRCUIT

General Information 240-15-1
How the System Works 240-15-1
Key Switch Continuity Check 240-15-3
>

240-00-2 Specifications and Special Tools Electrical Operation and Tests
Group 00
SPECIFICATIONS
GENERAL INFORMATION
Batteries
Item Specification
Battery ground Negative

John Deere part no AR47455
BCI group 5D
Battery voits 6.2 to 6.5
Cold cranking amps at 0F (-18C) 800
Reserve capacity (minutes at 25 amps) 340
Full charge specific gravity 1 .260
Circuit Breakers
A Front Rood Lamps and Upper Rear Flood Lamps

BHorn, Lighter
CKey Switch
DTurn Signals, Warning Lamps, Tail Lamps, Lower Rear
Flood Lamps
FSOUND-GARD Body Serial Number ( -167013)
Radio, Left-Hand Wiper, Blowers
FSOUND-GARD Body Serial Number (167014- )
Radio, Wipers
GSOUND-GARD Body Serial Number ( -167013)
Right-Hand Wiper, Blowers
GSOUND-GARD Body Serial Number (167014- )
Blower
HSOUND-GARD Body Relay
R 28792N
Fig. 1 -Circuit Breakers

Breaker "A" 30 amps

U
Breakers number "B", "D", E", and "F" at load center 20 amps
Breaker "G" at load center
SOUND-GARD Body serial number ( -167013) 20 amps
SOUND-GARD Body serial number (167014- ) 30 amps
Breaker number "C" at load center 1 amps
Power front-wheel drive breaker 10 amps
Electricalremote control breaker 25 amps
Breaker trip time with 50% overload 20 to 50 seconds
Breaker reset time with load removed 60 seconds

1
CHARGING CIRCUIT
hem Specification
Voltage checks:
"BAT terminal Battery voltage

Red wire to No. 2 terminal Battery voltage
Brown wire to No. 1 terminal (key switch on)
With wire connected to terminal 2 to 9 volts
With wire disconnected at alternator Battery voltage
Voltage increase at "BAT" terminal (engine running/engine stopped) 0.5 volts minimum
AC voltage ripple at No. 1 terminal (engine running) 0.4 volts maximum
Regulated voltage at "BAT" terminal after 15 minutes operation:
Air Temperature 1 in. (25 mm)

Behind Regulator Case Vottage
85F (29C) 13.8 - 14.9 volts

105F(41C) 13.6 - 14.7 volts
1 25T (52C) 13.4-1 4.6 volts
145T (63C) 13.2 - 14.4 volts
Output test (optional)

LIGHTING CIRCUITS
BULBS (12-16 volt) No.

Dual-beam headlight 4460
Flood lamp;
Front and lower rear 4466
Upper rear . . ; 441
Tail lamp (white, double contact) 1 157
Warning lamp (single contact) 1 1 56
Tachometer lamp (miniature bayonet base) 1 893

Console lamp:
Sound-Gard Body and 4-post Roll-Gard (wedge base) 681
Regular tractor (bayonet base) 53

Dome lamp (bayonet base) 1003
Cluster lamps (wedge base) 194
Transmission oil and air cleaner indicator lamps (wedge base, flashing) 557
Hi-beam indicator lamp (miniature bayonet base) 1893
>
TM-1181 (S&P-77) Lftho in U.S.A. Tractors - 4040 and 4240

INSTRUMENT AND ACCESSORY CIRCUITS

ltem
Specification
Voltmeter:
indicator at left edge of battery voltage green range 1 1.8 volts
Indicator straight up
........ 13.0 volts
Indicator at right edge of charging voltage green range 15.5 volts
Air cleaner indicator lamp switch:

Closes above 24 26
to in. water
(60 to 65 mbar)
Transmission oil pressure switch (Quad-Range):

Closes below 90 to 100 psi
(6.2 to 6.9 bar)
(6.2 to 6.9 kg/cm2)
Transmission oil temperature switch (Power-Range):

Closes above 215 to 225F (102 to 107C)
Horn (Robert Bosch, Model 320 023 006):
Current draw at 12.0 volts
3 3 amps
Radio and tape player fuses
5 amps
Tape player relay:
Current draw at 12.0 volts
07 amps
Winding resistance '.'.['.['.[]
180 ohms
NOTE: For fuel, coolant, and oil pressure gauge and sender unit resistance checks, see page 240-06-56.

INSTRUMENT AND ACCESSORY CIRCUITSContinued

Item Specification
Electric starting aid solenoid:

Current draw at 12,0 volts 4 to 5 amps
Winding resistance 1 .5 ohms
Wiper motor current draw:
Low speed 2 to 3 amps
High speed 3 to 4 amps
Additional accessories:
Maximum added to accessory circuit breaker 5 amps
Maximum connected to added circuit breaker 20 amps
Minimum power supply wire size to added circuit breaker 10 gauge
Minimum wire size to added accessories 16 gauge

Solenoids:
Current draw at 12.0 volts Approx. 1.4 amps
Winding resistance Approx. 8.5 ohms
piutch pressure switch 30 to 60 psi
(2.1 to 4.1 bar)
(2.1 to 4.1 kg/cm 2 )

SPECIAL TOOLS
General Information Tool Use
*D-24001MO Battery Tester Test batteries
R 28793N
*D-05136ST Voltage Test wiring circuits for opens, I
Detector shorts, or grounds I
R 28794N
*D-19001TT Volt-Ohm -Amp Test any electrical components

Meter for voltage, resistance, or cur-
rent draw
* Order from:
Service Tools, Inc.
P.O. Box 314

Owatonna, MN 55060
%m*m (
Fig. 4-D-19001TT Volt-Ohm -Amp Meter

A
General Information Continued

TOOL USE
I
D-05138ST Carrying Case Store D-24001MO Battery Tes-
ter,D-05136ST Voltage Detec-
tor,D-19001TT Volt-Ohm-Amp
Meter, and their operator's
manuals
Fig. 5-D-05138ST Carrying Case
Charging Circuit
D-19001TT Volt-Ohm- Amp Test charging circuit
Meter
Lighting Circuits
D-05136ST Voltage Detector Test wiring circuits for opens,

shorts, or grounds
Instrument and Accessory Circuits
JDST-33 Universal Gauge Test fuel gauge, water temper-
Tester ature gauge, engine oil pres-
sure gauge, and their senders
Fig, 6-JDST-33 Universal Gauge Tester
Order special tools from Service Tools, Box 314, Owatonna MN 55060,
>
TM-1181 (Feb-79) Litho in U.S. Tractors - 4040 and 4240

SPECIAL TOOLS
TOOL NUMBER USE
Power Front Wheel Drive Used in electrical circuit diagnosis of power front
wheel drive. See page 9 for instructions for making
tool.
R33261
Fig. 7-Power Front Wheel Drive Test Box


Parts required: 3. Knock out plug from outlet box and install
1-AR49298 PFWD Control Valve Harness "Romax connector (Fig. 9).

3-AR48034 Alternator Indicator Lamp
3-R32037 Splice (from AR84006 Wiring Kit) 4. Cut wire of each AR48034 Indicator lamp 1-1/2"
3-1/2 ft. (106.7 cm)-14 Ga. Wire (from AR84006 (3.8 cm) from lamp.
Wiring Kit)
1-2"x4"x2" Deep Box
Electrical Outlet 5. Install cut-off end of AR49298 Harness through
1-2"x4" (5.1x10.4 cm) Blank Box Cover connector and use R32037 splices to connect indicator
1-"Romax" Cable Connector lamps to harness.
1-10 amp Battery Clip
6. Cut two pieces 2-1/2" (6.4 cm) long, from 14 Ga.
Construct as follows: wire.
1. Cut AR49298 Harness (Fig. 8) 1-1/2" (3.8 cm)
from female plug end. 7. Connect battery clip to one end of remaining 14
Ga. wire. Install through connector and attach to
2. Splice, solder and tape the removed female plug ground terminal of center lamp.
end wires to the male plug end wires as shown.
8. Use the two 2-1/2" (6.4 cm) wires to connect
center lamp ground lead to right and left lamp ground
leads. Solder the three connections.
( \
Rk92k8 Black;
t ,.
I
Harness Ispl ice i
(Solder j
land Tape'
2-1/2" (64 mm)
1-1/2"
k Ga. Wire
(38 mm)
Outlet Box
R33262
Fig, 8-Hamess Revision

R33263
^ A
Fig. 9-Outlet
J)
Box Assembly
>

MAKING SPECIAL TOOLS Continued

9. Mark and drill three 11/16" holes in box cover, as
shown in Fig. 10, EMBOSSED TAPE
10. File 5/64" (2 mm) locating notches in cover.

TORQUE REV
1 FOR NOTCH
11. Stamp letters or install embossed tape on (2 mm)
cover.
Drill
11/16"
12. Assemble indicator lamps in cover and install 11
Hole
I
cover on box. Tighten "Romax" connector. ^25 mmV -[25 mnW+ZS
13. (Optional) Install three strips of magnetic tape

n/16"
(37 mm)
(available at large department stores or hobby shops)
R33264
to bottom of box, to hold box to any metaf surface of
tractor.
Fig. 10-Box Cover Changes

Electrical Operation and Tests General Information and Diagrams 240-05-1
Group 05
GENERAL INFORMATION AND DIAGRAMS
GENERAL DIAGNOSIS
Battery Test
When diagnosing a tractor for any electrical prob-
lem, regardless of the complaint, test batteries first.
Battery condition is vitally important to every part of

electrical system.
ABattery Voltage Switch CTemperature Switch

BSelector Switch DBattery Rating Switch
4. Set toggle switch (A, Fig. 2) on 6 volts and turn

selector switch (B) to "VOLTS." Check battery voltage.
SiiWi It should be 6.2 to 6.5 volts.
Fig. 1-Battery Inspection 5. If voltage is too high, turn headlights on for 30
seconds to remove surface charge. Then recheck

1. Inspect both batteries. Check for a cracked, voltage.
damp, or dirty case. (Case should be clean and dry to
prevent surface discharge.) Check for loose or corrod- 6. If voltage is too low, charge batteries. Then re-
ed terminals. Correct as necessary. check voltage. If the two batteries have unequal volt-
age, they must be charged individually.
2. Check electrolyte level in each cell. Add clean,
mineral-free water if necessary to bring level to bottom 7. If voltage is correct, check battery condition. Turn
of filler neck. temperature switch (C) to estimated battery tempera-
ture. Turn battery rating switch (D) to 800. Turn selec-
Connect D-24001MO Battery Tester, with red
3. tor switch to "BAT COND." and read battery condition.
clip to positive terminal and black clip to negative
terminal. Batteries must be tested individually, but it is 8. If tester indicates "REPLACE," disconnect bat-
not necessary to disconnect battery cables. tery cables and recheck. Problem might be due to a
poor connection.
9. When finished with tester, turn selector switch to

"OFF."
>

240-05-2 General information and Diagrams Electrical Operation and Tests
Preliminary Checks
After making sure batteries are in good condition,
perform the following operational checks. Regardless
of the complaint, check the entire eiectrical system.
Make a note of anything which doesn't work, and see
that it is repaired.
Repeat the operational checks after making repairs,

to make sure the entire electrical system works prop-
erly.
Fig. 5-Light Switch
3. Turn light switch to each position, and check all
lamps which should glow.

Jiiiiilii;
Fig. 3-Dome Lamp "W": Front and rear warning lamps (if flashing lamps
are prohibited by local ordinances, lamps
Make sure dome lamp glows when door is
1.
should glow steadily.)
opened, and goes out when door is closed. Also make

sure toggle switch turns lamp on and "H": Front and rear warning lamps, head lamps, tail
off.
lamps, instrument lamps, and console lamp.
With dimmer switch on high beams, also front

flood lamps and high-beam indicator lamp.
"F": Head lamps, front flood lamps, lower rear flood

lamps, instrument lamps and console lamp.
With dimmer switch on high beams, also upper

rear flood lamps and high-beam indicator
lamp.
Fig. 4-Turn Signal Lever
2. Push turn signal lever up. Right-hand warning

lamps should flash and left-hand lamps should glow
steadily. Pull turn signal lever down. Left-hand lamps
should flash and right-hand lamps should glow steadi-
ly-

A Lighter B Horn Switch Fig. S-Hadio and Tape Player
Fig. 6-Lighter and Horn Switch 7. With key switch on, turn radio on. Make sure both
4. Push lighter in, and make sure element heats. speakers and all controls work properly. If equipped
with tape player, check it also. Make sure relay shuts
5. Depress horn switch, and make sure horns radio off when a tape is inserted. See that channel
sound. If equipped with dual horns, make sure they selector and all controls work properly.
both sound.
^mm^mm^

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Hi
ALett-Hand Wiper Switch C Blower Switch

AVoltmeter OFuel Gauge B Air Conditioning D Heater Control
BOil Pressure Gauge E Indicator Lamps Temperature Switch E Right-Hand Wiper Switch
C Temperature Gauge
Fig. 9-Sound'Gard Body Controls
Fig, 7-lnstrument Cluster
8. With key switch on and windshield wet, turn
6. With key switch on, check instrument cluster. wipers (A and E, Fig. 11) on. Make sure both wiper
Voltmeter (A, Fig. 9) should rise to left-hand green motors operate on high and low speeds and return to
band. park position when turned off.
With key switch on, turn blower switch (C) on.

9.
Oil pressure gauge (B) should indicate zero. Make sure both blower motors run on both high and
Temperature gauge (C) should low speeds,
register correctly.
10. With key switch and blower switch both on, turn
Fuel gauge (D) should register correctly. air conditioning temperature switch (B) to maximum
On tractors with Perma-Clutch, transmission oil in-
cooling. Make sure air conditioning compressor clutch
dicator lamp (E) should glow. engages with an audible click.

240-05-4 General Information and Diagrams Electrical Operation and Tests
Fig. 10-Starting Aid Switch
11. With key switch on and transmission in park,

AVoltmeter DFuel Gauge
lightly tap starting aid switch. Make sure starting aid B Pressure Gauge
Oil EIndicator Lamps
solenoid engages with an audible click, but do not hold 0Temperature Gauge
button down and inject starting fluid.
Fig. 12-ln$trument Cluster
14. With engine running, check instrument cluster.
Voltmeter (A, Fig. 14) should rise to upper green

band. If alternator is charging, voltmeter will register
higher with engine running than with engine stopped.
Oil pressure gauge (B) should stay above red

warning zone.
Temperature gauge (C) should register correctly.
Fuel gauge (D) should register correctly.
Both indicator lamps (E) should go out.
ATransmission in Gear
BKey Switch in Start Position
CIndicator Lamps
Fig. 1 1-Checking Indicator Lamps
12. Shift transmission to any gear except neutral or

park, and turn key switch to start position.
Fig. 13-Power Front-Wheel Drive Switch
Make sure that starter does not operate.
15. If tractor is equipped with power front-whee!
drive, operate tractor on a sandy or gravelled surface.
Make sure that both indicator lamps glow. They about 2000 rpm, and drive tractor in
Operate engine at
should begin flashing within 60 seconds.
each transmission gear.
13. With transmission in park, turn key switch to Repeatedly engage and disengage front-wheel
start position. Starter should crank engine. drive, both high and low torque, in each gear. Watch
front wheels to see whether drive engages. Drive
should engage only in the following gears.

Electrica l Operation and Tests General Information and Diagrams 240-05-5
Drive should engage in the following gears: Diagnosing Malfunctions

Use any problem. Be sure
careful logic in diagnosing
POWER SHIFT QUAD-RANGE
exactly what iswrong before beginning the repair.
Gear Lo Hi Gear Lo Hi Always follow the seven basic diagnostic steps:
1 X X A-1 X X
2 X X A-2 X X 1. Know the system.
3 X X A-3 X X 2. Ask the operator.
4 X X A-4 X X 3. Inspect the system.
5 X A-1R X X 4. Operate the machine (if possible).
6 X A-2R X X 5. List possible causes.
7 B-1 X X 6. Reach a conclusion.

*
8 B-2 X 7. Test the conclusion.
*
B-3 X
1R X X B-4 Usually one of the first checks is to determine if there
*
2R X X B-1R X is voltage at the suspected component. If access is not
3R X X B-2R convenient, determine first at a more convenient place
*
4R X X C-1 X whether voltage is available to other units nearby.
*
C-2 X Check the voltmeter and various lights.
*
C-3 X
C-4 When checking at the component, be sure to include
* For example, the Sound-Gard Body
C-1R X the ground circuit.
C-2R ground wire at the right-hand front rubber mount is the

D~1 ground for the instruments and other electrical com*
D-2 ponents in the Sound-Gard Body.
D-3
D-4 Whenmeasuring current draw, remember to allow
*Automaticaily switched for the normal current draw when the key switch is
to low torque. turned on. The instrument cluster draws approximately
1 .2 amps with the transmission oil indicator lamp out
and 1 .5 amps with the lamp glowing. The Sound-Gard

Body relay draws approximately 0.5 amp.
NOTE: When using a tong-type ammeter, disregard

instructions to remove wire and connect ammeter in
series. Simply place tong around wire.
>

.
PRECAUTIONS ELECTRICAL DIAGNOSTIC KIT

The following electrical diagnostic equipment rec-
A
is
When working on system, observe
electrical
ommended for all tractors. All three tools are included
the following rules for your safety and preven-
in the Electrical Diagnostic Kit, and each too! can be
tion of damage to tractor:
purchased separately.
Safety
1 Keep all sparks and flames away from batteries.
Gas from battery electrolyte is highly flammable. Also
avoid spilling electrolyte on yourself or on anything
which could be damaged by the sulphuric acid.
2. Avoid sparks when connecting booster batteries

or battery chargers. When possible, make last con-
nection at a point away from batteries. Battery charger
should be turned off before connecting or disconnect-
ing.
3. When connecting batteries, always connect

ground cable last. Disconnect it first.
:R 2m\
4. When possible, disconnect battery ground cable
before working on electrical system. Fig. 14-D-24001MO Battery Tester
5. Before running engine of a tractor with power 1. D-24001MO Battery Tester quickly indicates
front-wheel drive, shut off main hydraulic pump, dis- battery condition. Battery testing instructions are on
connect three-terminal connector near solenoids, or page 240-05-1 and an operator's manual
, is included
raise both front wheels. This is to prevent tractor with the tester.
movement if drive is accidentally engaged.
For these tractors, each battery is rated at 800 cold
Prevention of Damage cranking amps.
1. Before connecting battery cables, be sure that

battery and alternator connections are correct. Re-
verse polarity can cause permanent damage.
2. When connecting a booster battery, connect

positive terminal of booster battery to positive terminal
of left-hand battery. Then connect negative terminal of
booster battery to tractor frame. Reverse polarity can
cause permanent damage.
3. Never run engine with alternator or battery cables

disconnected. Doing so might damage alternator or
regulator.
4. Never short across or ground alternator terminals

unless specifically recommended. Be careful to pre-
:
:;H. ll!P|pK|ii;
vent grounding alternator wires when disconnected. Fig. 15-D-05136ST Voltage Detector
5. Never attempt to polarize an alternator.
6. Before using an electric welder on tractor, dis-

connect battery ground cable. Connect welder ground i
clamp as near as possible to the area being welded,
and be sure it makes good electrical contact.

2. D-05136ST Voltage Detector aids in checking all .:

" .-î.:-/'
m>'m
wiring circuits. "A" light indicates battery voltage at the
component being tested. "C" light indicates a good
ground. No light indicates an open circuit or excessive
voltage drop. ("B" light is not used when testing these
tractors.)
An operator's manual is included with the voltage

detector.
Fig. 17-D-19001TT Voft-Ohm-Amp Meter
3. D-19001TT Volt-Ohm-Amp Meter is used for
testing alternator and for whatever other jobs require

measuring voltage, resistance, or current flow.
Alternator test instructions are in Group 10 of this

section. Also refer to the operator's manual included
with the meter. For accurate results and protection of
the meter, it is vitally important that you follow instruc-
tions carefully.
AKnown Source of Battery Voltage ("A" Clip)

BSuitable Ground ("B" and "C Clips)
Fig. 16-Voltage Detector Connections
For these tractors, connect "A" clip to positive ter-

minal of left-hand battery or to a known source of
battery voltage."BAT" terminal on alternator and large
terminalwhere battery cable attaches to starter are
convenient locations. Connect both "B" and "C" clips
to a good ground.
>

WIRING DIAGRAMS These diagrams refer to early tractors with Sound-

Gard Body serial number prior to 030059. Early trac-
Diagrams on the following pages illustrate all wiring
tors were built with a double rather than single blower
<
connections. Use these diagrams and information in
motor. Information about later tractors (Sound-Gard
the following groups for diagnosis.
Body serial number 030059 and beyond) can be found
in Group 25, Section 240.
Fig. 18 shows location on the tractor of all electrical
components.
Many wires are identified by circuit numbers.
Fig. 19 is a schematic diagram showing, in simplest
These numbers are helpful in locating the same circuits
in various diagrams.
relationships, how the system fits together.
As an example, "R-8" identifies a red wire in circuit
Figs. 20 and 21 show all the wires on a tractor (not
number 8.
including optional equipment).
Multiple connectors shown disconnected in the dia-

Figs. 22 through 25 illustrate individual harnesses,
grams are viewed from the terminal end. Multiple con-
showing connector terminal positions -
nectors shown connected to the key switch, light

switch, and dimmer switch are viewed from the wire
end.
i
TM-1181 (Feb-79) Litho in US, A. Tractors - 4040 and 4240
s
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240-05*14 General Information and Diagrams Electrical Operation and Tests
TURN SIGNAL 9 30 96 28
CONTROLLER 23 5 16
n 95
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AID
SWITCH
R 23826N W-3I
KEY (
SWITCH
Rg. 23-Main Instrument Harness Connections
TM-1181 (Sep-77) Utho in US, A. Tractors - 4040 and 4240

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Electrical Operation and Tests Genera! Information and Diagrams 240-05-17
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TM-1181 (Jun-80) Lltho in U.S.A. Tractors - 4040 and 4240

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>

CIRCUIT BREAKERS
9 30 96 28 Electrical system is protected by circuit breakers
located under left-hand cowl.
1
23 5 16
11 95
3 1
o
150
147 32 33
26 13 1
19 20 17 24
>
R 28829N
9 Ether Switch
30Fuel Gauge
96Transmission Oil Indicator
28 Air Cleaner Indicator
23Starter Circuit Relay
5 Horn
16 Ignition Circuit (Not Used)
11 Pressure Gauge
Oil
95 Engine Temperature Gauge
3 Alternator Energizing Circuit R 28830N
150 Front Flood Lamps
147 Upper Rear Flood Lamps A Front Flood Lamps
32 Radio, Compressor, Left Wiper, Left Blower BHorn, Lighter
33 Right Wiper, Right Blower C Key Switch
26 Dome Light DTurn Signals, Warning Lamps, Tail Lamps, Rear Flood
13 Hi-Beam Indicator Lamps
1 Console Lamp EHead Lamps
19 Lower Rear Flood Lamps
20Tail Lamps Fig. 31-Circuit Breakers
17 Right Warning Lamps (Tractor Without SOUND-GARD Body)
24 Left Warning Lamps
29-BuIkhead Connector Terminal Location as Viewed

A tractor without SOUND-GARD body has one 30-
Fig.
From Engine Side of Bulkhead amp breaker, three 20-amp breakers, and one 10-amp
breaker. All five are "hot" at all times.
R 25986N
AStarter D Band
BClamp EGround to Oil Filter Base
Fig. 30-Battery Connections for Tractor With 4-Post

ROLL-GARD or SOUND-GARD Body

The circuit breakers reset themselves, but only after

the load removed. A heater element keeps the
is
I breaker tripped as iong as the load is connected.
To reset a breaker, turn off the switches for all
circuits connected to that breaker. (If it's one of the

breakers connected to the SOUND-GARD body, turn
off the key switch.) Wait at least two minutes before
trying the circuit again.
If this doesn't reset the breaker, disconnect the

battery ground cable for at least two minutes. If breaker
does not reset itself, breaker is defective. If it does
reset itself, check carefully for a short circuit in the
wiring.
Maximum voltage drop across a circuit breaker

R 2B792N
should not exceed 0.15 volt. If voltage drop is exces-
sive, check for poor connections or a faulty breaker.
A Front Rood Lamps and Upper Rear Flood Lamps
BHorn, Lighter A circuit breaker should trip in 20 to 50 seconds
C Key Switch when carrying 150% of its rated loadfor instance, a
D Turn Signals, Warning Lamps, Tail Lamps, Lower Rear
Ffood Lamps 30-amp current through a 20-amp breaker.
F SOUND-GARD Body Serial Number ( -167013) Radio, SOUND-GARD Body Relay
Left-Hand Wiper, Blowers
F SOUND-GARD Body Serial Number (167014- ) Radio, The SOUND-GARD body relay (H, Fig. 32) provides
Wipers power breakers only when the
to the right-hand circuit
G SOUND-GARD Body Serial Number ( -167013) Right- key switch is in the on or accessory position. The relay
Hand Wiper, Blowers
G SOUND-GARD Body Serial Number (167014* should close with an audible click, and voltage drop
) Blower
H SOUND-GARD Body Relay across it should not exceed 0,2 volts.
Fig. 32-Circuit Break&rs Disconnect battery ground cable before removing

SOUND-GARD body relay.
A tractor with SOUND-GARD body also has two DO NOT substitute any other similar-appearing
additional 20-amp breakers. These two are "hot" only relay.Other relays may be normally closed or may be
when the key switch is turned on, closing the intended for intermittent use only.
SOUND-GARD body relay.
TM-1181 (Jun-80) Liiho in USA. Tractors - 4040 and 4240


Electrical Operation and Tests Electrical System Diagnosis 240-6-1
Group 6
ELECTRICAL SYSTEM DIAGNOSIS
ELECTRICAL DIAGNOSTIC KIT 2. D-05136ST Voltage Detector aids in checking all
wiring circuits. "A" light indicates battery voltage at the
The following electrical diagnostic equipment is rec-
ommended for ail tractors.
component being tested. "C" light indicates a good
ground. No light indicates an open circuit or excessive
voltage drop. ("B" light is not used when testing these
tractors.)
An operator's manual is included with the voltage

detector.
M$mm
1. D-24001MO Battery Tester quickly indicates

battery condition. Battery testing instructions are on
page 2, and an operator's manual is included with the
tester.
A Known Source of Battery Voltage ("A" Clip)

BSuitable Ground ("B" and "C" Clips)
Fig. 3-Voltage Detector Connections
For these tractors, connect "A" clip to positive ter-

minal of left-hand battery or to a known source of
battery voltage. "BAT" terminal on alternator and large
terminalwhere battery cable attaches to starter are
convenient locations. Connect both "B" and "C" clips
to a good ground.

240-6-2 Electrical System Diagnosis Electrical Operation and Tests
ELECTRICAL SYSTEM DIAGNOSIS

The following pages give a complete diagnosis pro-
cedure for electrical system.
Where circuit diagrams appear on a fold-out page,

you can lay that page out so the diagrams show as you
follow the test sequence through other pages.
Read the charts from left to right, starting with a step

inthe test sequence and following through the result.
Then go directly to the step indicated by your result.
IMPORTANT: Always start at beginning and fol-

low step-by-step instructions precisely. Never
perform steps out of sequence.
Fig. 4-D-19001TT Volt-Ohm-Amp Meter
3. D-19001TT Voft-Ohm-Amp Meter is used for

testing alternator and for whatever other jobs require
measuring voltage, resistance, or current flow.
instructions for testing alternator are in Section 4 of

the foflowing diagnosis. An operator's manual is in-
cluded with the meter.
R33261
Ftg. 5-Power Front Wheel Drive Test Box
4. Power Front Wheel Drive Test Box is used to test

the electrical circuits of the PFWD.
Instructions for using the test box are in Section 10

of the following diagnosis.
Instructions for building this test box are given in

Section 240-00.

CONTENTS
Section
INTRODUCTION-
1 PRELIMINARY CHECKS
A1 through A19 a, Key Switch Voltage Test
b. Battery Testing
OPERATIONAL CHECK of all switches and electrical components:

A. -Lighting Circuit
B. .Horn and Lighter Circuit
C. .Accessory Circuit
D. .instrument Cluster Circuit
E. .Starting Circuit
F. .Engine Running Checks
G. .Radio-Tape Player Circuit
H. _Power Front Wheel Drive Circuit
STARTING CIRCUIT -
A1 through A5 -Operational Checks
B1 .Starter operates, but engine does not crank.
C1 .Starter solenoid chatters (engine may or may not crank)
D1 through D13 .Starter solenoid does not operate with transmission in PARK
E1 through E7 _ .Engine cranks slowly.
F1 through F3 _ .Engine cranks in gear.
G1 through G4_ .Starter continues to operate after engine starts.
H1 through H6_ .Engine starts, but sfarting aid will not inject starting fluid.
J1 through J2 _ .Engine cranks but stops cranking when starting aid switch
pushed IN.
^^^^^^m
CHARGING CIRCUIT-
A1 through A3 ..Operational Checks ^^^^^^H
B1 through B22 .Delco Remy Alternator
C1 through C19 _John Deere ND Alternator
INSTRUMENT CLUSTER Gauge and Indicator Circuits

A1 through A10 .Operational Checks
B1 through B6 .Voltmeter
C1 through C13 .Fuel,Engine Temperature and Engine Oil Pressure Gauges
D1 through D12 .Transmission Oil and Air Cleaner Indicator Lamps
E1 through E6 .Transmission Oil Lamp does not come on.
LIGHTING CIRCUIT
A1 through A10 .Operational Checks (2-Speed SGB Blower)
B1 through B9 .Operational Checks (3-Speed SGB Blower)
Schematics No. 6-1 through 6-5
SGB ACCESSORY CIRCUIT

A1 through A10 Operational Checks
HORN AND LIGHTER CIRCUIT

A1 through A5 Operational Checks
Schematic No. 8-1
)
EZZ100

CONTENTS (Continued)
Section
RADIO AND TAPE PLAYER CIRCUIT

A1 .Operational Checks
AM okay, but FM inoperative.
FM okay, but AM inoperative.
B1 through B12. .Tape player okay, but radio inoperative.
Radio and tape player inoperative.
Radio okay, but tape piayer inoperative.
One speaker inoperative.
C1 .Poor Reception
D1. .Excessive static
Schematics No. 9-1 through 9-4.
POWER FRONT WHEEL DRIVE CIRCUIT

A1 .Operational Checks
B1 through B2. .Solenoid Test
B3 .PFWD Light Box Test
B4 through B15_ _PFWD Circuit Ground Test
C1 through C14. .PFWD Circuit Voltage Test
R33101

INTRODUCTION
When diagnosing any electrical problem, there are two common tests that must be performed.
PRELIMINARY CHECKS Key switch "ON" checks battery voltage. Key switch at "START"
(Refer to Section
OPERATIONAL CHECKS
1) checks battery condition. The tractor voltmeter indicates voltage at key
switch and buss bar.
Operational checks indicate which circuits are operating properly.

a
(Refer to Section 2) This is accomplished by turning each electrical function switch "ON" then
"OFF" and observing reaction of components. Operational checks should
be performed both before diagnosing circuit problems and after repair to
verify that the problem has been solved.
COMMON CIRCUIT PROBLEMS

SHORTED CIRCUIT A shorted circuit may result in the wrong component operating, i.e., im-
proper wire-to-wire contact. To test for a shorted circuit or improperly wired
circuit:
1. Turn the correct component switch "ON".
2. Start at controlling switch of component that should not be operating.
3. Follow circuit and disconnect leads at couplers until component stops
operating.
4. Short or improper connection will be between the last two leads discon-
nected.
HIGH RESISTANCE OR High resistance or open circuit usually results in slow, dim or no
OPEN CIRCUIT component operation, i.e., poor, corroded or disconnected connections. To
test for high resistance and open circuits:
1. Check all terminals and grounds of circuit for corrosion.
2. If terminals are not corroded or loose, the problem is in the component

or wiring.
GROUNDED CIRCUITS Grounded circuits usually result in no component operation and a tripped
circuit breaker, i.e., power leads contacting a "ground". To test for
"grounds", check for voltage in the power circuit from the circuit breaker.
HOW TO USE STEP-BY-STEP CHARTS

The charts are usually divided into three sections:
STEP SEQUENCE- RESULT
Always start at the first step and go through the complete sequence from left to right. Each sequence
ends with a result and tells you the next step. Work through the appropriate steps as directed until the
malfunction is found. Make the repair and return to the Operational Check (A1) for that circuit to be cer-
tain the malfunction has been corrected. Finally, repeat Section 2, "Operational Checks" to
be certain
other circuits were not affected during the repair.
ABBREVIATIONS USED
PST - Power Shift Transmission MA Milli-Amp -
BAT. - Battery
QRT - Quad-Range Transmission V - Volts or Voltage ACC. - Accessory
SRT - Syncro-Range Transmission SPEC. - Specification IGN. - Ignition
PFWD - Power Front Wheel Drive TEMP. - Temperature SW. - Switch
SGB -Sound-Gard Body MIN. - Minimum ST - Start
TRANS. - Transmission
MAX. - Maximum FWD. - Forward
HSG - Housing
NEG.(-) - Negative REV. - Reverse
WOT - Wide Open Throttle POS.( + )
- Positive TQ - Torque
RPM - Revolution Per Minute WL - Warning Light NO. - Number
AC - Alternating Current TL -Tail Light HI -High
CCA - Cold Cranking Amps V. Det. -Voltage Detector LO - Low
R33102
USING A PROBE LIGHT

The following examples show how to connect a probe light to check a circuit for voltage or continuity to
fk ground. When checking a circuit for battery voltage, connect the probe light clip to ground as shown:
I_
*SSB^
Switch
Neg. Circuit Ground
Ground Breaker
Batteries
CHECKING
FOR VOLTAGE
Ground
When checking a circuit for continuity to ground connect the probe light clip to a known source of battery
voltage as shown:
Switch
Neg. Ground
Ground
CHECKING FOR
A GROUND
The controlling switches MUST BE "ON" and the circuit connected to the component to locate low
resistance (0.5 to 5.0 ohms) in the load circuit or ground circuit of a component.
The following seven steps can be used to locate opens, grounds, high resistance or faulty components
with the use of the fold-out color electrical wiring diagram.* The simple circuit can be used as a reference
for each step but you must relate to the color wiring diagram for additional components that may be con-
nected in parallel.
You may want to start at step

component is easily accessible.
as your first step for diagnosing any m^nfunctioning circuit where the
battery voltage
If is not present at step (&) it will be necessary to go to
,
step ($) to isolate the malfunction.
IMPORTANT - This sequence is not to be used in a circuit that is functioning properly.
NOTE: After any repair, always return to Operational Check, Section 2, to be certain another circuit has
not been affected during the repair.
R31850

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PRELIMINARY CHECKS
Step Sequence Result
w
(Al) KEY SWITCH VOLTAGE
TEST:
Voltmeter Pointer should be
in LH green band.
Above
Voltage
or in Green:
OK 1
_____
GO TO A2
Transmission in
"PARK" Below Green:
Key Switch "ON" Voltage Low. | GO TO A3
@ BATTERY LOAD TEST:

Transmission in
Hold key switch at "START".
Voltmeter should indicate
Voltage
Indicated:
GOTO
SECTION 2
"PARK". Hold Fuel some voltage. OPERATIONAL
OK.
Shut-off "OUT". CHECKS
* * A f
No Voltage
Indicated: GO TO A3 1
*u^ Not OK
1
(A3) BATTERY INSPECTION Check both batteries for: Correct any abnor-
mal conditions. f.^^^-
Then... | GO TO A4 1
o o o
ft
o o o
fe
Cracked Case? Corroded Terminals? Loose Terminals
or Battery Posts?
dr. [k
g==" +%&Z^
Dirty Battery? Damp Battery? Electrolyte Level OK?
R32580

1
(A4) BATTERY VOLTAGE Battery Spec. (Min.) In Spec: I GO TO AS I

^-^ TEST: 6.2 Volts
Connect battery tester (D-24001 MO) Below Spec:
to battery cables as shown: Charge battery.
Then... I REPEAT A4
D Important: Test individually only.
Battery will not
charge. Replace.
Then... REPEAT A4]
BATTERY CONDITION TEST: In green:

Set tester at"BAT COND." and Cold Cranking Amps OK I GO TO A7 T
(CCA) at 800 for AR47455 battery.
Important: Test Individually only.
In red:
Check battery condition scale. Not OK IGOTOA6 |
"Bat. Cond."
Note: If battery tester is not available, use a hydrometer or
load tester. Follow manufacturers instructions. Then

GO TO A7.
Remove battery cables from posts. Repeat battery con- In green:

Connect tester as shown: dition test as in A5. Clean cables and
posts. Then... IGOTOA7 \
NOTE: Reconnect
cables after In red:
test or re- Replace battery.
pair. Then... 1GOTOA4 |
RZZ104
w
(A7) key switch voltage
TEST:
Key Switch "ON".
Voltmeter pointer should be
in LH green band.
Above
green:
Voltage
or in
OK
GOTO
SECTION 2
OPERATIONAL
CHECKS
Below green:
Voltage Low.
GO TO A8 |
(A8) Raise hood Key switch "ON". Check locations in- OK: GO TO A9
and LH steer- dicated with (v)""^* for battery voltage.
ing support NOT OK:
cowling as WITHOUT Repair. Then. GO TO A7
required. WITH SGB S<38
Circuit ^^
Relay Key Switch
(A9) Key Switch "OFF". Check load side of key switch circuit Battery Voltage: ,
^^^ breaker for battery voltage. OK |G0 TO A12
Low Voltage:
0**0, Replace circuit
breaker. Then... JGO TO A7 1
NO Light:
(Probe Light Only) |GOTO A10|
<gg4i
Continuity to
ground: GO TO A11
R347SS
(Aim (Probe
^-^
Step
light only.)
nect clip to battery
Con-
Sequence
Check load side of key switch

circuit breaker for continuity
Light:
Result
GOTOA11I
1
voltage ( + ) as shown: to ground. No Light:
Key switch "OFF". Replace circuit
_ggj breaker. Then... 1GOTOA7 1
OFF
Probe
Light
(All) There is a "GROUNDED" circuit: Repair circuit.

^-^ 1. Between circuit breaker and key switch (or) Then... IGOTOA7 1
2. At key switch.
(A12) Key switch "ON". Check load side of key switch circuit Battery voltage:
>~s breaker for battery voltage. OK lGOTOA17|
Low voltage:
w
Replace circuit
breaker. Then... 1GOTOA7 |
No Light:
(Probe light only.) lGOTOA13|
Continuity to
ground: GO TO A13 |
(A13) Key switch "OFF". Key switch "ON". Check cir- Battery voltage:
^-^ Connect a jumper wire cuit breakerjumped from for Replace key switch
as shown to a known battery voltage. circuit breaker,
good circuit breaker. then... | GO TO A7 1
No Light:
(Probe light only.) |GOTOA14l
Continuity to
ground. IGOTOA14]
Jumper
Wire
Power In i k
R32583

.
(A14) There is a "GROUNDED" Recheck load side of key Battery voltage: GO TO A15
^^ circuit at or after key switch circuit breaker for bat-
I I
switch. Turn key switch tery voltage. No voltage:

to "ACC" position. (Probe light only.) | GO TO A16|
4]
cfi*OA,
Continuity to
ground: | GO TO A16 |
B
t^
-^HJ]
Starting
F" Terminal
(A15) There is a "GROUND" Aid Repair circuit.
^ ' in the "IGN" circuit Switch Then... \ GO TO A7 "|
from the key switch.

1 Between @ and
2. Between
(or)
and
3. Between and F
terminal.
Bulkhead Instrument
Connector Cluster
(A16) There is a "GROUND" Repair circuit.

Power Accessory Relay
in the "ACC" circuit
Power In In Then... \ GO TO A7 H
from the key switch.
1. Between and
2.
(or)
Between ^
^ and
Key
Switch
Bulkhead
Connector
(A1 7) Remove RH. steering

(A17)l Key switch "ON". Check "B" Battery voltage: .
v *-^ support cowling. GO TO A19

terminal of key switch for bat- OK |
|
tery voltage.
w
PoweMn
Low or no
voltage: | GOTO A18|
NOTE: Engage differential

lock valve for easier
access to "B" termin-
al of key switch. RZZ106
Step Result
& There
v ~ / TANCE"
circuit
is "HIGH RESIS-
an "OPEN
or
between key
1 '
Key Switch
Repair
Then...
circuit.
1GOTOA7 |

switch circuit breaker Circuit Breaker
and key switch "B" ter-
D minal (Red wire).
Key Switch
Power In
(A19VThere
(A19) is "SUFFICIENT" voltage at the key switch "B" ter- GOTO
V-/ minal, but the voltmeter does not indicate correctly. SECTION 5-B3
EZZ1Q7

OPERATIONAL CHECK OF ALL SWITCHES AND ELECTRICAL COMPONENTS

(Perform all operational checks before and after repair.)
Circuit and Sequence Normal Operation Result
A. LIGHTING CIRCUIT:
Key switch "OFF".
1. Dome lamp and door
switch:
SGB door "OPEN". Lamp "ON"
2.
SGB door "CLOSED".
Dome lamp and dome
Lamp "OUT".
i
lamp switch:
SGB door "CLOSED"
and dome lamp switch
"ON". Lamp "ON"
3. Turn signal switch:

Lever "UP". R.H. warning lamps flashing
and L.H. lamps steady.
Lever "DOWN". L.H. warning lamps flashing

and R.H. lamps steady.
4. Light Jwjtch_gositionj. W _H_ _H_ _F_

Dimmer switch position: Hi Lo Hi "Lo
Warning lamps X X
Tail lamps X X
Instrument & console X X X X
Head lamps X X X X
Front flood lamps X X X
High beam indicator
If not OK, see Sec-
lamp X tion 6, after
Upper rear flood lamps X
Lower rear flood lamps
operational checks. GO TO B I
X
B. HORN AND LIGHTER

CIRCUITS:
Key switch "OFF". If not OK, see Sec-
1. Lighter pushed "IN". Lighter element heats. tion 8, after
2. Horn switch held "ON". Horn(s) sound. operational checks. GO TO C
|
R33108 (Continued)

ACCESSORY
(SGB with
blower switch.) Key
CIRCUITS:
two-speed
switch "ON". Engine
"STOPPED".
1. LH. and R.H. wiper
switches and motors:
Switches momentarily Wiper motors operate at slow
to "SLOW". speed.
Switches momentarily Wiper motors operate at a faster
to "FAST'. speed.
2. Blower switch and

motor:
Blower switch at
"SLOW". Blower motor operates at
Repeat at "MEDIUM "SLOW, MEDIUM and FAST'
and FAST". speeds.
3. Cooling Temperature
Control switch and air-
conditioning compres-
sor clutch.
NOTE: If ambient tem-
perature is be-
low 35 F. f (2 C)
clutch will not
engage.
Blower switch at
"FAST". If not OK, see
Turn temperature con- Listen audible click of
for Section 7,
trol switch to "MAXI-
compressor during engage- after operational
MUM" cooling. ment. checks. GO TO D
I |
( SGB with three-speed

blower switch .) Key
switch 'ON". Engine
"STOPPED".
1. L.H. and R.H. wiper
switches and motors:
Switches momentarily Wiper motors operate at slow
to "SLOW". speed.
Switches momentarily
to "FAST". Wiper motors operate at a
faster speed.
2. Blower switch and
motor:
Blower switch at
Blower motor operates at
"SLOW".
"SLOW, MEDIUM and FAST"
Repeat at "MEDIUM
speeds.
and FAST".
RZZ109 (Continued)
%
3. Cooling Temperature
Control switch and air-
conditioning compres-
sor clutch.
NOTE: If ambient tem-
perature is be-
low 35F., (2C)
clutch will not
engage.
Blower switch at
"FAST'. Ifnot OK, see Sec-
1
Turn temperature con- Listen for audible click of tion 7-B1, after
trol switch to "MAXI- compressor during engage- operational checks.
MUM" cooling. ment.
| GO TOD |
D. INSTRUMENT CLUSTER
CIRCUITS:
Key switch "ON". Engine
"STOPPED".
1. Observe the following
cluster gauges:
Voltmeter: Needle in LH. green band.
Fuel gauge: Indicating other than extreme
empty or full.
Temperature gauge: Indicating other than extreme
HOT.
Oil pressure gauge: Indicating zero pressure.
2. Observe indicators with

key switch at the
following positions: Trans. Oil Air-cleaner
SRT-QRT PST**SRT-QRT-PST
Key switch "ON".
ENGINE "STOPPED". ON OUT* OUT*
Key switch at "START".
Engine "STOPPED or
CRANKING". ON ON ON If not OK, see Sec-
tion 5 after
operational checks.
* Use a jumper wire to ground temperature and vacuum
switches. Indicator lamps s\lould come "ON". | GO TOE |
RZZ110
E. STARTING CIRCUIT:
1. Transmission "IN
GEAR". Key switch at
Starter should not crank
engine.
i
"START".
2. Key switch at "START". Starter should crank

Shift lever to engine.
"NEUTRAL".
1 3. Transmission at
"NEUTRAL". Engine
Starting fluid should flow into
intake manifold.
"RUNNING". Briefly
tap starting aid switch.
If not OK, see Sec-

4. Transmission "IN Starting fluid should not flow tion 3, after
GEAR". Push starting into intake manifold. operational checks.
JGOTOF I
aid switch.
F. ENGINE "RUNNING"
CHECKS.
Key switch "ON". Starter should not be operat- If not OK, see Sec-
1. Starting circuit: ing. tion 3.
Pull fuel shut-off NOTE: If starter is
knob "OUT" to stop operating:
engine. 1. Turn key switch "OFF".
2. Hold fuel shut-off "OUT",
2. Charging circuit: place transmission in gear.
3. Instrument circuit: Voltmeter needle at R.H. If not OK, see Sec-

Fuel gauge. green band at 1500 rpm. tion 4.
Temperature gauge. Needle indicating other than ex- If not OK, see Sec-
treme empty or full. tion 5.
Oil pressure gauge. Needle indicating other than
HOT.
4. Indicator lamps: Needle indicating pressure
Transmission oil indi- above RED danger zone.
cator lamp.
Air-cleaner indicator Lamp out. If not OK, see Sec-
lamp. tion 5, after
Lamp out. operational checks. I GO TO G |
R33111
RADIO AND TAPE

PLAYER CIRCUIT:
(If not equipped, go to H.)
Key switch "ON".
Radio switch "ON".
1. Select AM and turn
tuning knob to a sta- Radio operating.
tion. Repeat check on
2. if
FM (if equipped).
equipped with a tape Tape player operating.

If not OK, see Sec-
tion 9, after
operational checks. GOTO H
i
player, INSERT A TAPE
CARTRIDGE.
H. POWER FRONT-WHEEL
DRIVE CIRCUIT:
(No PFWD: Go to J.) If not OK, see Sec-
Key switch "ON". tion 10, after
Engine "RUNNING" . operational checks.
Shift to: SRT PST QRT
-
1st A1 Operational check

2000 rpm. "LOW" OK, but operator
Torque. Drive on loose has a specific com-
surface. plaint. See Section
10.
1. Turn full left.
Front wheel on inside of turn GOTO J
2. Turn full right.
Should spin slightly.
3. Repeat 1 and 2 in
"HIGH" torque.
4. Repeat 1, 2 and 3 in:
SRT PST- QRT
1-R A-1R
J. ALL OPERATIONAL YES Tractor ready for

CHECKS NORMAL? field operation.
NO Go to appropriate
section for repair.
R33112

.
STARTING CIRCUIT
w
(m) operational check of star.
TING CIRCUIT:
Depress clutch pedal.
Turn key switch to
Engine does not
crank: OK [GOTOA2 I
Place transmission in 1st gear.
"START" position.
Observe starter
Engine cranks in
gear.
operation.
NOT OK: 1GOTOF1 I
QRT PST SRT
A2) Shift to "PARK". Turn key switch to Engine cranks: _____

"START". OK IGOTO A3
Observe starter
operation. Engine does not ^_____
crank properly: [GOTO A5
(A3) Transmission in "PARK" With engine cranking,

Hold fuel shut-off
GOTO
momentarily hold Operation OK: SECTION 2
"OUT". Key at starting aid switch
"START".
"IN". Operation
Not OK: |GO TO A4 |
1 Starting fluid
should be flowing
into intake mani-
fold.
2. Starter should con-
tinue to crank en-
gine. Engine will
normally start
Key Switch
above 40F (5C).
Starting Aid Fuel

Switch Shut-off
RZZ11Z
(A4) 1. Starting aid will not inject starting fluid. I GOTOH1 I
2. Engine cranks but stops cranking when starting aid | GOTOJ1 |

switch is pushed "IN".
(AS) The following STARTING CIRCUIT problems will direct

you to the DIAGNOSING SEQUENCE for
that problem:
1. Starter operates, but engine does not crank. GO TO B1
2. Start solenoid chatters, (engine may or may not crank).- GO TO C1
3. Starter solenoid does not operate with transmission in
"PARK". GO TO Dl
4. Engine cranks slowly: GO TO E1
5. Engine cranks in gear. GO TO F1
6. Starter continues to operate after engine starts or ____^-_
after fuel shut-off pulled out. j GO TO G1 \
a B1J PROBLEM: Remove starter to inspect: Repair, then... JGO TO A1 l
1. Flywheel ring gear.

Starter Operates, But 2. Overrunning clutch drive.
Engine Does Not Crank. 3. Shift mechanism.
4. Solenoid plunger linkage.
5. Broken armature shaft.
R3S114

C1) PROBLEM: Connect ohmeter as 0.6 to 1.0

I
Starter Solenoid
shown: observe meter ohm. GOTO
reading. In Spec. SECTION
Chatters (engine 1-A1
may or may not
crank): Shunt
Lead
Out of Spec: Re-
Strap
Battery voltage at Removed place solenoid.
12 volts (Min.) Then... GO TO A1
Remove strap bet- Red
ween solenoid and
starter terminals.
Disconnect shunt
lead from terminal.
=" Black
Note: Reinstall strap
after testing or
repair.
Disconnect lead Transmission in

D1J PROBLEM: In spec: | GO TO D3~|
from neutral start "PARK". Observe
Starter Solenoid switch. Connect a meter for 0.3 ohms
Does Not Operate multimeter as (Max.).
Out of spec: | GO TO D2 1
With Transmission shown to check
In "PARK". continuity across
switch.
Battery voltage at
12.4 volts (Min.).
D2) Causes of no continuity across the neutral start switch Adjust or repair.
terminals are: Then... GO TO A1
1. Corroded lead and switch terminals.
2. Excessive transmission shifter shaft endplay.
(spec 0.001 to 0.004").
3. Switch ball corroded.
4. Improper switch shim adjustment.
5. Improper shift linkage adjustment.
>
R33115
TM-1181 (Nov-88) Litho in U.S.A. Tractors 4040 and 4240
(D3) Connect tester to Hold key switch at "START". Hold fuel Battery voltage I GO TO D7 I
(
white lead of shut off "OUT". Check white lead for OK: '
neutral start battery voltage. If both leads are

switch as shown: white, only one lead will have voltage. Low voltage GO TO
I D6~l
NOTE: Reconnect lead after testing or No voltage (Probe

|TOTOD4
,
repair. light only) I
White Continuity to
ground I GO TODS 1
Black
or
White/BS
D4) (Probe light only) Key Check white lead GO TO

of neutral Light I D5 1
switch "ON". Connect start switch for continuity to
tester clip to source of ground. No light 1GOTOD6 I
battery voltage ( + ).
White
Black
There is a
Repair circuit.
"GROUNDED" cir-
cuit:
Then... I GO TO A1 1
1. at key switch
2. between (a) and
(or)
3. at starter relay.
Neutral
Start
A) Switch
Starting
Aid
Solenoid Key Switch
Starting Aid Switch at Start
i
R33116
TM-1181 (Nov-88) Litho in U.S.A. Tractors - 4040 and 4240
D6) Thereis "HIGH Repair circuit.

RESISTANCE" or Then... | GOTOA1 1
an "OPEN" circuit:
1. between key
switch "B" and
"S" terminals.
2. between (K) and
3. between starter
relay terminals
and (5) (or) Starting
Aid
4. between and Solenoid Key Switch
Starting Aid Switch at Start
With transmission in Hold fuel shut-off No voltage. Good

"PARK" and lead con- "OUT". Hold key switch continuity to
nected to neutral start at "START". Check ground GO TO D9
switch, connect tester white lead for voltage.
to white lead as shown. Voltage I
GOTOP8"]
NOTE: Reconnect lead
after testing or repair.
White
&
Black
Thereis "HIGH Repair circuit.

RESISTANCE" or Then... | GO TO A1
an "OPEN" in the
ground circuit be-
tween neutral start
switch and starter
to()). ^
relay (black wireÂ)
Switch
Starting
Key Switch
Aid
at Start
Solenoid
Starting Aid Switch
> R33117
TM-1181 (Nov-88) Litho in U.S.A. Tractors 4040 and 4240
Connect voltmeter HoW fuel shut-off Spec. 8.5 vofts or more: I GO TO Pit 1 <
to starter shunt "OUT". Hold key switch (Min.)
terminal as shown: at "START". Observe 8.5 volts Below 8.5 volts: | GO TO Dl51
meter reading.
rf*2?
(Did) There is "HIGH Repair circuit.

v - RESISTANCE"
/
or Then... | GO TO A1 |
an "OPEN" circuit:
1. between (a) and
2.
^
between fB; and
3.
( r>
betwgen
^
relay (C)
and Key Switch
at Start
Starting
Aid Switch
Connect voltmeter
(p1l) to Hold fuel shut-off Spec,
^S starter terminal as "OUT". Hold key switch (Min.) 8.5 volts or more: GOTO D13
shown: at "START". Observe S.5 volts
meter reading. Below 8.5 volts: | GO TO D12H
oj*_Qv
i
R33118

@ Thereis "HIGH
RESISTANCE" or an
Repair or replace
solenoid. Then.., j GO TO A1 I
"OPEN":
1. In pull-in winding (A)
or
2. at solenoid contacts
@ Thereis "HIGH
RESISTANCE" or an
"OPEN" circuit in the
Repair starter.
Then... GO TO Al"
|
following: Field
1. field
2. armature (or) Armature
3. brushes Brushes
E1) PROBLEM: Hold fuel shut-off "OUT". to 1.2 voit:

Turn key switch to In Spec, GO TO E3 l
Engine Cranks Slowly: "START". Crank engine
and observe voltmeter for More than 1,2 volt.
Battery voltage at 12V
(Min.)
voltage reading. Out of Spec. t
GO TO E2 )
Transmission in "PARK".
Connect voltmeter as
shown:
NOTE: Starter terminal will

have battery voltage before
cranking- Switch meter to
lowest scale during cranking.
(E2) Reasons for a voltage reading:

1. Loose or corroded battery cable connections. Repair. Then... [ GO TO A1 f
2. Loose connections at starter solenoid and starter (or)

> 3. Corroded or eroded starter solenoid relay contact disk.
E34756

Hold fue! shut-off

E3) Connect voltmeter "OUT". Turn key to 0,5 volt:
to (-) battery post switch to In Spec: GO TO
I E5 1
and starter housing "START". Crank
as shown: engine and More than 0.5 volt
observe voltmeter Out of Spec. | GO TO E4 [
for voltage reading.
(E4) Reasons for voltage reading: Repair Then... GO TO

1, Loose or corroded battery ground cabfe connections
j A1*H
(or)
2. Poor contact of starter housing to engine block
E5) Connect voltmeter Hold fuel shut-off Spec 8.5 or more volts | GO TO E~
to starter terminal "OUT". Hold key at (Min.)
as shown. "START". Observe meter 8.5 volts Less than 8.5 volts GO TO E6
[ |
reading.
ojô*
One or more of the following exists:

1. Faulty cable connecting LH and RH batteries. Repair. Then... GO TO A1
|
2. Worn armature shaft bushings (armature contacting pole
shoes)
3. Worn drive pinion or flywheel ring gear
4. Shorted armature or field windings
5. Shorted shunt winding
6. Battery cold cranking amp (ampere hour) rating low (or) {
7. Starter cranking capacity low.
R34757
> (E7) One or

exists:
more of the following internal starter malfunctions Repair starter.
Then... GOTOA1 I
1. High resistance at brushes
2. Open armature (or)
3. Open field winding.
Ft) PROBLEM: Hold fuel shut-off "OUT". Engine does not '
Engine Cranks "IN

Turn key switch to "START", crank. j GO TO F2 I
Observe starter for cranking.
GEAR".
Engine cranks. j GO TO F3 j
Disconnect lead from
neutral start switch.
>
F2) The neutral start switch is: Repair. Then. GO TO A1

1. Improperly adjusted (add shims) or
2. "GROUNDED" 5
(replace)
F3) There Is a Repair circuit.

"GROUNDED" Then... \ GO TO A1 H
circuit.
1. at starting
aid solenoid
2. between (a)
and
3. between
and
4. between (D)
and(E)
Key Switch
at Start
NOTE: if a ground exists between D
and E the engine will stop cranking Starting
,
Starting Aid Switch

when starting aid switch is pushed
Aid Solenoid
"IN".
R33121

"STOPPED".
G1) PROBLEM: Holding fuel shut-off
key switch "OFF".
"OUT 1
, turn
Starter operation
Replace key switch^ i
Starter Continues To Then
Operate After Engine
| GO TO A1 |
Starts Or Fuel Shut-Off Observe starter operation.

Starter
PuNed Out. t
.
"OPERATING 1
, 1 GO TO G2 |
Starter operation "STOPPED".

(G2) Holding fuel shut-off
^-^ Replace starter circuit relay.
"OUT", place
transmission in any gear. [GO TO A1
Observe starter operation.
Starter
'OPERATING'. |GO TO G3 i
)
QRT PST SRT
G3] 1 . Place transmission in

"PARK".
2. IMMEDIATELY Jumper
disconnect RH battery Wire
ground (or)
3, If a jumper wire Is
available, connect one LgOTQ G4

]
end to solenoid pull-in
winding and strike
other end of jumper to i
ground.
Starter
\G4\ Remove strap between Hold key switch at Spec. 11.0 volts or more:
^~^ solenoid and starter "START", (Min,) Repair starter
f
terminals. Connect Observe meter 11.0 volts shunt. Then . . .
| GO TO A1
voltmeter as shown: reading.
Below 11.0 volts:
\ Repair shunt lead.

tf*
Then ...
[ GO TO A1~|
<^
Black
I
E34758
@ PROBLEM:
Engine Starts, But Starting Aid Plunger
OK: IGOTOH2"
WillNot Inject Starting Fluid.
Not OK:
Check the following possible Correct. Then... | GO TO A1
causes:
1. Loose can bail.
2. Empty starting fluid can.
3. Insufficient propellent in start-
ing fluid can.
4. Stuck solenoid plunger (or)
5. Plugged starting aid line or ori-
fice to manifold
Remove starting fluid Transmission in "PARK". Battery voltage

can. Connect tester to Hold fuel shut-off "OUT". OK: | GO TO H4 1
starting aid solenoid ter-
minal with a jumper wire Key switch "ON". Hold starting No voltage: (Probe
as shown. aid switch "IN". Observe tester
for battery voltage.
light only) GO TO H3
]E
Starting
Low voltage or
Aid continuity to
Solenoid ground. 1 GO TO H3 |
Starting
Aid
Switch Starting Aid Switch
NOTE: If no voltage at first

terminal, check other ter-
minal of solenoid.
Repair ciruit.
'H3) There is Power In
"HIGH RESIS- Neutral
Then... | GO TO A1
TANCE" or an Start
"OPEN" cir-
Switch
cuit:
1. at key
switch
2. at starting
aid switch
3. between (A
and () (cfi
4. between (C
and
Starting
Aid Solenoid
Starting
Aid Switch In
R3Z122

(H4) Connect tester to other

lead terminal of starting
aid solenoid with a
Transmission in "Park",
Hold fuel shut-off "OUT".
Key switch "ON".
Continuity to
ground. Replace
solenoid. Then...
.
[GO TO A1

|

jumper wire as shown: Hold starting aid switch
"IN". Observe tester for voltage. No voltage: (Probe .
light only) JGOTOH5 I
Power
In
Voltage: | GO TO H6*l
Start! ng A i d St a rt n g
i A id
Switch Solenoid
Starting Aid
Switch
j^ (H5) (Probe light only) Con- Check same terminal of starting

nect tester clip to aid solenoid as in H4 for conti- No Light: I GO TO H6"l
source of battery nuity to ground.
voltage ( + ).
Light: Replace (
.
solenoid. Then,., | GO TO A1 j
Starting Aid
Switch
H6) There is
Repair circuit.
"HIGH RESIS-
TANCE" or Then... IGOTOA1 |
an "OPEN"
circuit bet-
ween the star-
ting aid
solenoid (a)
and startercir-
cuit relay(&)
Key Switch
Starting at Start
Aid Switch ln^
R33123
@ PROBLEM: Hold fuel shut-off "OUT".

Key switch "ON".
Voltage: Replace
shorted starting
Engine Cranks But Stops Hold starting aid switch flirt QnlPnniH
Cranking When Starting "IN". Then... GO TO A1 I
Aid Switch is Pushed
"IN". No vnltagp- (Probe
o^-O/u light) I
GO TO J2 I
Disconnect lead from neutral

r.nntinnity in
start switch. Connect tester
to
white lead terminal of neutral around: | GO TO J2 I
start coupler with a jumper

wire.
White Starting Aid

Switch
Black
Check for battery voltage.
E
NOTE: Reconnect lead after
testing or repair.
Neutral
There is a Repair circuit.
Start
"GROUNDED" Switch
Then... | GO TO A1 I
circuit:
1. at starting
aid solen-
oid (OT)
2. Between
(A) and
Key Switch
Starting Aid at Start
Switch In
R33124

CHARGING CIRCUIT
^
(ai) operational check
of charging
CUIT:
cir-
Check voltmeter needle
tion.
posi- At LH green band. |GOTOA2 I
Key switch "ON". Below LH green GOTO

Engine "STOPPED". AI! band. SECTION 1
other switches "OFF".
(A2) Key switch "ON". Check voltmeter needle At RH green band. |GOTOA3 I
Engine at 1500 rpm. position.

Below Black Band
All other
orabove RH green DELCO
switches
"OFF". band. GO TO B1
JOHN
DEERE
GO TO C1
(A3) Key switch "ON". Check voltmeter needle posi- In orabove black GOTO
^^ Engine at 2000 rpm. tion. band. System nor- SECTION 2
Turn all lights and ac- mal.
cessories "ON" except
wipers. DELCO
Below black band: GO TO B1
JOHN
DEERE ND
GO TO C1
R33125

DELCO REMY ALTERNATOR
UNDER-
Step
OVERCHARGED Check
Sequence
connec- Check alternator Correct

Result
CHARGED BATTERIES: tions at alter- pulley and belt abnormal

BATTERIES: (Voltmeter needle nator "BAT" and tension. condition
(Voltmeter above RH green voltage regulator Then.,. I GO TO B2
needle below band at 2000 rpm) terminals.
black band
at 2000 rpm. Adjusting
- Brown Strap
w/white stripe
Red
Red
B2) ALTERNATOR Connect voltmeter to Spec. OK: j GO TO B4 l
BATTERY CIRCUIT alternator "BAT" terminal (Min.)

TEST: as shown: 12 volt Not OK: GO TO B3 1
Key switch "OFF".
Engine "STOPPED".
Battery voltage
12 volts (Win.)
Red
Black
There is high
resistance or an o o o Repair
"OPEN" circuit:
circuit.
1. Between Then... GO TO B2
and Solenoid
j
2. between (B)
and (C) (or]
3. weer (C)
between
i
Starter Starter
Circuit Relay Alternator
NO.2 VOLTAGE Connect voltmeter to No. 2 Spec.

REGULATOR TER- regulator terminal as shown: (Min.)
MINAL CIRCUIT Red- 12 volt OK: GOTOB6 |
TEST:
Key switch "OFF". Not OK: j GO TO B5 "[
Engine "STOPPED".
R34759
240*6-38 Electrical System Diagnosis Electrical Operation and Tests
B5) There
"OPEN"
cuit
is
between
an
cir-
Repair circuit
Then.,. | GO TO B4 |
4
No. 2 voltage Key
regulator ter- Switch
minal and
starter circuit
relay terminal
Alternator
B6) NO.1 VOLTAGE Connect voltmeter to Spec. In Spec. \ GOTO B1l"

REGULATOR TER- No. 1 regulator terminal 2-9 volts
MINAL CIRCUIT as shown: Below 2 volts | GO TO B7 |
TEST: -'Brown w/White Stripe Note: volt-

age regula- Above 9 volts GO TO BB
(Resistance wire T
tor coupler
I |
10-15 ohms.) must be con-

Key switch "ON". nected.
Engine "STOPPED".
Black
There Is an "OPEN" circuit: Switch Repair circuit.

1. at key switch "ACC" terminal.! Then,,. | GO TO B6 I
2. at bulkhead connector (|)

3.
4.
between
between
and
and
{)
(or)
Bulkhead
Connector (j$\
(ED
Starter
Circuit
Relay
Alternator W,
B8J Key switch "ON". Engine "STOPPED". GO TO B9

Connect voltmeter as shown. Ground
In Spec. | 1
field brush through test hole. Observe
Above Spec. GO TO B10
voltmeter reading.
Black
R33127

B9 ) One or more of the following causes exist: Repair. Then... | GO TO B?T

1. loose brush holder screws:
a. voltage regulator not properly grounded
b. brush terminal not properly contacting voltage regu-
lator terminal.
2. voltage regulator has an "OPEN" circuit
(Bid) One or more of the following causes exist: Repair. Then... GO TO B2

^-^ 1. Rotor slip rings dirty
| |
2. Brushes worn or broken

3. Rotor field winding has an "OPEN" circuit
(B11) ALTERNATOR OUT- Spec. In Spec. | GO TO B17H

PUT VOLTAGE 13-15
TEST: volts Below 13 volts | GO TO B13 I
Connect voltmeter
as shown. Above 15 volts | GO TO B12 I
Key switch "ON".

Engine at 1500
rpm. Observe
voltmeter reading.
(B12)The following are causes of high voltage: Repair Alternator.

^/ 1. "GROUNDED" between brushes and voltage regulator. Then... | GO TO B2 |
2. "GROUNDED" voltage
Internally regulator (or)
3. "GROUNDED" rotor field circuit.
(B13) Alternator output

^-^ voltage is low:
Voltmeter Above 15v, replace
E
needle voltage regulator.
Connect should go Then... GO TO B2
I \
voltmeter as above 15
shown. Key volts. Below 15v. Con-
switch "ON". tinue testing... GO TO B14
| [
Engine at 1500 Note: Do
rpm. Ground not allow
field brush voltage to
through test go above
hole. 16.5 volts.
@ FIELD CURRENT
DRAW TEST:
Key switch
Spec.
3.0-3.6 amps
at 12-12.5v
In Spec.
Below Spec.
I
1
GO TO Blil
GO TO B15 (
"OFF". Engine Note: If no

"STOPPED". amp draw, Above Spec:
Connect am- ground field Replace rotor.
brush through
meter as shown.
test hole. If
Then... | GO TO B2~l
Observe meter
now an amp
reading. draw, replace
bad regulator
I when repairing
RS3128 Red alternator.

-
If field current draw was below spec, one or more of the Repair alternator.
following causes exists: Then.. | GO TO B2 [
1. Rotor slip rings dirty.

2. Brushes worn or broken.
3. Rotor field winding "OPEN".
(B16)One or more of the following causes

(B1<^ exist: Repair alternator.
V-^ 1. Output "BAT." terminal loose. Then...
(
[ GOTO B2 |
2. Stator "SHORTED" or "GROUNDED".

3. Diode trio "OPEN".
4. Rectifier diode "SHORTED" or "OPEN".
(B17J AC
^^ TEST:RIPPLE
(Si?}' Key switch "ON". Engine at
1500 rpm. Observe voltmeter
Spec. (Max.)
0.8 volt AC In Spec. | GO TO Bli"!
Connect volt- reading.
meter as Out of Spec. 1 GO TO B16"l
shown:
Note:
If test meter is
not equipped Note: If bat-
teries are not
for AC ripple
fully charged
testing, use
AC rippte will
optional test
exceed 0.8
below. volt. See Sec-
Black tion 1-A3.
ALTERNATOR Connect carbon pile to Spec. (Min.)

AMPERAGE OUT- batteries as shown: at 13.5 volts: I n Spec. | GO TO B18~1
PUT TEST: 61 amp
Connect ammeter alternator: Out of Spec. | GO TO B16~1
(100 amp capacity) 50 amps
as shown:
72 amp
alternator
OR 60 amps
Hold fuel shut-off
"OUT". Turn lights
"ON". Crank engine for
20 seconds. _
Amp Black -
Volt Red -
Volt Black
Turn all accessories ex-

cept wipers "ON". Run
engine at 2000 rpm. (
Observe meter reading.
R33129
-
ELECTRICAL Connect test light with Spec. (Max.)

SYSTEM LEAKAGE 100 ma current draw as 100 ma (0.1 ^lo Light: OK: | GO TO B20 I
TEST: shown: amp):

Disconnect RH bat- Light: Not OK: j GO TO B19~l
tery ground cable. Light should
be "OUT".
g-j_
L
AT24693 Holder
Turn switches
all
AT38185 24V Bulb
"OFF". Close SGB
door. OR
Note: Reconnect Connect voltage detec- All lights
cable after testing tor as shown: should be
or repair. "OUT".
^j_
\B19)
(b19) Connect tester as in step B18. Follow circled numbers Repair circuit
^-^ with arrow O
*> in sequence, disconnecting components leak. Then... I GOTOB18"l
one at a time until light goes "OUT". Reconnect each lead
after check.
To Lighting Relay
B
To Horn and Lighter
To Key Switch
To Turn
Signal Controller
To Light Switch
To Light Switch-
To Dome Light
Red
w/WhitP
Hi
When interrupted, follow lead that was last disconnected

the leak is
to component supplies and disconnect lead at that component.
it
If the leak still exists, the problem is a "GROUNDED" or

"SHORTED" circuit. If the leak does not exist, the problem is at
the component.
E33130
TM-1181 (Feb-79) Lltho in U.S.A. Tractors - 4040 and 4240
(B20) ALTERNATOR Engine at 2000 rpm. Turn Spec.

CAPACITY TEST: "ON" allelectrical com- 13-15 volt In Spec. IGOTOA1 1
Connect voltmeter ponents and lights to
to alternator as load alternator. Out of Spec. | GO TO B21 |
shown:
Note: Remove windshield
wiper arms to prevent
scratching windshield.
Observe voltmeter reading.
Black
[B21) If additional electrical Turn "OFF" electrical com-

components have been ponents that have been add- In Spec. GO TO B22 |
installed, the alternator ed. Repeat alternator capaci-
is overloaded. ty test as in B20. Out of Spec. | GO TO B1 ~]
B22) Install a higher ampere rating stator or alternator. Repeat test se-
quence. | GO TO B1
S33131

JOHN DEERE ND ALTERNATOR
01) UNDER- OR OVERCHARGED Check connec- Check alternator Correct

CHARGED BATTERIES. tions at alter- pulley and belt abnormal
BATTERIES. nator output and tension. conditions. ,^_^__
(Voltmeter Voltmeter voltage regulator Then... JGOTOC2
terminals.
needle needle above RH
below black green band at -Brown Adjusting
band at 2000 rpm. w/White Stripe
2000 rpm.)
Red
ALTERNATOR- Observe voltmeter Spec. OK: I GO TO C4 I

BATTERY CIRCUIT reading. (Min.)
TEST: 12 volts Not OK: IGOTOC3 |
Key switch "OFF',

Engine "STOPPED".
Battery voltage 12
volts (Min.). Connect
voltmeter to
alternator output
terminal as shown:
Red
I
(C3^ There is an Repair
"OPEN" circuit: circuit.
1. between (3) and Then... {GO TO C4 1
2. between () and
Solenoi
3. between and
Starter
Circuit
Alternator
Starter Relay
VOLTAGE Observe voltmeter Spec. OK: IGOTOC6

REGULATOR "S" reading. (Min.)
TERMINAL CIRCUIT 12 volts Not OK: |GOTOC5
TEST:
Key switch "OFF"
Engine "STOPPED".
Connect
voltmeter to
voltage regulator
\ coupler "S" ter-
minal as shown: R33132
C5) There is an Repair circuit.

"OPEN" circuit Then.., ! GO TO C4 1
betwen "S" ter-
minal @
and
starter circuit relay
terminal (p)
Solenoid
Alternator
@ VOLTAGE
REGULATOR "IG"
TERMINAL CIR*
Connect voltmeter to
"IG" terminal as shown:
Spec.
(Min.)
12 volts
OK: | GO TO C8 |
CUIT TEST: Not OK: GOTOC7 1
Key switch "ON".

Engine "STOPPED".
Black
C7) There is an Repair circuit.

"OPEN" circuit: Z^f\ Key Switch Then... GOTOC6 |
1. at key switch Bulkhead

"ACC" terminal () Connector
2. at bulkhead con-
1 3.
nector
between
() and Starter
Circuit
4. between () and Relay
Alternator
ALTERNATOR Key switch "ON". Spec. In Spec. | GO TO C14]

OUTPUT VOLTAGE Engine at 1500 rpm. 13-15
TEST: Observe voltmeter volts Below Spec. f GO TO C1o]
Connect voltmeter reading.
to "B" terminal as Above Spec. | GO TO C9 |
shown:
(C9) The following are causes of high voltage:

^"^ 1. "GROUNDED" between brushes and voltage regulator.
2.
3.
Internally "GROUNDED" voltage regulator (or)
"GROUNDED" rotor field circuit.
Repair alternator.
Then...
^
| GO TO
__^
C1 ]
(
R33133

Remove cover Ground LH regulator terminal Spec. Above 15 volts:

from voltage "F". Observe voltmeter (Min.) Replace voltage ____-^_
regulator. reading. 15 volts regulator. Then... | GO TO C8 I
Reinstall one IMPORTANT: Do

screw In Not Ground "G" Note: Do Below 15 volts: ___^^^_
regulator. Terminal or not allow Continue testing... [GO TO C11J
Connect Alternator Will voltage to
voltmeter as go above
Be Damaged.
shown:
Cover
u
fip
16.5 volts.
Key switch "ON"

Engine at
1500 rpm.
FIELD CUR- Observe ammeter reading. Spec.

RENT DRAW 3.2-3.8 Ln Spec. | GO TO C1 3 |
TEST: amps
Connect am- Below Spec. |GOTOC12"|
meter as
shown: Key Above Spec:
switch "OFF". Replace rotor.
Engine Then.., | GO TO C1 "|
"STOPPED".
Black
(C12) If field current draw was below spec, one or more of the Repair alternator.
^-^ following causes exists: Then... GO TO C1
| "I
1. Rot&r slip rings dirty.
2. brushes worn or broken (or)
3. rotor field winding "OPEN".
^^ Oneloose
(ci3)
(13} or more of the following causes exists: Repair alternator. ^^^^^^^^
i
1. diode plate Then... | GO TO CI |

2. rectifierdiode "SHORTED" or "OPEN"
3. resistor open.
4. diode duo "SHORTED" or "OPEN".
5. stator "SHORTED" or "GROUNDED".
I
RS3134

(C14) AC RIPPLE TEST: Key switch "ON". Spec. n Spec. GOTOCin

^-^ Connect voltmeter Engine at 1500 rpm. (Max.)
i
|
as shown: Observe voltmeter VAC

1.0 Out of Spec. I GOTOC13~l
reading.
Note: If test meter
isnot equipped for Note: If bat-
AC ripple testing, teries are
use optional test not fully
below. charged, AC
ripple wi!!
IMPORTANT: Do Not exceed 1.0v_
Ground "G" Terminal Or See Section
1-A3, Page m.
Alternator Will Be
Damaged.
Black
ALTERNATOR Connect carbon pile to Spec. In Spec. GOTOC15

AMPERAGE OUT- shown:
batteries as (Min.)
I |
PUT TEST: amp

(Optional) Connect
75 Out of Spec. | GOTOClFI
alternator:
ammeter of 100 65 amps
amp (Min.) capacity
as shown: amp
OR 90
Hold alternator:
fuel shut-off
"OUT". Turn lights 80 amps.
"ON". Crank engine for
20 seconds. ^
Amp Red
Amp Black
Volt Red
Volt Black Turn all accessories
"ON" except wipers.
Run engine at 2000 rpm.
Observe meter reading.
ELECTRICAL Connect test light with

SYSTEM LEAKAGE 100 MA current draw as
TEST: shown: Spec. No Light:
Disconnect RH bat- (Max.) OK: | GOTOClTI
tery ground cable. 100 MA
(0.1 amp): Light:
AT24693 Holder
Light Not OK: | GQTQC16~J
AT3S1B5 24V Bulb" "OUT"
i I OR
Connect voltage detec-
tor as shown:
Turn all switches All lights
"OFF". SGB door "OUT".
'CLOSED'.
Note: Reconnect
cable after testing
or repair. (
R3313S
(bis) Connect
O^
tester as in Step C15. Follow circled numbers
) ^ with arrow in sequence, disconnecting components Repair circuit
one at a time untii light goes "OUT". Reconnect leak. Then... IGOTOCIS"!
each lead after check.
To UgTuing Retay_
h
To Horn and Lighter
To Key Switch
To Turn
Signal Controller,,
To Ltgtit Switch
To Ligjht Switch-^
To Dome Light
Red
When the leak is interrupted, foliow lead that was last

disconnectd to component supplies and disconnect
it
lead at that component If the leak still exists, the pro-

blem is a "GROUNDED" or "SHORTED" circuit. If the leak
does not exist, the problem is at the component.
ALTERNATOR
CAPACITY TEST:
Connect voltmeter
Engine at 2000 rpm. Turn
all electrical com-
ponents and lights "ON"
in Spec. I GO TO A1 |
D
to alternator as to load aiternator.
shown:
Out of Spec. | GO TO C18~)
Note: Remove windshield
wiper arms to prevent
scratching windshield.
Observe voltmeter reading.
fcl8) additional electrical Turn "OFF" electrical com-

If
^-^ components In Spec. |GOTOC19 |
have been ponents that have been add-
installed, the aiternator ed. Repeat alternator capaci- Out of Spec. | GO TO C1 |
is "OVERLOADED". ty test as in C17.
fclSj) Install a higher ampere rating stator or alternator. Repeat test se- ^__^^__
>
quence: | GO TO C1
EZZ1Z6
1
INSTRUMENT CLUSTER GAUGE AND INDICATOR CIRCUITS

(
OPERATIONAL CHECK Normal in LH green band:
OF GAUGES AND Satisfactory. | GO TO A2 |
INDICATORS.
Above LH green
Key switch "ON'\ band: | GO TO B1 \
Engine "STOPPED".
Observe voltmeter Beiow LH green _^^_^_.
NEEDLE position. band: |GOTOB3 |
Key switch "ON". Normal

Engine "STOPPED". OK: I GO TO A3
Observe needle position
of: Not OK: I GO TO C1 |
1. Fuel gauge
2. Engine temperature
gauge
3. Engine oil pressure
gauge
(A3) Key switch "ON". All Normal In RH

other switches "OFF". green band:
Engine at 1500 rpm. OK: I
GO TO A4~j
Observe voltmeter
NEEDLE position. Above or below GOTO
RH green band: SECTION 4
Not OK:
a
A4) Key switch "ON". Normai
Engine at 1500 rpm. OK: I GOTO AS"|
Observe needle position
of: Not OK: | GO TO CI |
1. Fuel gauge
2. Engine temperature
3. Engine oi! pressure
t
R33137
A5) INDICATOR
CHECK
Clutch pedal
BULB Hold
"OUT".
fuel shut-off
Hold key
switch at "START".
Both indicator
lamps should
glow.
Both lamps
glow: OK. JGO TO A6 |
depressed. Either lamp out: |GO TO D1 |

Transmission "IN
GEAR".
**d
(m!) Key switch "ON". Observe air cleaner indicator

^^ Engine "STOPPED". lamp for operation. Lamp out. OK: GO TO A7~l
|
Lamp ON. Not

OK: GO TO D4 I
W
n** /1/
w
(A?) AIR CLEANER IN- Key switch "ON". Engine A. Lamp Comes "ON".
DICATOR CIRCUIT
CHECK:
Remove air stack cap (if
"RUNNING". Slowly increase
engine speed
indicator
until air
comes "ON".
cleaner
(Operator Complaint)
1. None GOTOA8
G
equipped). Cover air |
opening with cardboard.

2. Lamp never -
comes on. [GO TO D12 |

Cardboard
t*fc" 3. Cleans
element -
,
frequently. | GO TO P11|
B. Lamp off
atWOT. IGOTOD8 |
Dump Valve
Installed Note: Indicator will normally
come on before 1500 rpm.
RZZ1Z8
Reposition
Remove cardboard.
cap
dump valve.
Reinstall

@
v -^
TRANSMISSION OIL INDICATOR CIRCUIT CHECK
Observe transmission
Key switch "ON".
oil indicator as follows:
A. Lamp operation OK:
(Operator Complaint)
i
Engine "STOPPED" "ON" y
1. None, GOTO
Engine "RUNNING" "OUT" SECTION 2
*PST Before these serial numbers, GO TO A9 2. Trans, oil

overheats,
4040P-001920 4640P-O04943 REPLACE
but lamp
4240P-004112 4840P-002951 TEMP.
never comes
4440P-008896 SWITCH
on.
B. Lamp does not .
go out: I GO TO E3 |
C. Lamp does not

GO TO -
-.- i
come on:
|
I eTI
PST Before Serial

Observe transmission
Key switch "ON".
Numbers
oil
Listed at Step AS.
indicator as follows: Lamp Out. OK: |GOTO A10J
Engine "STOPPED" "OUT" Lamp On:
Engine "RUNNING" "OUT"
Not OK: I GO TO E3 I
(A1ty Connect a jumper wire Key switch "ON". Engine A. Lamp on:
to temperature switch "STOPPED". Observe in- (Operator Complaint)
a as shown: dicator lamp for operation.

1. None. GOTO
SECTION 2
2. Trans, oil
ih J ve overheats,
if* CfcL
but lamp
REPLACE
never
TEMP.
comes on. SWITCH
Jumper HO
Wire
G H B. Lamp off: -^^_^__^
Not OK. | GO TO E2 |
Pressure
Regulating
Valve
Note: Remove jumper after
Housing
check.
R33139
TM-1181 (Feb-79) Litho in US.A Tractors - 4040 and 4240
B1) PROBLEM: VOLTMETER

INDICATES HIGH
VOLTAGE-
Light switch "OFF". Key
switch "ON". Engine "STOP-
PED". Observe voltmeter
In
OK:
LH green band: ____^^_
| GO TO B2
Turn light switch to "H" NEEDLE position. Above LH green
for 30 seconds to
remove battery surface
^r Normal band: Replace
voltmeter: iGO TO A1 1
charge. Dimmer switch
at "HIGH" beam.
B2) Connect test meter to Key switch "ON". Engine at

alternator output ter- 1500 rpm. Observe test meter GOTO
minal as shown: (voltage) reading. 13-15 volts: SECTION 2
RPM OK:
GOTO
Below 13 or above SECTION 4
15 volts:
John
Black Deere ND
(b3) PROBLEM: VOLTMETER Key switch "ON". Check volt-

^-^ INDICATES meter ground terminal (-) for No voltage: OK JGOTO B5 I
LOW VOLTAGE. voltage.

Remove LH and rear Voltage: Not OK [GOTO B4 H
steering support cowl-
ing.
1
-
(B4) There
ground
is an "OPEN" in the printed
circuit of the circuit board.
Replace circuit .^___
[GO TO
board. Then... A1 I
Printed
Circuit
R33140
(IS)Key switch "ON'\ Engine "STOPPED".

^-^ Check voltmeter shielded + ) terminal
for battery voltage.
(
,9
t
Battery voltage:
Replace
meter.
volt-
GOTOA1 I
4
+ *
Low or no
voltage: I GO TO B6 1
(B6) There is "HIGH RESIS- Repair circuit.

^-^ TANCE" or an "OPEN" Then... GOTOA1
Instrument J
circuit: Cluster
1. at key switch
2. between and ()
Pow&r
3. between () and "F"
terminal (or) In
4. in printed circuit of
circuit board.
Starting Ai
Key
Switch
Switch
@ PROBLEM:
FUEL, ENGINE
Disconnect gauge sender
lead at sendees) making an
Needle(s) posi-
tioned:
,
| GO TO C2
TEMPERATURE OR "OPEN" circuit.
ENGINE OIL PRESSURE Note: If gauge needle(s) posi- Needie(s) did not (
GAUGE(S) DOES NOT tioned as shown: position: | GO TO C3

OPERATE PROPERLY:
Key switch "ON".

a Engine "STOPPED".
Temp.
(C2) Attach sender lead(s) to See if gauge needle(s) posi- Needle(s) posi- . .
frame making a tioned to opposite side of tioned correctly: [GOTO C12 |
"grounded" circuit. Key gauge as shown:

switch "ON". Engine Needie(s) did not . .
"STOPPED". position correctly: | GO TO C3 \
R3S141 Fuel Temp.

%
J
(C3) Remove LH steering Disconnect coupler from in- Continuity to

support cowling. strument cluster, "GROUND" ground: | GO TO C5 |
sender lead(s) to frame (near
sender). Check terminal wires No continuity to _^^^_^_^
in cluster coupler for ground: |GOTOC4l
continuity to ground.
Temp.

&a
Oil Pressure
Bulkhead Connector Cluster Coupler

(C4) Sender wire(s) is
^^ "OPEN":
Repair circuit.
1. between sender and

Then... I
GO TO A1 |
bulkhead connector
(or)
2. between bulkhead
connector and clus-
ter coupler
Note: Reconnect
coup
Oil Pressure
Sender
Temp. Sender
E
(bs) Disconnect sender lead Check terminal wires No
from frame or sender
in cluster continuity to _^__^^_^
coupler for continuity to ground. ground: OK. |GO TO C7
making an "OPEN" cir-
cuit.
Continuity to ^____^^^
ground: Not OK. I GO TO C6 \
Temp.
Note: Reconnect
coupler after testing
or repair.
Oil Pressure
R3Z142
J
(C6) Sender wire(s) is

^-^ "GROUNDED":
1. between sender and
Bulkhead Connector Cluster Coupler
Repair
Then... v
\
circuit.
GO TO A1

bulkhead connector
(or)
2. between bulkhead
connector and clus-
ter coupler.
Oil
Pressure Temp.
Sender Sender
(bn Remove rear steering Key switch "ON". Check all Battery voltage: .
^""^
support cowling. four shielded ( + ) terminals of OK. | GO TO C9
gauges for battery voltage.
Low or no
voJtage or
continuity to
ground: Not OK. | GOTOC8
a
(C8) There is "HIGH RESIS- Repair circuit.
TANCE" or an "OPEN" Then... | GO TO A1
circuit in the power + ( )
circuit of the instrument Printed

cluster caused by: Circuit
1. loose gauge nuts
2. Missing spring
washers (or)
3. damaged printed
circuit.
Nuts
R33143
) (C9) Disconnect fuel, Check all four gauge ground

temperature and oil {-) terminals
pressure sender leads
for voltage. No voltage: OK. |GOTOC11 I
from senders. Key

switch "ON".
Voltage: Not OK. [ GOTOC10 |
*wh>
fciq) There is "HIGH RESIS- __^^_
v ' TANCE" or an "OPEN"
Repair circuit.
circuit in the ground (-)

circuit of the instrument

cluster caused by:
1. loose gauge nuts
Nuts
2. missing spring
washers (or)
3. damaged printed circuit
Printed
Circuit
Remove gauge(s) from Check gauge(s) for loose Nuts tight.

cluster. TERMINAL nuts. Replace gauge.
Then... GO TO A1
3 nuts Nuts loose.
at each
Tighten and
Gauge
reinstall gauge.
Then... | GO TO All
Nuts
Remove
Face
Glass
\
R33144
. .
Electrical System Diagnosis
C12 in Spec.
Disconnect sender iead(s). Check senders(s) for ohms resistance with an ohmmeter. GOTO ci:
NEEDLE SPEC:
GAUGE POSITION (ohms)
Out of Spec.
Replace sender
Fuel 1 Empty 03 Then . .
21/2 Full 42-^W

3 Full 8793
REPEAT C12
Water 138X -(100F) 300390

Temp. 271*C (160*F) 130150
NOTE: Specified ohms for oif
393X (200 F) P
7890 sender are for on tractor
testing. Bench testing wiiiresutt
498X (210F) 7080
in 610 ohms iess without
5 110*C <230 F) P
5565 machine vibration. Pressurize
6 116*C<240*F) 5055 sender to 60 psi and check
calibration after descending
pressure to each check point
Engine 10 psl (0 bar)
Oil (engine off) 010

Press. 210 psi (0.7 bar) 1620
330 psl (2.0 bar)
(est 1500 rpm) 4864

4 60 psi (4.0 bar)
(est 2000 rpm) 7842
AH7;ftW6feB7 40 U; 2400 10 IEX3 291086
C13
Connect green lead of JT01633 to sender lead and ground black lead as shown. Adjust knobs of JT01633 to get
gauge needles at specified check points. Then disconnect sender lead to check ohms across JT01633 with an
ohmmeter. Compare ohms to specs, in step C12.
OK;
GO TO SECTION 2
Not OK:
Replace gauge.
Then . .
GOTO A1
NOTE: Reconnect sender !ead(s) after testing or repair.

*
A1I7;RW1206 9 40U;240010 IF 1X3 MUSi
litho in U.S.A. 240-6-56 TM-1181 (Nov-86)

U17;TM11&1 a0t 111196
I Pi) PROBLEM: Replace lower in- Depress clutch

INDICATOR dicator bulb{s) in pedal. Hold Key
Both lamps ^__^__^
red socket(s). switch at "START'
glow: OK, | GOTO P&\
LAMP(S)
INOPERATIVE Either lamp out: ^^-*^^m
Not OK. |GO TO D2 1
Remove rear .Q
steering support
cowling.
Both indicator
lamps should glow.
Indicator
Bulbs
(D2) Remove LH Transmission in Check "C" ter-

steering support "1st GEAR". Key minal wire (white)
cowling. switch at "START". of cluster coupler No voltage:
for voltage with Replace "OPEN"
coupler connected. circuit board, | GO TO A5
Voltage: Not OK. GO TO D3 "1
|
Note: This is a
Ground Circuit
Check.
@ There is "HIGH RESISTANCE" or an "OPEN" circuit:

1. Between "C" terminal of cluster coupler and "G" terminal i
Repair
Then...
circuit.
1 GO TO A5 "~1
of key switch.
2. At key switch (or)
3. Key switch not "GROUNDED",
Power In
> R33146
Cluster
Coupler

240-6-58 Electrical System Diagnosis Eiectricai Operation and Tests
D4) PROBLEM: Key switch "ON". Lamp out: (

AIR CLEANER Engine "STOPPED". Replace switch.
LAMP "ON". Observe indicator lamp. Then... l GO TO A6~|
Remove coupler from Lamp on: Not
vacuum switch. OK. GO TO D5 1
Switch
Remove LH Disconnect instru- Reconnect coupler.

steering support ment cluster Lamp out: I GO TO D7
cowling. coupler. Remove
aircleaner "D" ^B~ Lamp ON: | GO TO D6
wire from coupler
as shown:
Push
Key switch "ON".
Engine "STOPPED"
Observe indicator
lamp.
Cluster
(D6) The following are causes of warning iamp(s) staying "ON":

Repair circuit. ^_^______^
1. Wires not correctly Then... |GO TO A1 |
matched in cluster Power In
coupler.
2. Wire between "C"
terminai of coupler
and "G" terminai of
key switch
"GROUNDED"
3. Cluster printed cir-
cuit "GROUNDED"
(or) Cluster
4. Cluster circuit board
diode "SHORTED". Cluster i
Coupler
R3314?
Bulkhead
D7) Switch wire is Connector Repair circuit.
"GROUNDED". Then... I
GO TO A1 |
1. Between vacuum
switch and bulkhead I Vacuum
connector (or) "
\ Switch
2. between bulkhead I**
Cluster
connector and clus-*zr
ter coupler. D Coupler
(bs) Connect a jumper wire Key switch "ON". Engine

to vacuum switch as "STOPPED". Observe air Lamp ON: IGOTOD9 |
shown: cleaner indicator lamp.
Lamp OFF: GO TO D1q"1

Jumper
Wire Frorn
^~~V Indicator
3
Note: Remove jumper wire after
testing or repair.
D9) Check air cleaner From Good continuity:

switch ground wire for indicator Replace switch. ^^^__^_^
continuity to ground. Then... 1 GO TO A7 |
No continuity:
Repair ground.
Then... IGOTQA7 l[|
(Did) Switch circuit has
^~S "HIGH RESISTANCE" Repair circuit. ___^_^,
Bulkhead
or an "OPEN":
Connector
Then...
| GO TO A1
1. Between vacuum
switch and bulkhead
2.
connector.
Between bulkhead Vacuum
Switch
e
connector and clus :
ter coupler (or) J

3. In cluster circuit
board.
j Cluster
Coupler
Check the following for restriction of air flow into intake OK: | GO TO D12"
manifold:
1. air cleaner elements. Not OK: Repair.
2. air cleaner housing, Then... GOTO
> 3. air stack or inlet pipe into air cleaner housing. SECTION 2
R33148

Raise hood. Connect ohmmeter Spec. in Spec:

Remove vacuum as shown:
24-26 (60-65 m Reinstall switch. GOTO
bar)
switch, install SECTION 2
water
switch in a Y*"
NPTTEEwitha
water vacuum
gauge as shown: Out of Spec.
Replace
D-05022ST TEE switch. Then... GO TO A7 |
I
Gauge Opening
Suck on TEE open-
ing. Observe gauge
reading when con- Note: Reconnect
tinuity through vacuum coupler after
testing or repair.
switch contacts.
E1) PROBLEM: Key switch "ON" Lamp ON:

Transmission Oil
PFWD Tem
Temp. Replace
Switch
Engine "STOPPED".
Does Not
Indicator
Pressure
pressure switch. ^^^_^__^
Come "ON". Then., | GO TO A8 |
Connect a jumper
wire as shown:
Switch
/ Observe indicator
for operation. Lamp OFF: Not
OK. | GO TO E2 |
Pressure
Switch
PST: SRT-QRT:
Jumper Pressure Oil Filter
Wire Regulating Relief Hsg.
Hsg.
Note: Remove
Temp jumper wire
Switch after testing
i or repair.
Switch circuit has Bulkhead

Repair circuit.
"HIGH RESISTANCE" Connector Then... I GO TO A8 1
or an "OPEN" circuit:
1. Between switch
coupler and bulkhead
connector.
2. Between bulkhead
connector and clus-
ter coupler (or)
3. on cluster circuit
board.
2> Press.
Switch \o n KQJ
>fc y
SRT-QRT
<
PST
R33149
Step Sequence Resutt
E3) PROBLEM: Key switch "ON".

Press.
Transmission Oil Switch Observe indicator Lamp OUT: I GO TO E5 1
Indicator Does Not
for operation.
Go "OUT. Lamp ON: j GO TO E4 "1
Disconnect transmission
oil pressure and {,
temperature switches
one at a time.
Temp.
Switch
c^b^V V*
PST: Pressure
Pressure Regulating Hsg.
Switch
SRT-QRT:
Q) Oil Filter
Relief Hsg,
(E4) Switch circuit is Bulkhead Repair circuit

"GROUNDED". Connector
1. Between switch and
Then... | GO TO A1 H
bulkhead connector.
2. Between bulkhead
and cluster coupler
(or)
3. On cluster circuit
board.
Temp.
PST: UsRT-GRT:
Pressure Oil Filter
Switch
Regulating Relief Hsg.
Hsg.
>
RSZ1SQ
CLUTCH Engine at Spec, (psi) Inspec:

PRESSURE 2000 rpm. Replace
SWITCH TEST: SRT-QRT PST pressure switch.
300 psi
Install Then... | GOTOA8"!
gauge as shown: 4040 135-145 175-195*
{9.3-10.0 bar) Out of spec? GOTO
4240 HYD. DIAG.
4640 155-165 175-195* SEC. 270
(107-11.4 bar)
Observe 4440 170-180 175-195
clutch (11.7-12.4 bar)
pressure/ 4840 175-195
charge pump *(1 2.0-13.4 bar)
pressure.
SRT-QRT
Pressure Regulating
Valve Hsg.
PST
Transmission
Control Valve
TEMPERATURE Observe temperature reading. Below 220F(104C):

SWITCH TEST: Replace switch.
PST (SRT-QRT with
Then... GO TO A8
Cooler Test
PFWD) Port Above 220 F: GO TO E6
j |
Place thermometer
(104C)
in oil reservoir or
cooler test port
Operate engine at
1500 rpm for five
minutes. QRT-SRT
Oil Filler Tube

Trans. Piug
E6) Inspect radiator and oil cooler

for restriction of air flow. OK: GOTO
HYD. DIAG.
-Oil Cooler
SEC. 270
Not OK: Clean.

Radiator
Then... GO TO A8
(
R33151

LIGHTING CIRCUIT
(aT) operational check of lighting circuit. AM lamps

operative: I GOTO A2H
Lamps Operatinq
ySll^^t^ôsitlon^ W H H F F Any lamp in-
Dimmer switch position Hi Lo Hi LO operative: t
GO TO A4 1
Warning lamps and indicators X X X

Tail lamps X X
Instrument and console lamps X X X X
Head lamps X X X X
Front flood lamps X X X
High beam indicator lamp X X
Rear upper flood lamps X
Rear lower flood lamps X X
SGB door "OPEN" Lamp "ON"

SGB door "CLOSED" and
Dome lamp switch Lamp "ON"
"ON"
(A2) Position turn signal Turn signal indicator and

^^ AM lamps
controller lever for LH warning lamps "FLASHING"
then RH turn.
operative: GOTO
on one side. Lamps on oppo- SECTION 2
Turn Signal site side will glow "STEADY".
Lever
Lamps in-
operative: GO TO A3
One of the following problems exists (see schematic No. 6-1): Repair circuit.
1. "OPEN" ground lead between lamp and top buss bar Then... GOTOA21
I
panel screw.
2. "OPEN" circuit between LH 2nd circuit breaker from bot-
tom and turn signal controller (dark blue wire) (or)
3. Turn signal controller "OPEN" between terminals No. 2
and No. 3 or No. 4.
A4) Check ground wire at

starter drivehousing OK: GO TO A5 "j
J
and front of SGB frame
for good contact Not OK: Repair.
Then.., I GO TO A1 1
E34760

(AS)
^^
One
pair
or both lamps of a
do not operate.
Check lamp ground
voltage at () .
circuit for
No voltage: OK: I GO TO A6 I
i
Remove necessary
mounting or shielding Voltage: Repair
around lamp. Position ground circuit. p^^^^-
switch(s) for lamp Then... | GO TO A1 |
operation.
Circuit Lamp
Breaker
Light Dimmer
Switch Switch
Of
Turn Dome
Signal Lamp
Switch Switch
(Afi) Position swftch(s) for Check power lead for battery Battery voltage:
lamp operation. voltage at .
Replace lamp. (
.
GO TO
^
Then... | A1 I
No voltage: Low . .
voltage: "C" light: | GO TO A7 |
Light Dimmer
Switch Switch
CM Circuit
Breaker
Lamp
Turn Dome
Signal Lamp
Switch Switch
(a^ The following schematics give a review of current flow to a Repair circuit
component or lamp from a circuit breaker through a switch Then... | GO TO A1 |
or relay. Fold out the. step-by-step sequence (Section 0) for use

with a probe light or voltage detector.
Reference the schematic required from chart below for

isolating malfunction to a component or wiring problem.
Malfunction occurs with:
Light switch positioned at: W H H F F

Dimmer switch positioned at: Hi Lo Hi Lo
Reference schematic No. 6 1 2 3 4 5
R31984
i
Front
. Flood
Front
Head
Schematic No. 6*1
Lighting Relays Light switch at "W"

Lamps operating:
1. Warning
2. Turn signal indicator
R31985

Fiood
Front
Head
Schematic No. 6-2
Light switch at "H*

Dimmer switch "HIGH"
beam
Lighting Relays
Lamps operating:
1. Warning
2. Head (high)
R31986
3. Front flood
4. Tail

Schematic No. 6-3

Light switch at"H"
Dimmer switch at "LOW"
Lighting Reiays
beam
Lamps operating:
1. Warning
2. Head (low)
3. Tail
R31987

A
Red \
o
Instrument
o
.Cluster Lights

Dome
SGB Door
Switch
r
MCr^ Dome Light
Switch
Light Green
Front
C^r/|>J
I Rear
Lower
Tan JP*^ .Head
^l]So| i00d Front
Flood
.
-^0h^=0*"
Turn Signal
Controller
Tea^
Upper
Flood
â^s=e
Rear
> Lower
Flood
Tan
Hi-Beam Fron t
Indicator Head
Light Green
a Schematic No. 6*4

Light switch at "F"
Dimmer switch at "HIGH"
beam
^|W^J r^M Lighting Relays
Lamp operating:
1. Head (high)
Front flood
> 2.
3. Rear upper flood
4. Rear lower flood
R31988
TM-1181 (Feb-79) Litho in US. Tractors - 4040 and 4240

,
*
o
o

Dome
SGB Door
Switch
*~\
F
Light/ T~*
Red w/White
Dome Light
Switch
Console /Tg\
LigHyVS^.
Light Green
'Fron t
"^^^1
Rear
l
Rear Tan i L.H.
Fron t
Head
Upperl
Flood jaQtei? Flood
/W> / n Orange
^@h(^=e*
/> f%
7\
Turn Signal
Controller Orange/Black
Rear
Upper
Flood
Hl
a*^=0 r Fron t
Rear R.K Flood
> Lower
Flood
Tan
Hi-Beam -Front
/ V H. Head
^
Indicator
Light Green
8,
CD
CO
1
Schematic No. 6-5
.^^J r)>4-l Light switch at

ll
Dimmer switch "LOW" beam

F"
Lighting Relays
Lamps operating:
1. Head (low)
2. Front flood
3. Rear lower flood
R31989


SGB ACCESSORY CIRCUITS
(Al) OPERATIONAL CHECK: Observe LH blower and LH

v -' (SGB with 2-speed
blower wiper motors for operation.
switch)
Both operate: j GO TO A2 1
(Three-speed switch GO TO B1) One

Key switch "ON".
operates: | GO TO A3 I
Blower switch at "HIGH". Neither operates: | GO TO A4~l

Momentarily turn LH
wiper switch to "SLOW".
(A2) Key switch "ON". Observe RH blower and RH

Blower switch at wiper motors for operation.
"HIGH".
Both operate: | GO TO AS I
One operates: I GO TO A3 I
Momentarily turn RH
wiper switch to
"SLOW".
Neither operates: | GO TO A4 j
Blower
Wiper
@ There is "SUFFICIENT" voltage to the SGB control panel.

Reference schematic No. 7-1 to isolate malfunction to a Repair circuit. ,_^____
motor or wiring problem. Then... | GO TO A1 |
(m) There is "INSUFFICIENT" voltage to the SGB control panel.

Reference schematic No. 7-1 and 7-2 to isolate malfunction Repair circuit. ,
to a motor or wiring problem. Then... \ GO TO A1 ]
Key switch "ON".

(A5)
^^ Blower switch at
Observe LH blower motor
operation.
for Audible click and ______
"HIGH". If ambient
motor operating: \ GO TO A7 I
temperature is below No click and LH

35F(2C), gotoA7.
motor stops
Listen for an audible click
operating: Clutch
of compressor clutch
circuit "GROUND-,
engagement as you turn
cooling temp, control to
ED" | GO TO A6 I
Blower
"MAX. COOLING". No click and
motor operating.
Clutch circuit ______
"OPEN" JGOTOA6 |
>
B331S2

(A6) Reference schematic No. 7-1 to isolate malfunction between Repair circuit.
^^ the blower switch and compressor clutch. Then... [ GO TO A1 |
(A7) Key switch "ON". Observe both blower motors for

^^ Blower switch at operation. Motors operating: | GO TO A9 j
"SLOW".
Motors not
mm mm mm mut operating GO TO A8j
^
\
<p
Blower Motors
(A8) Reference schematic No. 7-2 to isolate malfunction to a Repair circuit.

blower switch or wiring problem. Then... \ GO TO A1
(A9) Key switch "ON". Observe operation of both Motors operating

^^ Momentarily turn LH wiper motors. OK: GOTO
and RH wiper switches SECTION 2
to "FAST' speed.
^ man mm
Wiper Motors J*> Motors do not

operate properly:
^___^
Page
GO TO A1Q|
|
2-1
Reference schematics No/s 7-5, 7-6, 7-7 for checking con- Repair circuit. ^_____^
tinuity through wiper motor circuits. Then... | GO TO A1 \
(Si) OPERATIONAL CHECK: Observe LH and RH wiper Both operate pro-

(SGB with 3-speed blower motors for operation. periy: I
GO TO B4
switch)
Key switch "ON One does not .
>
.
^
1
'.
jnm mis operate properly: GO TO B3
Turn LH and RH wiper | |
switches momentarily to
"SLOW" speed.
Neither operates: I
GO TO B2 |
Repeat check at "FAST"

speed.
(S) There is "INSUFFICIENT" voltage to wiper motor switches Repair circuit -

t
from wiper circuit breaker or SGB relay. Reference Then... JGOTOB1 j
schematic No. 7-3. \

R331SS
(B3)
x^-y
There is "SUFFICIENT" voltage to SGB roof from wiper
cuit breaker Reference schematic No.'s 7-5, 7-6 and 7-7
for checking continuity through wiper motor circuits.
cir-
Repair
Then...
circuit.
| GO TO B1 *|
(B4) Key switch "ON". Observe blower motor opera- Motor operation
Blower switch at tion and direction of air flow.
"SLOW".
OK: | GO TO B8 |
Motor does not

operate: |

GO TO B5~
^-i
Motor does not

Repeat check at "MEDIUM" operate at all ______
and "FAST' speeds. speeds: | GO TO B7 |
(Bs) Key switch "ON". Listen for audible click as you

Blower switch at turn temp, cooling switch to
"FAST".
Audible click: | GO TO bF"]
"MAX" cooling.
No audible click: | GO TO BJ"1
/> There is "INSUFFICIENT" voltage to SGB roof from blower

V> circuit breaker. Reference schematic No. 7-3 to isolate
ReDair
Thf
cirrilit
malfunction.
Then. I GO TO B-TJ
There is "SUFFICIENT" voltage to SGB roof from blower cir-

cuit breaker. Reference schematic No. 7-4 to isolate Repair circuit. ^^_^_^^^
malfunction. Then... | GO TO B1 I
(ie) Key switch "ON". Observe blower motor for Audible click and
Blower switch at
"SLOW".
operation. motor operating: GOTO
Listen for an
SECTION 2
audible click of com-
pressor clutch engage-
ment as you turn cool- No click and
ing temp, control to
motor stops
"MAX" cooling. operating: Clutch
NOTE: Clutch will not circuit "GROUND-
engage below 35 F (2C). ED" j GO TO B9 1
No click and
motor operating:
Clutch circuit
E
"OPEN" | GO TO B9 1
(Bg)
R331S4
Reference schematic No. 7-3 to isolate malfunction.
Repair circuit.
Then... \
,___^_^^_
GO TO B1 |

L.H. Wiper R.H. Wiper
Schematic No. 7-1

(Two-Speed Blower Switch)
Key switch "ON'\ Blower

switch at "HIGH", Cooling -3- Compressor
control at "MAX. COOLING
^rv
(
B i
0m
< Jf5555i>
gg*>|-
SGBRelay^T"
ni ir
Schematic No. 7-2

(Two-Speed Blower Switch)
Key switch "ON". Blower
switch at "LOW". Cooling
control at "MAX COOLING".
Compressor
R33155
Schematic No. 7-3

(Three-Speed Blower Switch)
Key switch "ON". Blower -^ Compressor

switch at "LOW". Temp. Control
at "MAX. COOLING".
From
Circuit Breaker
To Clutch
SLOW SPEED MEDIUM SPEED HIGH SPEED
Schematic No. 7-4

(Three-Speed Blower Switch)
E331S6

Wiper Motor Wiper Motor
Motor * Black . Motor - Black

Motor - Red . Motor Red -
Circuit Breaker Circuit Breaker
Power In Power In
Motor Red /LH. Motor Red-
Motor Black *Park

. -
Motor - Black
Schematic No. 7-5 Schematic No. 7-6

Wiper switch at "PARK" Wiper switch at "SLOW"
Wiper Motor
Motor- Black
Motor- Red
Circuit Breaker
Power In
Motor - Red
Motor - Black
Schematic No. 7-7

Wiper switch at "FAST"
ESS1S7

HORN AND LIGHTER CIRCUIT
Step Result
(m) operational check

^^ Push horn button "IN".
Horn operation
OK: 1GOTOA3 |
Horn operation _______

Not OK: |GO TO A2
Starting Aid Key

Switch Switch
(A2) Reference schematic No. 8-1 for isolating malfunction be- Repair circuit. -__-___-_
tween circuit breaker and horn grounds. Then... j GO TO A1 \
3) Push lighter element Observe element for heating

"IN". after 30 seconds.
Element heats GOTO
OK: SECTION 2
Page 2-1
Element does not ________

heat: |GOTOA4 \
Starting Aid
Switch
(A4) Check center terminal

Battery voltage:
of lighter socket for bat-
tery voltage.
Replace element, _______
Lighter
Low or no
,-___________
Socket voltage: IGOTO Asl
(A5) Reference schematic No. 8-1 for isolating malfunction

tween horn switch and lighter socket.
be- Repair circuit. --__-___
Then...
I
GO TO A1 |
R31994

Lighter
Socket
Schematic No. 8-1
(Horn and Lighter Circuits)
1 R31995

RADIO AND TAPE PLAYER CIRCUITS

> Step Sequence Result
(M) OPERATIONAL CHECK:

Key switch "ON". Tape cartridge "REMOVED" (if equipped
Radio and tape
player operation. GOTO
I
with a tape player). Radio switch "ON".
OK: SECTION 2
Turn tuning knob to a local station (AM then FM if Page 2-1
equipped). Observe radio operation from both speakers.

Check volume, balance and tone controls.
AM OK, but FM in-
operative: Repair
Insert a tape cartridge (if equipped with a tape

radio. Then... JREPEATA1|
player).
Observe tape player operation from both speakers. Check
volume, balance and tone controls.
FM OK, but AM
in-
operative: Repair _^__^_^^
radio. Then... | REPEAT All
Selector
Tape player OK,
but radio in-
Tone
Speaker operative: GO TO B1
Balance
Radio and tape

2S* player
On-Off Push
Volume Selector
Channel inoperative: | GO TO B4 1
Control
Selector
Radio OK, but

Channel tape player in-
indicator Channel
Key Switch Selector operative: I GO TO B4 |
Button
One speaker in-
operative: | GO TO B9 |
Balance Tone
Poor reception: 1 GO TO Cl"1
\ \ // i V\ I / Excessive static: | GO TO DlH

Speakers
// i \\ // I \X
@ PROBLEM:
Tape Player OK, But Radio
Observe both speakers
humming.
for Both speakers
humming: | GO TO B2~[
Inoperative.
Key switch "ON". Speakers not _^_^_fc_
Radio switch "ONT. humming: [GO TO B4 |
\\ 1
i/ ^ \vj //
Speakers
/f 1 W /J !W
On-Off
Volume Control
> R31996

240-6-80 Electrical System Diagnosis Bectricai Operation and Tests

<
(52) Lower radio assembly. Disconnect antenna cable from
a radio jack.
Check for continuity between

No continuity:
Continuity:
OK GO TO B3
I 1
center plug and plug shield. Replace antenna. t

>
Then.., | GO TO A1 |
(B3) Raise SGB roof panel. Check antenna cable for continuity
^^^ between the following;
1. Cable center plug and wire at end of cable (a). Continuity: OK.
2. Plug shield and ground (b). Remove radio for
repair. After .
reinstallation... | GO TO A1 |
No continuity:
Replace antenna.
Then... 1GOTOA1 T
B4J Lower radio assembly.

Check the following possible causes: v Radio & OK: |GO TO B5 I
Radio Tape Player
Only Equipped Not OK: Repair .
circuit. Then,,. JGO TO A1 |
1. Power lead connection X X

2. 5 amp fuse X X
3. Ground lead connection X X
4, Speaker coupler connection X
5. Tape player coupler connection X
6. Serviceable radio-tape player relay X i
R31997
TM-1181 (Feb-79) Utho in USA, Tractors - 4040 and 4240

^
(is) Key switch "ON". Radio
switch "ON". If check-
ing tape player, insert a
Check power lead to radio and
tape player (if equipped) for bat-
Battery
voltage:OK: | GO TO B7 I H
tery voltage. Reference
tape cartridge. schematic: Low or no
No. 9-1 AM radio only voltage: GO TO B6 1
I
No. 9-2 AM-FM radio
o**o>v No. 9-3 AM/tape player
No. 9-4 FM/tape player
Tape Cartridge Slot
On-Off Volume Control
There is "HIGH RESISTANCE"

or an "OPEN" circuit: Repair circuit.
1. (radioequipped only) between lighting harness coupler Then... GO TO A1
in SGB roof and radio
| 1
2. between lighting harness coupler and tape player coupler
3. between tape player coupler and relay
4. at radio-tape player relay
5. between relay and radio
B7) Key switch "ON". Radio Check ground lead from radio No voltage:
switch "ON". If check- and tape player (if equipped) for Good continuity
ing tape player, insert a voltage. See schematic: to ground. I GO TO B9 |
tape cartridge. No. 9-1 AM radio only
No. 9-2 AM-FM radio Voltage: GO TO B8
of* o,
No. 9-3 AM/tape player
| 1
No. 9-4 FM/tape player
Tape Cartridge Slot
1 M M M M Itt IB m
il 1 yjy
On-Off Volume Control
B8) There is "HIGH RESISTANCE" or an "OPEN" circuit:

Repair circuit.
1. (Radio equipped only) between radio and
ground Then... j GO TO A1
2. between tape player and radio \
3. between tape player and relay

4. at radio-tape player relay
>
R31998

'
Lower radio assembly. Check brown to yellow and 3.0 to 4.0 OHMS: t ,
D Disconnect 3-wire
speaker coupler.
brown to pink terminals for con-
tinuity.
OK:
Above
below 3.0
4.0 or
iGOTOBUl
_^^___
To
^ Gray From
Radio
or To
OHMS: Not OK: |GOTOB10 |
Speaker
Relay Speaker
-*V
@ Above
"OPEN"
Below
4.0
3.0
OHMS:
circuit in
OHMS:
there is "HIGH RESISTANCE"
speakers or harness:
there is a "SHORTED" or
or an
"GROUNDED"
Repair
Then...
circuit.
\ GO TO A1 |
circuit in speakers or harness:
(Bll) NO TAPE PLAYER: GO TO B12 OK: | GO TO B12l

Check all tape player harness wires for continuity.
Reference schematic No. 9-3 (AM radio) or No. 9-4 (AM/FM Not OK: Repair
radio).
harness. Then... 1 GO TO A1
B12) Remove radio or tape player for repair. After reinstalla- .

,
tioru.. | GO TO A1 |
PROBLEM: Remove turning knob. Adjust

POOR RECEPTION trfmmer antenna capacitor screw Adjustment OK: | GO TO Al"l
in hole below tuning shaft.
Key switch "ON". Radio Adjustment Not l
_^____
switch "ON". Tape car- OK: | GO TO B1 |
tridge removed (if equip-

ped). Select a weak AM
station near 1400 khz.
Motorola
Antenna
Trimmer
Adjusting
Screw
On-Off
Volume Channel
^r
Control
!W1_H_tt
fiat iiwhi
* J. -
Selector
*Z Bowman
Remove radio to adjust.

(RH side view) (
R31999

[D1) PROBLEM:
EXCESSIVE STATIC
Step Result
Repair faulty cir-

cuit as required,
,
GO TO A1
.
1
j |
Follow this sequence to isolate radio static:
1. All electrical switches "OFF" except key switch and radio
switch.
2. Turn all switches "ON" one at a time, until radio static
is excessive.
3. When static is excessive, study all circuits attached to
the last switch turned "ON".
4. Start disconnecting the leads from last switch one at a
time to isolate the circuit causing the static.
Note: To duplicate radio static, starting the engine or driving
the tractor may be necessary.
Note: If radio static exists with the key switch "OFF" and
battery voltage jumped directly to the radio, replace one or
both speakers.
Note; Reconnect all leads after testing or repair
Installation of noise suppression kit may be necessary.
Pink
3-Wire
Coupler
Yellow
AM
Radio
toFM
Power IN Speaker
From SGB Lighting Harness Adaptor
AM Radio
Schematic No. 9-1

AM Radio Without Tape Player
R32540

Brown
Pink
i
a
Yellow
,3-Wire
Green
i / Coupler
Speakers Antenna *
C
Red
O
5 Amp
Fuse j. BW â^ ^
w
Power IN
from SGB Lighting Harness
io
1
14
i 11
he
IB IS
lis mlI
IBM
O
ffÂft
AM-FM Radio
Schematic No. 9*2

AM-FM Radio Without Tape Player
Gray
/ X_
Brown hx Black .
Red
/sJVhitey^
Black s
5 Amp
Fuse
J\
c
L.h. Speakers r.h.
o
Power IN
from SGB Lighting Harness AM Radio
Schematic No. 9-3

AM Radio and Tape Player
R32541

Gray
Black
Power IN
from SGB Lighting Harness AM-FM Radio
Schematic No. 9-4

AM-FM Radio and Tape Player
R32542

i
i


POWER FRONT WHEEL DRIVE CIRCUIT
(A1) OPERATIONAL 1. Turn full left. Front wheel on side

CHECK: 2. Turn full right of shortest turning Operation OK: GOTO
Key switch "ON". 3. Repeat 1 and 2 in radius should spin SECTION 2
Engine "RUN- "HIGH" torque. slightly.
NING". Shift to: 4. Repeat 1, 2 and 3
SRT-PST QRT in: Operation Not
1st A-1 SRT-PST QRT OK: | GO TO B1 |
2000 rpm. "LOW" 1 Rev. A-1R
torque. Drive on
loose surface.
PFWD CONTROL Check top of each solenoid for a

VALVE SOLENOID magnetic
TEST:
field. Magnetic field EE
Engine "OFF". Discon-
OK: | GO TO B3
nect control valve No magnetic
coupler. Connect a
jumper wire to each
field: Not OK: | GO TO B2 \
solenoid one at a time

as shown:
Alternator Output
Terminal
PFWD
Control
Valve Coupler
(B2) Connect jumper wire as

in B1 to bad solenoid.
Ground solenoid with a
screwdriver as shown:
Check
magnetic
top
field.
of solenoid for Magnetic field;
Repair solenoid
ground. Then...
.
|
^
GO TO B1 |
Jumper Wire -
No magnetic
field: Replace -
Jumper Wire (
solenoid. Then... |gO TO B1 |
Grounded
B331S8

PFWD TEST BOX LAMP Insert screwdriver into each All lamps
TEST: female coupler terminal one at a operate: OK: 1 GO TO B4 1
Connect test box time. "GROUND" screwdriver to
ground lead to alter- frame. Observe for lamp opera- Any lamp in-
nator output as shown: tion. operative: Repair ,

t
test box. Then... | REPEAT B3 1
ID
PFWD CIRCUIT Connect a jumper wire

GROUND TEST: to clutch pressure | GOTOBsl
Engine "OFF". Key switch as shown:
switch "OFF". Connect
test box to switch end Jumper PFWD
of solenoid coupler and Wire Pressure
alternator as shown: Switch
iC^
QRT- Pressure
SRT: Regulating Jumper
Valve
PFWD Wire
Press. PST: Clutch Pedal
Housing
Switch Valve Housing
Caution: Remove
jumper wire after
testing or repair.
(Ss) Engine "OFF". Key Observe test box for glowing Alllamps stay
^^ switch "OFF". PFWD lamps. Transmission speeds: OFF: No
switch at "LOW" torque. "GROUNDS" I GO TO C1 1
PST-SRT:1Fand 1R
Any lamp comes
QRT: A-1 and A-1R on: Circuit is . .
"GROUNDED" RSO TO B6 ]
Repeat "GROUND" test at

"HIGH" torque.
R33159
*
\ B6) PFWD switch at Transmission at speed when Lamp(s) not

"NEUTRAL". lamp was "ON" at B5, Observe glowing: JGOTOB7 |
test box for glowing lamps (s).
Lamp(s} glowing: [ GO TO BJT"|
High -V
REV-FWO
TQ-
Neutral
Low
ooo
(5?) There
PFWD
is a "GROUND" between the following locations:
breaker and clutch switch (or)
Repair circuit. ___^^
1, circuit Then... | GO TO B4 j
2. clutch switch and PFWD operating switch.
Note: Reference schematic: PST - No. 10-1, QRT - No. 10-2,

SRT - No, 10-3. Reconnect all
leads after testing or repair
(Be) Connect test box coupler to 3-wire Transmission at Lamp(s) not

coupler above engine. . speed when lamp glowing: | GO TO B9 I
was "ON" at B5.
Observe test box Lamp(s) glowing: | GO TO Biol
for glowing
lamp(s).
^L
TQ- REV-FWO
Test Box
OOO
(B9) There is a "GROUND" in PFWD harness between solenoid

valve coupler and 3-wire coupler above and to rear of engine.
Repair circuit.
r
_
Then... | GO TO B4
SRT No. 10-3. Reconnect all couplers after testing or repair.
-
feio) Disconnect 5-wire coupler above and

^^ Transmission at Lamp(s) not _^_^__
to rear of engine. speed when lamp glowing: | GO TO B11I
*^\ was "ON" at B5.
Observe test box Lamp(s) glowing: PST:
for glowing GOTO B12
famp(s).
m
SRT-QRT:
GO TO B13
TO- REV-FWO
OOO
>
R33160
Step Result
(fill) There is a "GROUND" in harness from the PFWD Hi-Lo Repair circuit.
f
(
^->operating switch. Then... |
GO TO B4
*^\
Hi-Lo
Switch
Note: Reference schematic: PST No. 10-1,

QRT - No. 10-2, SRT - No. 10-3. Reconnect
all couplers after testing or repair.
a "GROUND" in harness from the

(B12)(PST Only) There
^--^transmission
switch
control
is
valve switches or clutch pressure
^ Repair
Then...
circuit.
GO TO B4
Note: Reference schematic: PST No. 10-1.

Reconnect all couplers after testing or repair.
@(SRT-QRT only) Transmis- Lamp(s) not

Disconnect 4-wire sion at glowing: GOTO B14|
coupler at RH front SGB speed when
or 4-post roll-gard lamp was Lamp(s) glowing: | GO TO B15J
mount. "ON" at B5.
*^ Observe
test box for
glowing
lamp(s).
-"V
REV-FWD
TQ-
OOO R34761
(

Step Result
There is a "GROUND" in range

switch or speed switch harness.
Disconnect switch harness
couplers. Use an ohmeter, voltage Repair circuit. _^__^^
detector or probe light to check Then... |GO TO B4 |
each harness coupler terminal for

a "GROUND". Transmission at
speed when lamp was "ON" at
B5.
Note: Reconnect all couplers

(BIS) There is a "GROUND" in the switch to solenoid valve harness.

Note: Reference schematic: QRT - No. 10-2,
SRT - No, 10*3. Reconnect all couplers after testing or repair.
Repair circuit.
Then... GO TO B4
To Rotary
Switches
R3S162
PFWD CIRCUIT Connect a jumper wire to

VOLTAGE TEST: clutch pressure switch as | GO TO C2 H
Key switch "OFF". shown:
PFWD
Engine "OFF". Connect Pressure
PFWD test box to Switch
switch end of solenoid
coupler and ground as
shown: c^s
QRT- Pressure Jumper Jumper PST: Clutch Pedal

SRT: Regulating Wire Wire Valve Housing
Valve
Housing
Caution: Remove
jumper wire after
testing or repair.
Reconnect pres-
sure switch leads.
(C2)Key switch "ON". Observe test box for glowing Ail 3 lamps will
^-^ Engine "OFF". PFWD lamps at the following gear: operate: I GO TO C1ll
switch at "LOW" tor-
Gear Test Lamps "ON"
que. Any lamp does
PST-SRT TQ REV FWD not operate: | GO TO C3 "1
1 Lo Lo-Hi
1-R Lo Lo-Hi
QRT TQ REV FWD

A1 Lo Lo-Hi
A1-R Lo Lo-Hi
Repeat at "HIGH" torque (Hi).
(c3)Key switch "ON". Observe test box for glowing All 3 tamps will
^-^ Engine "OFF". Wiggle lamp(s). operate: GOTOC4 j
shift lever(s) fore and
aft at gear that lamp(s) Gear Test Lamps "ON" Any lamp does ^
does not operate from not operate: | GO TO C5 ]
Step C2.
PST-SRT TQ REV FWD
1 Lo Lo-Hi
1-R Lo Lo-Hi
QRT TQ_ REV FWD

A1 Lo Lo-Hl
A1-R Lo Lo-Hi
RS3163
Step Result
(C4) PST: Clutch switches on

transmission control valve are
not properly adjusted.
SRT-QRT: Speed switch

and range switch are
not properly adjusted.
EC
Adjust switches. ___^^^_

Then... | GO TO C1
Note: For switch adjustment, re-

fer to the following step:
PST: C12 page 10-9

QRT: C13 page 10-10 and 10-11
SRT: C14 page 10-11 and 10-12
(C5) Connect test box coupler to 3-wire

Transmission
coupler above and to rear of engine. at speed when Lamp(s) operate: | GO TO C6 |
lamp(s) was
"OUT" at C3. Lamp(s) does
Key switch not operate: | GO TO C7 I
"ON". Engine
"OFF".
Observe test
box for glow-
ing lamps.
!=
TQ- REV-FWD
ooo
(C6) There is "HIGH RESISTANCE" or an "OPEN" in harness be-
tween solenoid valve and 3-wire coupler above and to rear of
Repair circuit ____^_-
Then... | GO TO C1 |
engine.
SRT - No. 10-3. Reconnect all couplers after
testing or repair. R33164
(C?) Remove RH
support cowling.
Steering Key switch "ON".
at "LOW" torque.
terminals of PFWD operating
PFWD switch
Check center
Battery voltage:
OK.
^_^^_^^_^
j GO TO C9 1
i
switch for battery voltage. Low or no
voltage: Not OK: j GO TO C8|
Power In
Back of Switch
PFWD
Q -Operating-
Switch
C8J There is "HIGH RESISTANCE" or an "OPEN" circuit: Repair circuit. .
1. at PFWD circuit breaker (or) Then... | GO TO C1

2. between PFWD circuit breaker and PFWD operating
switch.
SRT-No. 10-3.
(C9) Key switch "ON". Check upper two terminals of

^^ Engine "OFF". PFWD switch for battery voltage.
switch at "LOW" torque.
PFWD switch at "HIGH" Check lower terminal of switch

torque. for battery voltage.
Battery voltage: ,__ .
OK. I
GO TO C10 |
CD Low or no
Power In voltage at LOW
or HIGH torque.
h~ Replace switch.
Then... | GO TO C1 |
(C10J) Disconnect the switch harness couplers as required to Repair circuit.

check coupler terminals for battery voltage. Isolate the "HIGH Then... GO TO C1
RESISTANCE" or "OPEN" circuit to a switch or the wiring.
Note: Reference schematic: PST - No. 10 - 1 SRT - No. 10*2, T
QRT - No. 10-3. Reconnect all couplers after testing or repair.

R33165
Step Result
6* Key switch "ON". Engine "OFF". Move

(C11)
^-^ forward and reverse
for proper test
shift lever to
speed. Reference the following charts
box lamp operation:
each Correct lamps
operate: |
^_^_^__
GO TO A1
Incorrect lamps
SRT PST operation:
PST:
Low Torque High Torque Low Torque
Gear TQ REV FWD TQ REV FWD
High Torque
Gear TQ REV FWD TQ REV FWD
GOTOC12
1 X X X 1 X X X
2 X X X 2 X X X
X
QRT:
3 X X 3 X X X
4 X X X 4 X X X
GO TO C13
5 X X 5 X X
6 X X 6 X X
7 X 7 X SRT:
8 X 8 X GO TO C14
1R X X X 1R X X X
2R X X X 2R X X X
3R X X X EC
4R X X X
X
*Park and Neutrals
QRT QRT
Low Torque High Torque Low Torque High Torque
Gear TQ REV FWD TQ REV FWD Gear TQ _REV FWD TQ REV FWD
Park D-1 X
A-1 X X 2 X
2 X X 3 X
3 X X 4 X
B-
4
1
X
X
X
X
A-1R
2R
XX
XX X
X
2
3
X
X
X
X
X
X
B-1R
2R
XX
X
XX
C-1
4
X X X
01R
2R
XX
X
XX
2 X X X D-1R
3 X X X 2R
4
J_
C121 PST: Repair circuit.

Disconnect wiring harness from transmission switches. Test Then... I GO TO C1 |
each switch for continuity in each gear. Switches should be
closed only in the gears listed below.
Switch No. 1 (top switch) - Closed in all reverse speeds.
Switch No. 2 - Closed in afl forward speeds.
Switch No. 3 - Closed in 1, 2, 3, 4, 5 and 6 speeds.
Switch No. 4 (bottom switch) - Closed in 1, 2, 3 and 4
speeds.
Add or remove shim washers to adjust switches.
Note: Reconnect all couplers

' 2
3
R33166
Step Result
<Q)QRT:
V-/ Remove shift and
hydraulic control lever
Disconnect Hi-Lo leads, range
and speed switch couplers.

console cover.
-Range Switch
Speed Switch
Hi-Lo Switch
Check between the following lead terminals for continuity

with shift levers or switch arms positioned as indicated:
Note: There will be continuity between several other ter-
minals in each position but only the following are necessary.
RANGE SWITCH TEST:
On Tractor A-Range White and green.

BENCH TEST: Rotate switch shaft
counterclockwise to stop then
rotate shaft clockwise 1 detent.
On Tractor:B-Range White and red.

BENCH TEST: 2 detents clockwise Orange + ) and black
( (-).
from stop.
On Tractor C-Range White and red.

BENCH TEST: 3 detents clockwise Blue ( + ) and orange (-).'
from stop. Blue < + ) and black (-).*
Orange + and black -
( ) ( ).
On Tractor D-Range NO continuity between

BENCH TEST: 4 detents clockwise any wire terminals.
from stop.
*Note: Diode in circuit. Replace

switch if current flow in both direc-
tions.
(continue)
R3316?

Step
> SPEED SWITCH TEST:
On Tractor. Speed 3 or 4. Green and blue.

BENCH TEST: Rotate switch shaft Tan( + )and blue(-).*
counterclockwise to stop then ro- Orange + and blue(-),
( )
1
tate clockwise 1 detent
On Tractor Speed 1 or 2 Green and blue.

BENCH TEST: 3 detents clockwise Tan and blue.
from stop. Orange + and blue(-).*
( )
Purple + and blue(-).*

( )
On Tractor 1R or2R. Tan and yellow.

BENCH TEST: 5 detents clockwise Orange and yellow.
from stop, Green and yellow.
KB
tions. Reconnect couplers after
Repair circuit.
test or repair. Then... GO TO C1
KM 4) SRT:
(cii); Disconnect change and range
^-^ Remove shift and switch couplers.
hydraulic control lever
console cover.
A-Change Switch B -Range Switch
Check between the following lead terminals for continuity

with shift lever or switch arms positioned as indicated
on next page.
(Continue)
R33168
Step Result
CHANGE SWITCH TEST: (

On Tractor 1st or 3rd Gear Blue and orange.
BENCH TEST: Rotate switch shaft
counterclockwise to stop then
clockwise 4 detents.
On Tractor 1 st, 3rd, 2nd or 5th gear Blue and green.

BENCH TEST: 3 and 4 detents
clockwise from stop.
On Tractor 4th or 7th gear Blue and purple.

BENCH TEST: 2 detents clockwise
from stop.
KB
RANGE SWITCH TEST:
OnTractor: 1st gear Brown and blue.

BENCH TEST: Rotate switch shaft White + and green
( ) (
- ).
Counterclockwise to stop then ro- White and purple.

tate clockwise 5 detents.
On Tractor 3rd gear. Brown and green.

BENCH TEST: 3 detents clockwise White and orange.
from stop.
On Tractor. Reverse Brown and yellow.

BENCH TEST: 1 detent from stop. White and yellow.

tions. Reconnect couplers after
test or repair.
Repair circuit. __^^_
Then... | GO TO C1^
\
RZZ169

Direction of
Circuit Breaker B - Black
Internal Contact
Movement
BL
BR
R
T
W
Y
-
-
Blue
Brown
Red
Tan
White
Yellow
Rear Valve
Harness
Reverse Forward
Solenoid Solenoid
W-62
PST: Schematic No. 10-1
R33170


Circuit Breaker
Direction of
Internal Contact
B - Black
Movement
BL - Blue
BR * Brown
GR - Green
O Orange
PU - Purple
R - Red
T - Tan
W - White
Rear Vafve
Harness
8-60
BL-66
Underdrive-
Direct Drive
Switch
GR-64 w'62
QRT: Schematic No. 10-2
R34762
Direction of Circuit Breaker B - Bfack
Internal Contact BL - Blue

Movement BR - Brown
GR - Green
O - Orange
PU - Purple
R - Red
T - Tan
W - White
Y - Yellow
High
Rear Valve
B-6Q Harness
Switch to
Valve
e and
BL"66
y-67
yS\
-*- B-60
E
Y-67t
Engine
ine Harness \ |
Torque K^ m^^^ BL-66
Solenoid ^_ |\ tT
Control Valve H / I I
(Viewed from / /
Rear) Reverse Forward
Solenoid Solenoid
Range
Moveable Switch
Contact
Change
Switch
Diode
SRT: Schematic No. 10-3
R33172

<
Electrical Operation and Tests Charging Circuit 240-10-1
Group 10
DELCOTRON CHARGING CIRCUIT DIAGNOSIS
GENERAL INFORMATION HOW THE SYSTEM WORKS
NOTE: See Section 40, Group 10 for charging
cuit repair.
cir-
r^/VW^
^
*
(53-
R 26519N
A Batteries D 10- Amp Circuit Breaker

BStarter
C Starter Circuit Relay E
No. 2
Key Switch
Alternator
i
6(^6 ,
rr hLh-
F
^sjuumsm^ 2T
Fig. UCharging Circuit
I
Fig. 1 shows components of charging circuit Wiring

is contained in engine and instrument harnesses.
A 72-amp alternator is jsed on tractors with i
SOUND-GARD body. A 61 -amp alternator is used on R34S04
tractors without SOUND-GARD body. The two are

1
_@_J
identical in operation. Ali parts except stator are com- AResistance Wire E Regulator
mon to both. BSwitch F Rotor (Field)
C Battery GStator
Regulator mounted inside alternator,
is
Diode Trio H Rectifier Bridge
it is solid
state, sealed, and no n -ad just able. Fig. 2-Schemattc Diagram of Defcotron Alternator
Alternator does not require any periodic mainte- Fig. 2 Schematic of

illustrates circuitry of alternator.
nance or lubrication. regulator somewhat. Regulator actually
is simplified
contains many more components than shown, but
performs the same function.
NOTE: Resistance is extremely high in resistor R3,

preventing battery run-down. It does allow a constant
drainon battery, but drain is insignificantly small only
a few milfiamps. Resistors R3 and R4 are needed to
provide the voltage differential required to turn tran-
sistors on.

240-10-2 Charging Circuit Electrical Operation and Tests
OPERATIONContinued
*WW
In
Magnetic
an alternator (unlike
netic field rotates,
a
and windings are
field is externally
DC generator) the
excited,
stationary.
meaning
mag-
it re-
t P51 \o +

quires an outside current source. Rotor consists of two
interlocking soft iron sections and a wire coil wrapped
around an iron core. When current is passed through
wire coil, rotor becomes an electromagnet.
Rotating magnetic field induces alternating current

in stator windings. This is converted to direct current by
six diodes in rectifier bridge.
A capacitor inside rear housing protects rectifier

bridge and diode trio from voltage surges. It also
suppresses radio interference.
This alternator uses an "A" field circuit with regulator

located after field. Full output is obtained by grounding
field.
Solid state regulator is mounted inside alternator. It
controls output by controlling current through field. In
operation, regulator has the following three phases.

R34805
Phase I Alternator Stopped
(Phase I also applies when alternator is running, but Fig. 3-Regulator in Phase i (Alternator Stopped)
not fast enough for output to exceed battery voltage.)

3, Transistor TR1 then provides a path to ground so
1. Current flows from battery through key switch current can flow through field, enabling alternator to
and resistance wire to terminal 1. generate electricity.
2. From there, current flows through resistor R1 to 4. Zener diode D2 prevents flow of current from
transistor TR1 and turns it on. terminal 2 to transistorTR2. A zener diode is a special
type of diode which will not permit current to pass until
voltage reaches a certain preset level. If voltage ex-
ceeds that level, current can pass through the zener
diode.

.
Electrical Operation and Tests Charging Circuit 240-10-3
Phase II Generating Electricity Phase III Shut-Off
MAAA^
wmm^ =
~
_
BAT
js_
!* m
:!
I I
^ i i I i T
I rrtr
'-*-^. I
R34806 R34807
Fig. 4-Regutator in Phase If (Generating Electricity) Fig. 5-Regula.tor in Phase fit (Shut-Off)
1 Diode trio, key switch, rectifier bridge, and termi- 1. Output voltage reaches critical voltage of zener
nal 1 all have equal voftage. Therefore no current flows
diode D2.
through resistance wire.
2. Current can now pass through zener diode D2 to
2. Current, now coming from diode trio, still flows turn on transistor TR2.
through resistor R1 to turn on transistor TR1.
3. Transistor TR2 now provides a direct path to
3. Transistor TR1
provides a path to ground so
still ground for any current coming through resistor R1.
current can flow through field, enabling alternator to
generate electricity. 4. This cuts off the current to transistor TR1 turning ,
it off. There is now no path to ground for current

4. Since field is rotating, it does indeed generate through field.
electricity. Alternating current is induced in stator
windings. Rectifier bridge converts it to direct current, 5. Current through field is shut off instantly, and
providing current to run electrical accessories and alternator stops generating electricity,
charge batteries.
6. Phases \\ and IN are repeated many times per
5. Output voltage still has not reached critical volt- second to maintain voltage at proper level.
age of zener diode D2 so no current can flow from
T
terminal 2 to transistor TR2.

.
240-10-4 Charging Circuit Electrical Operation and Tests
PRECAUTIONS Ripple Test
A
of damage
When working on charging
following rules for your safety
to tractor:
circuit, observe the
and prevention

Safety
1Keep aJJ sparks and flames away from batteries.
Gas from battery electrolyte is highly flammable. Also
avoid spilling electrolyte on yourself or on anything
which could be damaged by the sulphuric acid,
2. Avoid sparks when connecting booster batteries

or battery chargers. When possible, make last con-
nection at a point away from batteries. Battery charger
should be turned off before connecting or disconnect-
ing.
3. When connecting batteries, always connect Fig. 6-Checking AC Voltage Ripple

ground cable last. Disconnect it first.
4. When possible, disconnect battery ground cable With volt-ohm-amp meter connected to terminal 1,
before working on electrical system. AC voltage ripple.
switch meter setting to check for an
5. Before running engine of a tractor with power If exceeds 0.8 volts, stator or rectifier bridge is
ripple
front-wheel drive, shut off main hydraulic pump, dis-
defective. Replace or disassemble and repair alterna-
connect three -term in a! connector near solenoids, or tor. See Group 1 of Section 40.
raise both front wheels. This is to prevent tractor
movement if drive is accidentally engaged.
Prevention of Damage
1. Before connecting battery cables, be sure that
battery and alternator connections are correct Re-
verse polarity can cause permanent damage.
2. When connecting a booster battery, connect

positive terminal of booster battery to positive terminal
of left-hand battery.Then connect negative terminal of _<2'_
booster battery to tractor frame. Reverse polarity can
cause permanent damage. i
3. Never run engine with alternator or battery cables
disconnected. Doing so might damage alternator or
regulator.
4. Never short across or ground alternator terminals

unless specifically recommended. Be careful to pre-
vent grounding alternator wires when disconnected. R 28S38N
5. Never attempt to polarize an alternator. A Voltage Output of One Phase

B Voltage Output of One Phase After Passing
6. Before using an electric welder on tractor, dis- Through Rectifier Bridge
connect battery ground cable. Connect welder ground C Smooth Voltage Output from Three Phases
clamp as near as possible to the area being welded, D Voltage "Hippie" Caused by One Defective Phase
and be sure it makes good electrical contact.
Fig. 7-Output Voltage Ripple

Electrical Operation and Tests Starting Circuit 240-15-1
Group 15
STARTING CIRCUIT DIAGNOSIS
GENERAL INFORMATION When starter circuit relay closes, it provides conti-
nuity between large terminals. Current flows to switch

NOTE: See Section 40, Group 15 for starting circuit terminal of starter solenoid, engaging starter.
repair
IMPORTANT: Never operate starting motor

longer than 30 seconds. Allow at least two minutes
for cooling and battery recovery before operating
again. Overheating, caused by excessive opera-
tion, will seriously damage starting motor.
R 26564N
GWire from Relay L Main Contacts

HCable from Battery MField Windings
I Pull-in Winding N Commutator Brushes
J Hold-In Winding OArmature
K Solenoid Plunger P^Shunt Windings
R 26563N
Fig. 2~Circuitry inside Starter

ABatteries D10- Amp Circuit Breaker
B Starting Motor EKey Switch When wire from relay (G, Fig. 2) is energized, cur-
CStarter Circuit Relay FStart-Safety Switch rent flows through both pull-in winding (I) and hold-in
Fig. 1 -Starting Circuit winding (J) to ground.
Fig. 1 shows components of starting circuit. Wiring is Current through windings engages solenoid plunger
contained in engine and instrument harnesses. For (K), which closes main contacts (L). When main con-
additional wiring diagrams, see Figs. through in
tacts close, both ends of puIMn winding have same
Group 05. voltage, so current through pull-in winding stops. Cur-
rent continues through hold-in winding, keeping sole-
Current flows from batteries (A, Fig. 1) by way of noid engaged and main contacts closed.
starter (B) and starter circuit relay (C) to electrical foad
center. Unless circuit breaker (D) is tripped, current With main contacts closed, current flows from bat-
flows on to BAT terminal of key switch (E). tery cable (H) to starting
motor at a very high rate. Four
heavy field windings (M) carry current to commutator
When key switch is in start position, current flows brushes (N).
back to upper small terminal on starter circuit relay. If
start-safety switch (F) is closed, current can flow to Light shunt windings (P) are wrapped together with
ground, closing starter circuit relay. two of the heavy field windings. Shunt windings are
connected to solenoid switch terminal and directly to
ground. They prevent overspeeding of motor, and as-
sist in pinion engagement with ring gear.

240-15-2 Starting Circuit Electrical Operation and Tests
OPERATIONContinued
R 2522SN
1 Snap Ring 7 Field Connector 13 Field Windings 19 Brake Washer

2Drive End Housing 6End Frame Cover 14Armature 20Wear Pads
3Shift Lever 9Brush 15 Pole Shoe 21Overrunning Clutch
4Plunger 10Bushing 16Oil Seal 22^Pinion Stop
5 Shunt Field Terminal 11_Thrust Washers 17 Bushing
23 Bushing
6 Solenoid Assembly 12Commutator 18 Felt
Fig. 3-Starter
From field windings, current flows through armature When key switch is released, current to solenoid
windings (O) to ground, making contact through com- hold-in winding is shutCurrent can feed through
off.
mutator brushes (N). both pull-in and hold-in windings from main contacts,
but direction of current is reversed in pull-in winding.
Strong magnetic fields are set up by current flow The two windings cancel each other, and solenoid is
through field windings and armature windings. Wind- released.

ings are arranged so that magnetic fields constantly
repel each other, rotating armature. A spring pushes solenoid back to disengaged posi-
tion. This opens main contacts and shuts off current to
When solenoid engages, it pulls shift lever (3, Fig. field windings and armature.
3). Shift lever pushes overrunning clutch drive (21) to
engage pinion in starter gearon flywheel. As armature Shift lever retracts overrunning clutch drive, disen-
turns, it cranks engine. gaging pinion from flywheel. Brake washer (19) slows
armature to a stop.
When engine starts, overrunning clutch spins freely
on shaft. This prevents overspeeding of armature by
flywheel.

Electrical Operation and Tests
Starting Circuit 240-15-3
Key Switch Continuity Check

If necessary to remove and check key switch, test
for continuity between the following terminals.
R 26543N
Fig. 4-Key Switch Terminals
Accessory position BAT to ACC.
On position BAT to ACC.

BAT to IGN.
Start position BAT to IGN.

BAT to ST.
G to ground.
NOTE: See Section 40, Group 15 for removal and

repair of starting motor.
TM-1181 (Jun-80) Litho in U.S.A.

240-15-4 Starting Circuit Electrical Operation and Tests

.
Electrical Operation and Tests Lighting Circuits 240-20-1
GENERAL INFORMATION
Group 20
LIGHTING CIRCUIT DIAGNOSIS
Circuitbreakers reset themselves, but only after
load removed. A heater^ element keeps breaker
is
Fig,3 on page 2 shows all lighting circuits on a
tripped as long as load is connected.
tractor with Sound-Gard Body, Other wiring is included
in most harnesses and connectors, but is not shown in
this diagram.
To reset a breaker, turn off switches for all circuits
connected to that breaker. Wait at least two minutes
before trying circuit again.
See Figs, 18 through 25 in Group 05 for additional
wiring diagrams.
If this doesn't reset breaker, disconnect battery
ground cable for at least two minutes. If breaker does
Circuit Breakers
not reset, breaker is defective. If it does reset, check
carefully for a short circuit in the wiring.
Trouble Shooting with Voltage Detector

The D-05136ST Voltage Detector is ideal for trouble
shooting lighting circuits.
r-xD
R 28792N
ATo Front and Upper Rear Flood Lamps

B To Horn and Lighter
CTo Key Switch (Then to Instruments and Accessories)
DTo Lower Rear Flood Lamps, Warning Lamps, Taillights
ETo Headlights and Dome Lamp Fig, 2-Connecting Voitage Detector
FTo Radio, Left-Hand Wiper, and Blowers
GTo Right-Hand Wiper and Blowers 1 Attach "A" clip to a known source of 12 volts. If all
HSound-Gard Body Relay other electrical components are working properly, at-
tach clip to battery terminal on starting motor or BAT
Fig. 1Circuit Breakers
terminal on alternator. If not, attach clip to positive
terminal on left-hand battery.
All lighting circuits are protected by circuit breakers
located behind left-hand cowl. If all on one circuit
lights
2. Attach "B" clip to a convenient ground on tractor
fail at the same time, a circuit breaker may be tripped.
frame, making sure it makes a good electrical connec-
,f
tion. Attach "C clip to "B" clip.

240-20-2 Lighting Circuits Electrical Operation and Tests

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<auouiu.ei.-)SjSz , . ,

Electrical Operation and Tests Lighting Circuits 240-20*3
Relays
Fig. 4-Using Voltage Detector
3. Use probe to check lighting circuit for voltage.

Starting at light, trace circuit back until you detect
voltage, then try to correct problem. "A" light will glow
when probe makes contact with a source of 12 volts. Fig. 5-Ughting Relays
4. Always check ground circuit, as many Relays are mounted inside control support. For
lighting
problems are caused by a poor ground. "C" light will access, remove cowl rear cover and left-hand cowl.
glow when probe makes contact with a good ground.
NOTE: Center relay uses five terminals and is not
5. Check interchangeable with other two. Do not mix.
connectors, including bulkhead. Faulty
all
connections also cause many lighting problems, par-

ticularly intermittent problems.
FLOOD LIGHTS
Operation
All 4040 and 4240 Tractors are
equipped with an
improved lighting package. Flood lights are controlled
by three relays, and the operation is more complex
than earlier systems.
1.Front flood lamps are switched on when light

R 31172
switch is in the "F" position. In addition,
they are
switched on in the "H" position when headlights are on A^-Ground DPower Out
high beam. This gives improved highway lighting. B Power In E Power Out (Center
CControl Circuit Relay Only)
2. Lower rear flood lamps are switched on when
,f
Fig. 6-Lighting Relay Terminals
light switch is in the "F position.
To test a relay, carefully note mounting of terminals

3. Upper rear flood lamps are switched on only and position as shown in Fig. 6.
when light switch is in the "F* position and headlights
are on high beam. Switching to low beam reduces
1. Connect ohmmeter leads to
terminals B and D.
glare in extremely dusty field conditions.
Switch should be open, giving a resistance of infinity. If
not, replace relay.
2. Connect a 12-volt battery to terminals A and C,

and note ohmmeter reading. Switch should close, giv-
ing a resistance of zero. If not, replace relay.
TM-1181 (Eeb-78) Utho in U.S.A.

HEADLIGHTS AND TAILLIGHTS Turn Signal Controller

Operation
Dual-beam headlights are switched on when light
switchis in either "H" or "F" position. Foot operated
dimmer switch selects high or low beam.
TaiHights are switched on only when light switch is in
the "H" position.
Headlight Adjustment
ATurn Signal Lever C Mounting Bracket

STurn Signal Controller D Indicator Lamp Ground
R265B0N Fig, 8-Tum Signal Controller
NOTE: If by local reg-

flashing lights are prohibited
AHeight of Lamp C Lower Light Zone an AR67398 Turn Signal Controller.
ulations, install
BCenterline of Tractor 0 Upper Light Zone Warning lamps will then glow steadily.
Fig. 7-Ught Pattern at 25 ft. (8 m)
Terminal usage is indicated in following chart. For
Adjust headlights so they shine slightly down and to access to turn signal controller, you must remove left
the right. cowl.
WIRE
Use 7 as a guide for adjustment. Have lights on
Fig.
USE
TERMINAL COLOR
low beam. Sight across hood ornament and steering
wheel to locate tractor centerline. Power in from light switch for
1 Purple
warning lamp operation
TURN SIGNALS AND WARNING 2 Blue Power in from circuit breaker
LAMPS for turn signal operation
Operation 3 Orange To left turn lamp and indicator

lamp
When light switch is in the "W" or "H" position,
To lamp and
4 Orange right turn indica-
power feeds through flasher in turn signal controller to
& Black tor lamp
all four warning lamps.
5 Not used
6 Not used
When used, lamps on one side flash
turn signal is
and lamps on other side glow steadily.

Electrical Operation and Tests Lighting Circuits 240-20*5
To test controller, use an ohmmeter or test lamp to INSTRUMENT, INDICATOR, AND

test for continuity as shown in the following chart. CONSOLE LIGHTS
Switch Terminals in Continuity Operation
Position with Terminal No. 1
Instrument cluster lights, tach light, and console light
are powered by terminal HD on light switch. Ail four
Off 3, 4 (Through flasher for flashing operation;
should glow whenever headlights are turned on.
not through flasher for steady operation)
Left 3, 6 (Through flasher)
Right 4, 5 (Through flasher)
Overtightening the long turn signal lever attaching

screw may cause the turn signal controller to bind,
making it difficult to move the lever. If this happens,
loosen the screw four or five turns and gently drive the
screw inward to reposition the threaded insert in the
controller.
LIGHT SWITCH
AInstrument Lights DHigh-Beam Indicator

BIndicator Lights ETurn Indicators
CTach Light
B17193N
Fig. 10-lnstrument and indicator Lights
Fig- 9-Ltght Switch Terminals

Instrument cluster lights make contact with printed
Light switch should have continuity between termi- circuit board. They use terminal L
of multiple connec-
nals listed in To test switch, dis-
the following chart. tor. For more information on instrument cluster, see
connect wiring and use an ohmmeter or test lamp to Group 25,
test for continuity.
Indicator lights also make contact with printed circuit
Switch Position Continuity Between board. Transmission indicator light uses terminal B,
W Bat. A to WL and air cleaner indicator light uses terminal D.
H Bat. A to TL, WL Both indicator lights are powered by terminal IGN on

Bat. B to HD key switch, using terminal F on multiple connector.
Bulbs are "hot" any time key switch is turned on, but
Bat. A to FLR are grounded only when sender switches close.
Bat. B to HD
To provide a test circuit, both lights should glow
when key switch is in the start position.

DOME LIGHT BULB REPLACEMENT

Dome light is connected to bottom, left-hand circuit
breaker. Bulb is "hot" at all times, but is grounded only
Flood Lights and Headlights
when either door switch or toggle switch on lamp
housing is closed.
Rg r 11 -Dome Light
If dome light stays on with door closed and toggle

switch turned off, add R41337 Washers beneath door
switch.
Fig. 12-Removing Headlight Bulb
On certain tractors, Sound-Gard body door may not 1. Use a screwdriver to pry bulb from rubber bezel.
be adequately grounded. This causes intermittent Work your way around circumference, taking care to
operation of dome lamp and left-hand wiper motor not break bulb.
As a remedy, install a ground wire between door and 2. Disconnect wires, and connect new bulb.
frame. Later tractors include a ground wire in left-hand
wiper harness. Carefully push bulb into rubber bezel.
3. Make sure
it is properly positioned.
TM-1181 (Feb-78) LHho in USA. Tractors - 4040 and 4240

Electrical Operation and Tests Lighting Circuits 240-20-7
Warning Lights and Taillights Instrument Lights and Indicator Lights

1. Remove cowl rear cover and left-hand cowl.
Fjg. 13-Removing Tatitight Bulb
Fig. 14-Removing Instrument Light Bulb

1. Remove lens by removing four screws.
2. Remove bulb by pressing it slightly inward and

2. Remove bulb socket from back of instrument
turning counterclockwise.
clusterby turning counterclockwise. Remove bulb from
socket by pulling straight out.
3. Press new bulb in, turn clockwise t
and replace
3. Press new bulb firmly into socket, install socket m
[ens.
instrument cluster, and reinstall cowl.

Tach Light, High-Beam Indicator, Dome Light and Console Light

and Turn Indicators
1. Remove cow! rear cover and right-hand cowl.
Fig. 17-Removing Dome Light Bulb
To remove dome lamp bulb, remove lens by

Fig. 15-Removing High-Beam Indicator Bulb
squeezing sides Press bulb
slightly together. slightly
inward and twist counterclockwise to remove.
2. On tach light or high-beam indicator, pull bulb
socket from back of tube. On turn indicators, reoiove
mounting bolts and raise dash panel.
R 2&813N
Fig. 18-Removing Console Light Bulb
To remove console light bulb, lower lamp housing

Fig. 16-Removing Turn Indicator Bulb
from roof by removing two screws. Remove bulb
socket by twisting slightly counterclockwise. Press bulb
3. Press bulb slightly inward and twist counter-
lightly inward and twist counterclockwise to remove.
clockwise to remove.
4. Reverse the procedure to install new bulb.

Electrical Operation and Tests Instruments and Accessory Circuits 240-25-1
Group 25
INSTRUMENT AND ACCESSORY CIRCUIT DIAGNOSIS
INSTRUMENT CLUSTER Entire duster is grounded through terminal G, which
is connected to a ground screw near the circuit break-
ers. All electrical components in SOUND-GARD body
are grounded by a wire at front right-hand SOUND-
GARD body mount.
Access and Removal

For access to back of instrument cluster, remove
left-hand cowl. This provides enough room to change
bulbs or connect wiring.
1Water Temperature Gauge Terminals

2 Fuel Gauge Terminals
3 Engine Oil Pressure Gauge Terminals
4Voltmeter Terminals R26S32N
Fig. 1-lnstrument Cluster Terminals Fig. 2-lnstrument Cluster Removal
Operation To have enough room for removal of cluster, you

Instruments and indicator lamps are grouped into an
must tilt dash panel back.
instrument cluster. All circuits feed through an 11 -ter-
minal connector. Nine of the 11 terminals are used.
1. Remove four cap screws securing dash panel.
2. Tilt dash panel back, and remove cap screw at

A printed circuit board carries current from connec-
each corner of instrument cluster.
tor to gauges and bulbs.
Terminal F of multiple connector provides battery 3. Disconnect multiple connector, and remove
cluster.
voltage to cluster whenever key switch is turned on.

.
240-25-2 Instruments and Accessory Circuits Electrical Operation and Tests
Testing Power Shift tractors use a temperature switch as
0 0 sender for transmission oil indicator lamp. It is normally

open and should close above 220F (105C).
PERMA-CLUTCH tractors use a pressure switch

and may also have the temperature switch described
above.
Make sure AR61970 switch is used on 4040 and

4240 Tractors. has a blue lead and should close at
It
pressures below 95 psi (6.5 bar) (6.6 kg/cm 2 ).
4. If both lamps glow when only one should, one or

both of the diodes are defective. Replace printed circuit
board in instrument cluster.
Gauges
If all four gauges malfunction, either power in or
R 26582N ground circuit is probably defective.
1Transmission Oil 10 Multiple Connector 1. Instrument cluster is protected by 10-amp circuit

Indicator 11Transmission Oil breaker number 2. If it trips, you will also lose power to
2Air Cleaner Indicator Sender starter and SOUND-GARD body circuits. (See page 2
3 Engine Temperature 12Air Cleaner Sender for information on circuit breakers.)
Gauge 13Engine Temperature
4 Fuel Gauge Sender
2. If breaker is not tripped, remove left cowl and
5Engine Oil Pressure 14 Fuel Sender
Gauge 15 Engine Oil Pressure disconnect multiple connector from instrument cluster.
6Voltmeter Sender
7Instrument Lamp 16Light Switch
8Instrument Lamp 17Key Switch
9 Diodes
Fig. 3-Schematic Diagram of instrument Cluster
Indicator Lights
1 Make sure both lamps glow when key switch is in
start position. A test circuit is provided through terminal

C of multiple connector and terminal G of key switch.
Power source is ignition terminal of key switch, through
terminal F of multiple connector.
R 26583N
lamps do not glow, check for a defective bulb, poor
If
ANot Used
connection, poor ground at key switch, or open diode BTo Transmission Oil Sender
on printed circuit board. CTo Terminal G of Key Switch
DTo Air Cleaner Sender
2. Remove wire from sender, and touch it to ground. ETo Engine Temperature Sender
With key switch on, lamp should glow when wire is
FTo IGN Terminal of Key Switch
GTo Ground
grounded, if it doesn't, check for poor connection, open HTo Fuel Sender
circuit, or defective bulb. KTo Engine Oil Pressure Sender
LTo HD Terminal of Light Switch
3. Test sending units. Air cleaner indicator sender is
Fig. 4-MuitipIe Connector Terminal Usage
normally open and should close at 22 to 26 inches (500
to 640 mm) of water. Measure with a water manometer
as instructed in Group 05 of Section 30.

3. Turn key switch on. Use voltage detector, voltmeter,

or test lamp to test for battery voltage at terminal
TESTING VOLTMETER
F of
multiple connector. If terminal does not have
voltage, IMPORTANT: Never ground terminal F on a gauge
check poor connection at key switch or
for
circuit (shielded terminals on back of in-
breaker or for a defective key switch.
strument cluster). To do so would
destroy printed circuit board.
4. Use voltage detector, ohmmeter, or test lamp to
make sure terminal G of multiple connector provides
Voltmeter has only two terminals. Indicator
a good ground. It not, check for a poor connection should rise
t edge of solid green band with 1 1.8 volts applied
to left
ground screw near circuit breakers or at ground
wire to terminal F and terminal G grounded. With 13 volts,
at front right-hand Sound-Gard Body mount. itshould point straight up. With 15.5 volts, it
should
reach right edge of solid green band.
If a single gauge malfunctions,
either that gauge or its
sending unit is probably defective.
if a gauge dies not read correctly with tester
connected
to gauge terminals, replace gauge.
NOTE: For fuel, water andpressure gauge and
oil
sending unit resistance checks, see page
If gauge does read
correctly, check carefully for a poor
240-06-56.
connection or open circuit between gauge and
sender.
Problem could be in sender wire terminal,
bulkhead
connector, multiple connector at cluster,
or printed
circuit board.
Fig. 7Spring Washers
Gauge terminals must have spring washers to

make
contact with printed circuit board, as shown
in Fig. 7.
TM-1181 (Nov-86) UTHO IN USA,

Tractors-4040 and 4240
2
240-25-4 Instrument and Accessory Circuits Electrical Operation and Tests
Assembly ACCESSORIES
If cluster is disassembled,make sure each gauge Electric Starting Aid
terminal has a spring washer to make contact with
printed circuit board.
InstaJI glass with blue coated surface inward.
a new gasket Turn smooth side inward, and

Install
make sure will seal across both glass and cluster

it
case.
Ar-Circuit Breaker No. 2 DStart-Safety Switch

B Starting Aid Switch EStarting Aid Solenoid
O Key Switch FStarter Circuit ReJay
Fig. 8Electric Starting Aid Circuit
Electric starting aid will operate only if key switch is on

and transmission is in neutral or park. It should be used
only when engine is cranking and only in short bursts.
Wiring is in instrument harness and engine harness.

Power comes from 10-amp circuit breaker number 2
to key switch. When switch is turned on, blue wire to
starting air switch should be hot.
White wire goes through bulkhead connector to starting

air solenoid. Solenoid is grounded at screw near starter
circuit relay, but only when start-safety switch is closed.
Solenoid should engage at voltages down to 4 volts

and should release within 0.1 second when switch is
released. Current draw should be 4 to 5 amps at 1
volts.
IMPORTANT: Always keep a starting fluid can in

place to prevent drawing dirt into
engine.

. )
Electrical Operation and Tests Instruments and Accessory Circuits 240-25- 5
Horn Radio and Tape Player
V,
0p 1%
R 2658SN
A Solenoid CDiaphragm
B Plunger DContact Points
Fig. 9-Horn
A Radio Fuseholder C To Ground
BTape Player Fuse-
When horn
energized, solenoid (A Fig. 9) puffs
is 7
holder
plunger (B) attached to diaphragm (C). Movement of
plunger opens contact points (D), opening circuit to Fig. 10-AM-FhA Multiplex Radio and Tape Player Assembly
solenoid and releasing plunger. As pfunger returns, it
closes contact points and starts cycle over, setting up a Radio and tape player have 5 amp fuses (A and B,
rapid vibration. Fig. 10).
Horn has no provision for adjustment or servicing. To gain access to radio fuse on radio without tape
Test procedures are outlined in following paragraphs. player, remove the six screws. Radio and grille are
removed as a unit.
1. See if lighter works. If not, check for a tripped
circuit breaker or poor connection. To gain access to a fuse on a radio and tape player,
open SOUND-GARD body roof. Remove the two radio
With key switch on and horn button depressed,
2. and tape player assembly mounting screws from the
tap on horn.
If horn operates, release button and try jt top side of the inner roof. Then remove the six screws
again. If horn now works normally, problem was ap- from grille. Lower radio and tape player assembly.
parently due to foreign matter between points, and no
further service is needed. Electrical Connections
Dual speakers are now installed in all tractors at the
If horn must be tapped each time to start it, points
factory. When installing radio or tape player, make the
are defective. Horn must be replaced,
following electrical connections.
Disconnect horn lead and connect an ammeter

3.
the disconnected ends. With key switch on, depress
to
1 AM-FM radio Connect radio wiring (A, Fig. 1 1
directly to speaker harness (B).

horn button and check current draw.
current draw
2. AM radio Connect AR73923 two-to-three wire
If is high (20 amps or more), points are
adapter (C) between radio wiring and speaker harness.
defective. Horn must be replaced.
If current draw is zero, use voltage detector , volt-

3. Tape player Connect radio wiring, tape player
wiring (D), relay, and speaker harness to radio and
meter, or test lamp to test for battery voltage at horn
tape player harness (E). Use AR60557 harness with
lead. Use voltage detector, ohmmeter, or test lamp to
make
AM radio or AR69589 harness with AM-FM radio.
sure ground wire provides a good ground, if both
circuits check out, solenoid has open circuit or points
are stuck open. In either case, horn must be replaced.

Electrical Connections Continued

i
Fig. 12-Adjusting Antenna Trimmer Capacitor Screw
On Motorola radio, screw is located behind tuning

knob. Remove tuning knob and the knob behind it.
Insert a screw driver in small hole below tuning shaft to

adjust trimmer.
FM portion of an AM-FM radio does not have an

antenna trimmer capacitor. When stereo FM signal is
weak, radio automatically switches to monaural re-
ception.
R 26590N
NOTE: If radio works on FM but not on AM, check
A Radio Wiring DTape Player Wiring for a poor connection to antenna.

B
Speaker Harness E Radio & Tape Player
C Two-to-Three Wire Harness Relay
Adapter (AM Only)
Fig. 1 1 -Radio and Tape Player Electrical Connections
4. Connect power in (fused) wire to brown wire in
SOUND-GARD body harness.
5.To assure a good ground, make a ground wire

with an eyelet on one end and an R32025 male blade
connector on the other. Connect to radio chassis and
to black wire in SOUND-GARD body harness.
Antenna Trimmer
If AM radio reception seems poor, adjust antenna
trimmer capacitor screw. To do so, select a weak
station near 1400 and adjust trimmer screw to obtain P.ZStBZU
maximum volume.
Fig. 13-Relay

When a tape cartridge is inserted into tape player, it
engages a relay (Fig. 8). Relay opens circuit to radio to

prevent radio operation while tape is playing.
Relay plugs a multiple connector. To remove

Into
relay, slide bail off sideand pull relay straight out.
Never exert excessive force on relay mounting bracket.
16 10
14 15 8
13* 7
*Park Adjusting Disk B Lock Screw
Hi 12^5
Fig. 15-Left-Hand Wiper Motor
/3Tftftf\ yOTBBV To mechanism, loosen lock screw (B,

adjust park
R 25255U 4 Fig. Rotate park adjusting disk (A) clockwise
15).
(move tab upward) until wiper runs continuously with
switch turned off. Rotate disk counterclockwise just
No Winding Current Windings Energized enough so that wiper stops in park. Then rotate disk
Radio Operation Tape Player Operation counterclockwise just slightly more for insurance.
Tighten lock screw.
Fig. 14-Reiay Terminal Continuity
Fig. 14 shows relay terminal continuity without tape

IMPORTANT: Never manually move wiper arm.
To do so would damage drive gear teeth and might
in slot (left-hand) and with tape in slot (right-hand).
ruin motor.
Noise Suppression
When connecting wiring to wiper, connect green
Three kits are available to reduce radio interference wire to lower terminal, red wire to terminal next to
from electrical components. motor, and black wire to terminal next to wiper shaft.
If blower motor noise is the problem, install Left-hand wiper motor should draw approximately 2
AR78446 Blower Noise Suppression Kit. to 3 amps on low speed and 3 to 4 amps on high
speed.
wiper motor noise is the problem,
if install AR71569
Wiper Noise Suppression Kit. If motor will not operate, either of two circuit break-
ers might be tripped
20-amp breaker in electrical
If reception ispoor and source of interference is not load center (radio would not operate) or the six-amp
known, install AR75563 Fender Mounted Antenna Kit. breaker mounted on wiper switch. In either case,
breaker should reset if key switch is turned off for at
All necessary materials and instructions are includ- least two minutes.
ed in each kit.
See page 8 for circuit checks at wiper switch. If

Left-Hand Wiper switch terminals have proper voltage, check for a poor
connection in wiper harness or a defective motor.
Failure to stop when wiper switch is turned off could
be due to faulty park adjustment or to a short circuit
between wires.
On certain tractors, Sound-Gard body door may not
be adequately grounded. This causes intermittent
operation of dome lamp and left-hand wiper motor.
NOTE: Wet windshield or remove wiper arm before
running wiper motor This minimizes load on motor and
As a remedy, install a ground wire between door and
prevents scratching windshield.
frame. Later tractors include a ground wire in left-hand
wiper harness.

Right-Hand Wiper Repair

Drive gear for right-hand wiper motor is available as
a service part. See Section 40, Group 25 for repair
instructions.
Wiper Switch
A six-amp circuit breaker is attached to each wiper
switch.
Each switch is also protected by a 20-amp breaker

at the electrical load center. upper breaker number 5
If
at electrical load center trips, neither left-hand wiper

nor radio will operate. If lower breaker number 6 trips,
neither right-hand wiper nor low speed blowers will
A Retaining Screws B Nylon Hex Stud operate.
Fig. 16-Right-Hand Wiper Motor

Any of the four breakers should reset if key switch is
To adjust wiper park position; turned off for at least two minutes. If it will not, replace
breaker.
1. Open Sound-Gard Body roof and remove wiper
motor cover,
Testing
2. Loosen two lower retaining screws (A) on round
1. Remove all five switch knobs. Remove bezel
cover.
covering switches.
3. Turn nylon hex stud clockwise so wiper blade win
travel farther on upstroke or counterclockwise so blade 2. Remove retaining nut from wiper switch. Pull
will stop sooner. switch down from roof.
NOTE: Wet windshield or remove wiper arm before 3. Leave power in wire attached to circuit breaker,
running wiper motor This minimizes load on motor and but disconnect other three wires.
prevents scratching windshield.
4. With key switch turned on, use voltage detector
4. Tighten cover screws after adjustment.
voltmeter or test lamp to test for battery voltage at
IMPORTANT: Never manually move wiper arm. unprotected terminal of circuit breaker. If terminal does
To do so would damage drive gear teeth and might not have voltage, check for a tripped circuit breaker at
ruin motor. electrical load center, a poor connection, or an open
circuit.
When connecting wiring to wiper motor, connect
wires of same color together.
5. If unprotected terminal has voltage, test protect-
ed terminal If it does not have voltage, replace switch.
Right-hand wiper motor should draw approximately
2 to 3 amps on low speed and 3 to 4 amps on high
speed. With wiper arm removed, current draw should
be only half this much.
If motor will not operate, either of two circuit break-

ers might be tripped 20-amp breaker at electrical
load center (blowers would not operate on low speed)
or the six-amp breaker mounted on wiper switch, in
either case, breaker should reset if key switch is turned
off for at least two minutes.
See following paragraphs for circuit checks at wiper

switch. If switch terminals have proper voltage, check
for a poor connection in wiper harness or a defective R 26593N
switch.
Fig. 17- Wiper Switch Terminals
TM-1181 (Feb-78) Utho in U.SA. Tractors - 4040 and 4240

6. If protected terminal has voltage, test for voltage Testing

at other three terminals as follows.
Switch in off terminal
position P.
1. Power source for blower switch is a short brown
Switch in low terminal L

position
wire from left-hand wiper switch, if left-hand wiper
Switch in high speed position terminal H.

works, there is no need to check circuit up to that point.
If not, check for tripped circuit
breaker, poor connec-
Replace switch if any terminal does not have voltage tions, or an open circuit.
when should.
it
A tripped circuit breaker or poor connection can 2. Power source for right-hand blower motor is red
sometimes carry enough current to indicate voltage, wire from SOUND-GARD body harness. The same
yet be unable to carry a load. To double check, connect wire loops back into harness and goes to right-hand
a headlight or other suitable load to terminal and a wiper switch, if right-hand wiper works, there is no
good ground. need to check circuit up to that point. If not, check for
tripped circuit breaker, poor connections, or an open
Blower Switch (Early Tractors) circuit.
NOTE: See page 10 for tractors with SOUND- 3. Remove all five switch knobs. Remove bezel
GARD body (Serial No. 167014- covering switches.
).
4. Remove retaining nut from blower switch.

5. Pull switch down from roof and disconnect all
wires.
R 26594N
A Blower Switch E From Circuit Breaker

B Left-Hand Blower Motor No. 6 R 26595N
C Right-Hand Blower Motor FTo Air Conditioner
DThermostat Switch Compressor
GFrom Circuit Breaker
Fig. 19-Blower Switch Terminals
No. 5
Fig. 18-Schematic Diagram of Blower Circuit 6. Use an ohmmeter or test lamp to test for conti-
nuity between the following switch terminals.
Blower switch (A, Fig. 18) connects blower motors
(B and C) series for low speed. Switch provides a
in Switch Position Terminals with Continuity
separate 12-voIt circuit for each motor for high speed.
Left-hand motor grounded at all times. Right-hand
is Off None
motor is 'hot' any time key switch is turned on. Low 1 and 4
For low speed, switch simply connects the two 2 and 5

motors (continuity between terminals 2 and 5).
For high speed, switch provides a power source for High 1 and 4
left-hand motor (continuitybetween terminals 1 and 5) 1 and 5
and a ground for right-hand motor (continuity between 2 and 3
terminals 2 and 3).
In both high and low speeds, switch also
provides a Replace switch if continuity does not check out as
power source to air conditioner thermostat (continuity specified.
between terminals 1 and 4).

Testing Continued 2. Remove knob and retaining nut from blower

switch. Puli switch down, but do not disconnect wires.
7. Reconnect wires as follows.
3. Power source is red wire to "B" terminal. With
Terminal 1 Brown
key switch on, check terminal for battery voltage. If wire
Terminal 2 Orange (to right-hand blower
does not have voltage, check for problem in lower rear
motor)
Terminal 3 Black
circuit breaker (30-amp), accessory relay, or wiring
Terminal 4 Orange (to thermostat)

harnesses.
Terminal 5 Yellow
8. Check operation of switch, if correct, reinstall
switch, bezel, and knobs.
Blower Switch (Later Tractors)

NOTE: See page 9 for tractors with SOUND-GARD
body (Serial No. - 1 67013).
Tractors with SOUND-GARD body (Serial No,

167014- ) have a single blower motor, three-
speed switch, and a resistor to control blower speed.
R32575
Fig. 22-Blowet Circuit
A, Use an ohm meter to check resistance between

"B" and "H" terminals in each switch position. Resis-
tance should be as follows:
off no continuity
low about 1 .0 ohm
med- about 0.5 ohm
high ohm
5. If resistance is not correct, disconnect wires and

between the following termi-
test switch for continuity
nals. Replace switch if continuity is not correct.
off no continuity
Fig. 20-Bezef low "B" to "L" and "C"
med. "B" to M" and *'C"
lt
1. Remove bezel covering switches. high "B" to "H" and "C"
6. If resistance is not correct in Step 4 but switch
continuity is correct in Step 5 f check for a defective

resistor. Use an ohmmeter to check resistance be-
tween wires disconnected from blower switch.
between yellow and tan wires about 0.5 ohm
between yellow and light blue wires about 1.0
ohm
Replace resistor if it is shorted or open. For access

to resistor, open SOUND-GARD body roof and remove
right-hand wiper cover.
NOTE: Resistor is protected by a thermal fuse, if
fuse blows, blower motor will run only in high speed.

When this happens, resistor must be replaced.
Fig. 21 -Blower Switch

7. Connect wires to blower switch as follows:

"B" terminal red
"L" terminal light blue
"M" terminal tan
"H" terminal yellow
"C" terminal orange (to cooling temperature
switch)
Blower Motor (Later Tractors)

When installing blower motor, take care to properly
install fans on blower motor shaft, properly install motor
in housing, and properly connect wiring. Otherwise,
airflow would be greatly reduced.
S?a22iS2
Fig. 25-Centering Fans in Housing
3. Make sure that fans turn freely, and center them

in the housing. If necessary, slide fans slightly on shaft.
mm&>
Fig. 23-Rotation Direction Marks
1. Note rotation direction marks on motor and on

fans. Install fans so that all arrows point in same
direction.
BBlack Y-Yellow
OOrange
Fig. 26-Wiring Connections
4. Connect black to black and yellow to orange.

Otherwise, motor would run backward.
ADDITIONAL ACCESSORIES
If additional accessories draw less than five amps,
they may be connected to the protected terminal of
circuit breaker which is second from top on left side.
Heavier loads should be provided with a separate

mnm circuit breaker, similar to arrangement for outlet socket.
Fig. 24-Notch for Wires See Group 45 in Section 240.
2. Install motor in housing with wires next to notch in

lower half of housing.


Electrical Operation and Tests Power Front-Wheel Drive 240-30-1

POWER
Group 30
FRONT-WHEEL DRIVE DIAGNOSIS
ACircuit Breaker OTransmission Switches

BClutch Pressure Switch ESolenoids
COperating Switch
R 26504N
Fig. 2-Power Front-Wheel Drive Electrical

Flowchart
A Circuit Breaker OTransmission Switches
BClutch Pressure Switch Solenoids
C Operating Switch The transmission switches (D) automatically disen-
gage power front-wheel drive when the higher gears
Fig, 1 -Power Front-Wheel Drive Electrical System are selected. They also reverse the motors when a
reverse gear is selected. With a Quad-Range Trans-
An additional circuit breaker (A, Fig. 1) in the elec- mission, they automatically switch to low torque in
trical load center provides the power source. certain gears.
The cfutch pressure switch (B) shuts off power any Electric solenoids (E) control three valves which
time the clutch is disengaged. supply oil for hydraulic motors which drive the front
wheels.
The operating switch (C) selects off, low torque
(hydrauiic motors connected in series) or high torque For information on the hydraulic and mechanical
(hydraulic motors connected in parallel). components power front-wheel
of drive, see Group 30
of Section 250.

240-30-2 Power Front-Wheel Drive Electrical Operation and Tests
o p Ms) B BR R
= =^
Y- -=f+ ir
n
\y T W
1
BR W BL
BL Y
l-V-/-/ Y T R
"1
4-BL
~0
R 25916N

A Operating Switch EClutch Pressure Switch B Black RRed WWhite
CCircuit Breaker FTransmission Switches BL Blue TTan YYellow

D Solenoids BRBrown
Fig. 3-Power Front-Wheel Drive Wiring Diagram for Power Shift Tractors
fopWc) B BR R T W
r
f^
m \..__
-v>
\y BR W
\
Sf
^
BL Y GR BL BL Y B BL Y B
rat /
L..J
rVA-V R T B
4-R
R 25918N
v-/
AOperating Switch FRange Switch B Black PUPurple
C Circuit Breaker GSpeed Switch BLBlue R Red
D Solenoids H Hi-Lo Switch BRBrown T Tan
E Clutch Pressure Switch GRGreen W White
O Orange Y Yellow
Fig. 4-Power Front-Wheel Drive Wiring Diagram for Quad-Range Tractors

Electrical Operation and Tests Power Front- Wheel Drive 240-30-3
R 25917N
AOperating Switch EClutch Pressure Switch B Black O Orange TTan

C Circuit Breaker F Change Switch BL Blue PU Purple WWhite
D Solenoids G Range Switch BR Brown R Red Y Yellow
GR Green
Fig. 5-Power Front-Wheel Drive Wiring Diagram for Syncro-Range Tractors
POWER FRONT-WHEEL DRIVE 4. Lift up on control lever guide, and remove con-
ELECTRICAL TESTS sole cover.
NOTE: Electrical tests, power shift transmission

switches, and OUAD-RANGE transmission switches
are covered in Group 06 of this section,
SYNCRO-RANGE
control console cover (A, Fig. 6).
1. Loosen the three special screws (B) securing

control lever guide (C).Screws are reached from out-
side SOUMD-GARD body, below right-hand fender.
2. Remove the five special screws securing console

cover.
3. Remove rockshaft selector lever knob (D). A Console Cover C Control Lever Guide
B Special Screws D Selector Lever Knob
Fig. 6-Access to Transmission Switches

SYNCRO-RANGE TRANSMISSION Blue and orange should have continuity in first and
SWITCHESContinued third gears only.
Blue and purple should have continuity in fourth and

seventh gears only.
Blue and green should have continuity in first, sec-

ond, third, and fifth gears only.
Testing Range Switch
i
f*
<E>
c
\
6
/
k... *
R2S97SW \
A R32025 Terminal BTrim

Fig. 9-Modified R32025 Male Terminal
:
bsj:Jii::s?r r
~'
rrrfir*
:s: Make a jumper wire, using two R32025 male termi-
l**%;s -SlsLik:^l= nals and a length of 14-gauge wire. Trim one side off
both terminals as shown in Fig. 9,
A Change Switch B Range Switch
Fig. 7-Syncro-Range Transmission Switches
R291G8N

A Change Switch BL Blue PU Purple AWiring Harness CJumper Wire
BRange Switch BR Brown W White B Clutch Pressure Switch
C Movable Contacts GR Green Y Yellow
D Diode O Orange Fig. 10- Jumper Wire
Fig, 8-internai Connections for Syncro-Range Disconnect the wiring harness (A, Fig. 10) from the
Transmission Switches
clutch pressure switch (B). Connect the jumper wire
(C) to both sides of harness terminal. Hang the wire
Testing Change Switch
across the clutch pedal or some place so obvious you
Disconnect the change switch wiring harness. Use cannot forget to remove it. Otherwise, depressing the
an ohmmeter or test lamp to test for continuity between clutch pedal would not disengage the front wheel drive.

Electrical Operation and Tests Power Front-Wheel Drive 240-30-5
1. Disconnect clutch pressure switch wiring and

Test switch again. If it still fails the test, replace it.
install a jumper wire as instructed on page 4.
Replace range switch if a faulty diode is indicated by
the test.
2. Disconnect change switch.

3. Turn key switch on.
4. Use a voltmeter or test lamp to check for battery
voltage at the following wires.
Orange wire at connector between switches should

have voltage with transmission in third gear
and
operating switch in high torque position.
Green wire at connector between switches should

have voltage with transmission in third gear
and
operating switch in low torque or with transmission in
gear and operating switch in high torque. (An open
first
diode will cause no voltage in first gear high

torque
position.)
Purple wire at connector between switches

should
have voltage with transmission in first gear
and
operating switch in high torque. (A shorted diode will
cause voltage also in third gear low torque position.)
Blue wire at connector between switches or at

con-
nector near solenoids should have voltage
with trans-
mission in first gear and operating switch in low torque.
Yellow wire at connector near solenoid should

have
voltage with transmission in reverse and
operating
switch in either high or low torque.
A
mm
CAUTION: When electrical checks are
completed, remove the jumper wire and
connect the harness to the clutch pressure switch.
Switch Adjustment
If either switch fails the preceding tests,
check
switch adjustment as follows.
1. Place shift lever in fifth gear.
2. Disconnect rod from switch.
3. Turn switch counterclockwise to stop. Then turn

back three notches.
4. Adjust rod length to this position. Reconnect rod.


Electrical Operation and Tests Remote Electrical Circuits 240-35-1
Group 35
REMOTE ELECTRICAL CIRCUIT DIAGNOSIS
ELECTRICAL REMOTE CONTROL
ASwitches BConnector R2S980N
Fig. 1-ElectricaI Remote Control Installation

CStarter GTo Sound-Gard Body
DCircuit Breaker Relay
F Relay HTo Electrical Remote
Control
Fig. 3-Relay and Circuit Breaker Connections
Fig. 3 shows connections for power supply. When

installing relay (F), position cap downward.
R 28850N
ASwitches OCircuit Breaker

BConnector E Sound-Gard Body
CStarter Relay
FRemote Control Relay
Fig. 2-Electrical Remote Control Wiring
For a power supply, electrical remote control is R 28845N

connected to positive battery terminal on starter sole- ATractors with Sound-Gard Body
noid (C, Fig. 2). BTractors without Sound-Gard Body
CPurple Wire to Key Switch
A 25-amp circuit breaker (D) provides overload pro- Fig. 4-Remote Control Relay Lead Connection
tection.
A wire from Sound-Gard Body relay (E) activates

remote control relay (F) when key switch is turned on.

240-35-2 Remote Electrical Circuits
Electrical Operation and Tests
Electrical Remote Control Continued

BR-4 R-l DKBL-2 T-7 R-l LTBL-3
R-l
6 6 066 i
QOO OOO R-l /
DKBL-2
:=t 0-5 PU-6
i
-*
LTBL-3 Y-8 GR-9
R 2U266IT
<)
A Front View of Lower Switch Box Wire Colors:

Harness
B B - Black PU Purple
CTo Current Source BR Brown R
-
DTo Ground
- - Red
DKBL - Dark Blue T - Tan
E Female Plug
F Locating Keyway
GR - Green W - White
LTBL - Light Blue Y - Yellow
O - Orange
Fig, 5-Singfe Switch Box
BR-h R-l DKBL-2 T-7 R-l LTBL-3
1 & ir
DKBL-2 0-5 PU-6 LTBL-3 Y-8 GR-9
BR/W-14 R-l 1 DKBL/W-12 T/W-17 R-l I LTBL/W-13
R-l 1
ffi
9 9 9
4>
T
TV V" f 9- 9
1
V J w-20 t ..,
Y
OKBL/W-12 PU/W-16 LTBL/W-13 GR/W-19
O/B-15 Y/B-IB
R 2U2.67S
Wire Colors:
AFront View of Upper Switch Box B - Black PU Purple
BFront View of Lower Switch Box BR Brown R
-
Red
CHarness DKBL
-
- Dark Blue T
-
- Tan
DTo Current Source GR - Green W White
E To Ground
-
LTBL - Light Blue Y Yellow

F Female Plug O - Orange
-
GLocating Keyway
Fig. 6-DuaJ Switch Box
TM-11&1 (Sep-77) Litho in U.SA. Tractors - 4040 and 4240

Electrical Operation and Tests Remote Electrical Circuits 240-35*3
Figs. 4 and 5 indicate terminal locations, wire colors, Testing
and circuit numbers.

1. Turn key switch on.
&2 <>-
sS 2. Use voltage detector, voltmeter, or test
test for battery voltage at terminal
connector.
1 of
lamp to
remote control
tnnr WW make
3. Use voltage detector, ohmmeter, or
sure that terminal 21 provides a good ground.
test lamp to
o o-o ) o~o cT Connect a headlight or other suitable load to

4.
f
terminals1 and 21 A poor connection or tripped circuit
.
breaker might pass enough current to indicate voltage,

yet be unable to carry a load.
A Left Switch Position D End View 5. Use voltage detector, voltmeter, or test lamp to
B Right Switch Position EContinuity test for battery voltage at the terminals listed in the
C Side View
chart below.
Fig. 7-Rocker Switch Continuity
6. Use an ohmmeter or test lamp to test for conti-
Fig.7 shows which terminals have continuity when a nuity between the terminals listed in the chart below.
rocker switch is depressed. Both momentary
(AR49797) and detent (AR49798) switches are avail- The 25-amp circuit breaker should trip in 20 to 50
able. seconds when carrying a 38-amp load.
To prevent dust accumulation, install an R48049 The circuit breaker should reset itself, but only after
plug in any unused switch location. the load removed. A heater element keeps the
is
breaker tripped as long as the load is connected.
To reset the breaker, turn all electrical remote con-
trol switches off. Wait at least two minutes before trying

the circuit again.
If this doesn't reset the breaker, turn the key switch

off for at least two minutes. If breaker does not reset
breaker is defective. If it does reset, check carefully for
a short circuit in the wiring.
VOLTAGE AND CONTINUITY TEST
Continuity Between
Switch Terminals with Voltage Female Plug Terminals
Switch Position Single Box Dual Box Single Box Dual Box
All Off 1, 10 1, 10, 20 _

Top left Left 1, 2, 10 1, 2, 10, 20 5-6 5-6
Top left Right 1,4, 10 1, 4, 10 20
t
2-5 2-5
Top right Left 1, 3, 10 1, 3, 10, 20 8-9 8-9
Top right Right 1, 7, 10 1, 7, 10, 20 3-8 3-8
Bottom left Left 1, 10, 12,20 15-16
Bottom left Right 1, 10, 14, 20 12-15
Bottom right Left 1, 10, 13,20 18-19
Bottom right Right 1, 10, 17, 20 13-18
TM-1181 (Sep-77) Litho in US, A Tractors - 4040 and 4240

240-35-4 Remote Electrical Circuits Electrical Operation and Tests
OUTLET SOCKET
Testing
Fig. 9 shows recommended wiring connections for
outlet socket. When testing, see whether socket is
connected as shown. If not you must carefully check
each circuit for its source. The following instructions
assume the recommended connections.
1. Use voltage detector, ohmmeter, or test light to

make sure Terminal 1 of outlet socket provides a good
ground.
1 Ground SRight Turn
2Work Lights (20-Amp) 6Tail Lamps 2. Use voltage detector, voltmeter, or test light to
3Left Turn 7Auxiliary Power (10- Amp)
check for voltage at each terminal of outlet socket.
4 Auxiliary Power (20-Amp) Terminal 2when flood are turned on.
lights
Fig. B-Outiet Socket Connections Viewed Terminal 3when left-hand turn signal or warning
from Wire End of Connector flasher on. is
Terminal 4when key switch turned on. (May

is
A seven- terminal outlet socket is available for con- also have a control switch.)
necting lights, turn signals, and other remote electrical Terminal 5 when right-hand turn signal or warning
equipment. Standard terminal usage is indicated in Fig. flasher on. is
8, but other applications may be used. Terminal 6when are on. (Turn
tail lights light
switch to "H".)
NOTE: Colors stamped on connector terminals are Terminal 7when key switch is turned on. (May
standard colors for trailer wiring. In order to match color also have a control switch.)
of tractor wiring where each circuit ties in, three wires
to connector differ from the standard. See Fig. 9. 3. If Terminal 4 or Terminal 7 does not have volt-
age, check control switch or patch cord.
Switches may be added in circuits to Terminals 4
and 7. 4. any terminal does not have voltage when it
If
should, check thepower source for that circuit.

Terminal 2 relay, 20-amp circuit breaker, or splice
to flood light lead-
Terminal 3 or Terminal 5connection to turn signal
circuit.

Terminal 4 or Terminal 7 relay, 30-amp breaker, or
connection to key switch lead.

Terminal 6 connection to tail light circuit.

Electrical Operation and Tests Remote Electrical Circuits 240-35-5
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240-35-6 Remote Electrical Circuits Electrical Operation and Tests

Power Train Operation and Tests Specifications and Special Tools 250-00-1
Section 250
POWER TRAIN OPERATION AND TESTS
Page
Page
GROUP 00 - SPECIFICATIONS AND GROUP 20 - POWER SHIFT TESTS
SPECIAL TOOLS AND DIAGNOSIS
Specifications 00-2 Testing System Pressure 20-1
Special Tools 00-3 Testing Control Pressure 20-2
Lubrication Pressure Test 20-4
GROUP 05 - PERMA-CLUTCH SYSTEMS TestingPTO Clutch and Brake Pressure 20-4
OPERATION OilFlow Trouble Shooting Illustrations 20-5
Perma-Clutch Q5-1 Power Shift Diagnosis 20-6
Operating and Lubrication Circuit 05-3
Transmission Oil Pump 05-3 GROUP 25 - DIFFERENTIAL AND
Oil Filter Relief Valve Housing 05-5 FINAL DRIVE
Oil Pressure Regulating Valve Housing 05-5 How The System Works 25-3
Clutch Valves 05-6
*
Differential Lock Valve Pressure Test 25-3
Oil Cooler Check Valve 05-7
Lubrication Reduction Valve 05-7 GROUP 30 - POWER FRONT-WHEEL DRIVE
Syncro-Range Transmission 05-9 Electrical Control System 30-1
Creeper Transmission 05-10 Control Valve Housing 30-2
Quad-Range Planetary 05-12 Wheel Oil Manifold **.".*
30-4
Power Flow 05-12 Wheel Housing 30-5
Control and Shift Valves 05-15 Planetary and Brake 30-6
Quad-Range Eight Speed 05-16 Power and Oil Flows
PTO 05-18 Neutral 30-6
Forward-Low Torque 30-8
GROUP 10 - PERMA-CLUTCH TESTS Forward-High Torque 30-10
AND DIAGNOSIS Reverse-Low Torque 30-12
Diagnosing Malfunctions (General) 10-1 Reverse-High Torque 30-14
Clutch Pressure Test 10-4 Diagnosing Malfunctions (Genera!) 30-16
Lubrication Pressure Test 10-5 Testing
Lubrication Reduction Valve Test 10-6 Pressure Control Valve 30-18
Circuit Leakage Isolation Test 10-6 Bleed Leakage
PTO 30-18
Clutch and Brake Pressure Test 10-7
Transmission Cycle Test 10-8
Oil Pressure Switch Test 10-8
GROUP 15 - POWER SHIFT SYSTEM

OPERATION
Power Flow 15_1
Hydraulic System 15_4
Transmission Oil Pump 15_5
Oil Pressure Regulating Valve Housing
15-5
Transmission Control Valve Housing 15-5
Pedal Valve Housing 15-6
Control System Flow [.[..] 15-8
PTO 15-8
>
TM-1181 (Apr-81) Utho in U.S.A.

250-00-2 Specifications and Special Tools Power Train Operation and Tests
Group 00
SPECIFICATIONS
Perma-Clutch System
ITEM MEASUREMENT SPECIFICATION
Filter relief valve differential
opening Pressure (to lube) 70 kg/cm 2 )
psi (4.8 bar) (4.9
(to sump) 91 psi (6.2 bar) (6.4 kg/cm 2 )
Cooler relief valve opening Pressure (to lube) 115 psi (7.9 bar) (8.1 kg/cm2 )
(to sump) 135 psi (9.3 bar) (9.5 kg/cm2 )
Clutch oil Pressure See 250-10-4
Lubrication oil Pressure See 250-10-5
PTO clutch and brake oil Pressure See 250-10-7
Transmission oil pressure switch
operating Pressure See 250-10-8
Transmission temperature switch
operating Temperature 220F (100C)
Low pinion lubrication oil Flow 0.7 gpm (2.6 i/min)
Transmission drive shaft
lubrication oil Flow 2.8 gpm (10.6 l/min)
Differential drive shaft
lubrication oil Flow 1 .3 gpm (5.0 !/min)
PTO clutch lubrication oil Flow 2.0 gpm (7.6 l/min)
Transmission clutch lubrication oil Flow 6.0 gpm (22.7 l/min)
Power Shift Transmission
Filter relief valve differential

opening Pressure 70 psi (4.8 bar) (4.9 kg/cm2)
Lubrication relief valve opening Pressure 40 psi (2.8 bar) (2.8 kg/cm 2 )
Transmission system Pressure 175-195 psi (12.0-13.4 bar) (12.3-13.7 kg/cm 2 )
Cooler relief opening Pressure 115-135 psi (7.9-9.3 bar) (8.1-9.5 kg/cm 2)
Transmission control operating Pressure See 250-20-5
Transmission lubrication oil Pressure See 250-20-7
PTO clutch and brake operating Pressure See 250-20-9
Priority lubrication oil Flow 1.5 gpm (5.7 l/min)
Transmission temperature
switch operating Temperature 220F (100)
Transsmission pressure
oil
switch operating Pressure 90-100 psi (6.2-6.9 bar) (6.3-7.0 kg/cm2 )
Differential and Final Drive
Differential lock operating Pressure 435-485 psi (30.0-33.4 bar) (30.6-34.1 kg/cm 2 )
Planetary speed Reduction 40 to 1
Neutral bleed valve closing Pressure 143-187 psi (10-13 bar) (10.2-13.3 kg/cm 2)
System operating Pressure 1930-1970 psi (133-136 bar) (136-139 kg/cm 2)
Bleed oil return leakage Flow per wheel 3/8 gpm (1.4 l/min) (

Power Train Operation and Tests Specifications and Special Tools 250-00-3
SPECIAL TOOLS*
TOOL NUMBER USE
Perma-Clutch Tests And Diagnosis A0-60 psi (0-5 bar) To test transmission lube
Pressure Gauge pressure.
B0-300 psi (0-25 bar) To test transmission clutch
Pressure Gauge pressures.
C0-600 psi (0-45 bar)
Pressure Gauge
00-5000 psi (0-400 bar)
Pressure Gauge
ED-19 Hose (3 used)
FD-6 90 Elbow
G D-12 Adapter
HD-5 Adapter
I D-8 Coupling
Also Required:
Destroking Screw To destroke main hydraulic
pump
z.c 8 2 B Z J
Fig. 1-Universal Pressure Test Kit
AD-01019AA Hand Pump To test transmission oil

B0-300 psi (0-25 bar) pressure switch.
Pressure Gauge (See Fig. 1)
COhmmeter

D Oil Pressure Switch
* Order from;
&m2H Service Tools
Fig. 2-Pressure Switch Test Toots

250-00-4 Specifications and Special Tools Power Train Operation and Tests
TOOL NUMBER USE
Power Shift Transmission Tests 0-15005 To test operating pressures of

And Diagnosis power shift transmission ele-
ments.
Also Required:
0-60 psi (0-5 bar) To test transmission lubrica-

Pressure Gauge tion oil pressure.
(See A, Fig. 1)
0-300 psi (0-25 bar) To test PTO clutch and brake

Pressure Gauge oif pressures.
Fig. 3-PST Test Kit
Differential and Final Drive
Nuday Tee 135-5.1 To test differential lock oil

0-600 psi {0-45 bar) pressure.
Pressure Gauge
(See C, Fig. 1)
Fig. 4-DifferentiaJ Lock Pressure Test Tools

0-5000 psi (0-400 bar) To test pressure control
Pressure Gauge valve setting.
0030 (9/16-1 8F JIC To measure bleed oil Tine

Cap Nut and one
1 gallon (4 I) container

I
(unaeranve wane *&#"*"/

Power Train Operation and Tests Perma-Clutch Systems Operation 250-05-1
Group 05
PERMA-CLUTCH SYSTEMS OPERATION
PERMA-CLUTCH OPERATION Three adjustable clutch operating levers (C, Fig. 1)
Power from the engine flywheel and three adjustable PTO operating levers (J) me-
is connected or
chanically engage the clutch when the appropriate
disconnected from the transmissron input shaft by
piston in the operating piston housing is applied.
means of the Perma-Clutch. The Perma-Clutch as-
sembly consists of two independently operated clutch The annular clutch and PTO operating pistons (F
packs.
and D) are actuated when pressure oil from a clutch
valve is routed to the rear of the appropriate piston.
The Quad-Range hi-low planetary Creeper Plane-
tary and eight-speed Syncro-Range Transmissron are
Aneedle thrust bearing absorbs thrust between the
described later engaging piston and operating levers.
in this Group.
The front clutchpack is the transmission disconnect The clutch separator plates (l) rotate whenever the
engine flywheel is turning. The clutch disks are in mesh
clutch, whife the rear pack is the PTO clutch (See Fig.
1).
with the clutch hub (H) which is splined to the clutch
Each clutch assembly consists of oil-cooled clutch shaft (E). The clutch shaft provides transmission input.
disks alternately installed with steel separator plates on

a clutch hub.
-r^v -
.
c
/- I 111 II
R 28322N
AEight-Speed CClutch Operating Lever EClutch Shaft GPTO Hub t Separator Plates
BPlanetary Unit D PTO Operating Piston FTransmission Piston H Cfutch Hub JPTO Operating Lever
(Quad-Range) K PTO Shaft
Fig. 1 -Perma-Clutch Power Train

250-05-2 Perma-Clutch Systems Operation Power Train Operation and Tests
PERMA-CLUTCHContinued
R 29090N
Fig. 2-Perma-Ctutch Power and Oil Row Transmission Clutch Engaged, PTO Clutch DisBngaged
(Quad-Range Shown)

Perma -Clutch Operating and Operation

Lubricating Circuit
The transmission oii pump draws oil from the trans-
The Perma-Clutch system generates,
hydraulic mission reservoir through a mesh strainer.
directs, and controls oil pressure and flow to the clutch
housing and transmission components (Fig. 2). An orifice (in the pump manifold) allows the pump to
lubricate the transmission drive shaft, Quad-Range
This accomplished by the following assemblies:
is hi-io bearings, and differential drive shaft directly from
transmission oil pump and check valve, oil filter, oil the pump.
filter relief vafve housing, pressure regulating valve
housing, oil cooler check valve, lube reduction valve, Oil flows through an orifice to the transmission drive
transmission clutch valve, and PTO clutch valve. shaft inner diameter between the transmission drive
shaft and the hex drive shaft (R, Fig, 2).
TRANSMISSION OIL PUMP
Oil from return fine (E, Fig. 3) combines with pump
General flow to lubricate the transmission drive shaft and dif-
The external gear transmission oil pump is located

ferential drive shaft. A check ball prevents loss of lube
at the rear of the transmission drive shaft in the dif-
oil to the lube reduction valve when pressure in the
return line is low.
ferential case. It is driven by a long, hexagonal shaft
extending from the engine crankshaft. Pressure oil is
Oil flow in the transmission drive shaft lubricates the
therefore available whenever the engine is running.
shaft, bearings, and gears. A bushing with a hex. I.D.
(inthe transmission input shaft on Quad-Range, in the
The transmission oil pump circulates oil to cool and
transmission drive shaft on Syncro-Range, and in the
lubricate the clutches and transmission. It lubricates
and charges clutch shaft on Creeper) has a notch to allow lube oil to
the main hydraulic pump.
the pilot bushing (O, Fig. 2).
The transmission pump supplies oil to the hydraulic

oil cooler for the entire hydraulic system.
Oil is also metered to the PTO and transmission
clutch for cooling.
The pump supplies pressure oil to operate the

Perma-Clutch and Quad-Range planetary hi-lo.
A Quad-Range Brake Housing KTransmission Separator Plate V Transmission Clutch EE PTO Drive Gear
BOperating Bearing Housing L Lever Return Spring Hub and Oil Shield
CNeedle Bearings MClutch Operating Bolt W PTO Clutch Hub FF PTO Gear and Shaft
DClutch Operating Piston N Clutch Pressure Plate X PTO Adjusting Screw GG PTO Clutch Shaft
EClutch Operating Lever O Bushings Y PTO Operating Lever HH-Clutch Shaft
FClutch Cover PCrankshaft Z Drive Pin 3-;g Pressure Free Oil
GPTO Clutch Disks Q Pump Drive Adapter AA PTO Operating Piston Hfg Power Flow
HPTO Separator Plate R Hex. Drive Shaft BB Seals System Pressure Oil
I Clutch Backing Plate SFlywheel CC PTO Brake Piston
J Transmission Clutch Disks TRing Gear DD Bearing Assembly
UClutch Housing
Legend for Fig. 2

250-05-4 Perma-CJutch Systems Operation Power Train Operation and Tests
R 29Q91N
ALube Oil Check Valve J To Clutch Operating Piston T OHPressure Regulating AA Return Check Valve
B Transmission Oif Pump KTo PTO Operating Piston Valve BBSump Strainer
CTransmission Drive Shaft LTo PTO Clutch U Cooler Relief Valve CCDifferential Drive
DTo Low Pinion MTo Transmission Clutch V^TO Clutch Valve Shaft
ELube Tube NPilot Bushing WOil Filter DDPump Drive Shaft
F Clutch Housing OQuad-Range Planetary XFilter Relief Valve % System Pressure Oil
GCooler Return Check Ball P Hex. Bushing Y Relief Valve Housing gggg Lubrication Oil
HTo Clutch Operating Q_To PTO Valve Z From Hydraulic Pressure-Free Oil
Bearing RTo Main Pump and Cooler Functions
I Lube Reduction Valve S Pressure Regulating Valve
Housing
3-Perma-Cfutch and Transmission Lubrication (Quad-Range Shown)

Fig.
i

Power Train Operation and Tests Perma-Ciutch Systems Operation 250-05-5
Oil Filter Relief Valve Housing Return Pressure Check Valve

The oil filter relief valve housing (Y, Fig. 3) is located The return check valve (AA) allows return oil from
on the left-hand side of the transmission case. It re- the hydraulic functions (Z) to enter the charge circuit to
ceives charge oi! from the transmission oil pump and the oil filter and cooler.
return oil from the rockshaft housing. The oil filter relief
valve housing contains the following valves: The check valve prevents charge oil from entering
the return side of the hydraulic circuit when no hy-
draulic functions are being used.
OH Filter Relief Valve
Oil flows through the valve housing to the transmis- Oil Pressure Regulating Valve Housing
sion filter (W) and also to the top of the oil filter relief
valve (X). The pressure regulating valve housing (S) is located

If the oil filter becomes restricted, oil pres-
sure to the filter increases to maintain flow to the on the left-hand side of the clutch housing.
oil
pressure regulating valve. Oil under pressure from the oil filter relief valve
At the specified pressure

housing passes through the oil filter to enter the pres-
differential, the relief valve
open against sure regulating valve housing and perform these func-
will spring force to dump oil to the lubri-
tions:
cation circuit.
Further filter restriction, creating additional differen- Oil Pressure Regulating Valve
tial pressure allows the valve to open further to dump
oil to the hydraulic reservoir.
The oil pressure regulating valve (X) maintains
charge pressure from the oil filter relief valve housing.
Warning System This assures Quad-Range planetary and Perma-
Ciutch operation.
pressure oil at the lower part of the filter relief valve
If
(and to the pressure regulating valve) falls below a The pressure regulating valve shuttles in its bore
against spring force to relieve oil whenever oil pressure
specified pressure, a pressure actuated switch will
cause the transmission exceeds system pressure. This excess charge oil
oil indicator lamp to light.
routes to the main hydraulic pump and oil cooler.
The housing may also be equipped with a tempera-
ture switch that lights the same lamp when oil temper-
ature exceeds 220F (100C). This switch is standard
on Power Front-Wheel Drive models.

250-05-6 Perma-CIutch Systems Operation Power Train Operation and Tests
Oil Cooler Relief Valve The operating arm shaft (D, Fig. 4) is held in the
engaged position by the clutch pedal return spring. Oil
The oil cooler relief valve (U, Fig. 3) limits the
at system pressure is routed to the clutch operating
pressure of oil to the oil cooler and main hydraulic
piston to engage the transmission clutch (A).
pump.
Oil pressure is also routed to the bottom of the valve
When oil pressure in the valve housing exceeds
(I) to counteract the upper spring (F) which is pushing
specified pressure, the oil cooler relief valve opens to
the valve down. This pressure provides modulation
bypass the oil cooler. Oil is directed to the transmission
during engagement.
lube circuit.
As the valve land uncovers the clutch pressure
If pressure in the valve housing exceeds the
the oil
passage, pressure oil also acts on the valve to oppose
second stage pressure, the valve opens further to
spring force preventing sudden clutch engagement.
dump oil to sump.
The lower spring (H) provides initial modulation. When
the spacer pin (G) bottoms in the valve, the stiffer
Clutch Valves
upper spring provides modulation.
The clutch valve housing is attached to the inside of The clutch valve is forced open as the arm com-
the pressure regulating valve housing. The clutch pletes downward compressing the upper spring.
travel,
valves receive pressure oil directly from the pressure When the clutch is disengaged, the operating arm
regulating valve housing. rotates upward (B). The valve is pulled up by its cross
The PTO and transmission clutch valves operate pin (C). System pressure is shut off and the clutch
independently of one another. pressure passage is routed to sump.
The clutch pressure plate return springs return the
Transmission Clutch Valve operating bearing to the disengaged position byway of
the dutch operating levers.
^ PTO Clutch Valve and Lock Piston

This assembly is located in the same housing as the
transmission clutch valve.
R28Z04E
A^-To Clutch Operating GSpacer Pin

Bearing HLower Spring
BDisengaged Position I Clutch Valve
CPin R2S205N
System Pressure Oil
DOperating Arm Shaft Lubrication Oil
EFrom Transmission Pressure Free Oil A^-To PTO Clutch OSpacer Pin
FUpper Spring Operating Piston H Lower Spring
BOperating Arm Shaft I PTO Clutch Valve
Fig, 4-Transmission Clutch Vaive Engages CLock Arm JTo Sump
D Lock Piston , IBB System Pressure Oil
E From PTO Brake mm Pressure Free Oil
F Upper Spring
Fig. 5-PTO Clutch Valve Engaged

the engaged position, the operating arm shaft (B,

In
Oil Cooler Check Valve
Fig. 5) rotatescounterclockwise compressing the PTO
valve springs (F and H). The valve is forced down and The oil cooler check valve
is located on top of the
oil system pressure is routed to the PTO clutch

at clutch housing. prevents unfiltered oil from the oil
It
filter relief valve from supplying the main hydraulic

operating piston to engage the PTO clutch (A).
pump through the oil cooler return line.
Pressure oil to the bottom of the PTO piston pro-
vides modulation as with the transmission clutch valve. It also allows cooled oil to flow to the transmission
and dutch lubrication circuit when oil cooler pressure is
When the PTO is nearly engaged, the bottom land greater than lubrication pressure.
on the PTO valve uncovers a hole that routes pressure
oil to the bottom of the PTO lock piston (D). The
Cooling oil for the clutches returns to the transmis-
lock
piston moves up and the PTO is locked into position by sion through a cast opening in the clutch housing. Oil in
the lock arm the bottom of the clutch is thrown upward by the
(C).
rotating clutch.
LUBRICATION REDUCTION VALVE

The lube reduction valve is located in the clutch
operating bearing housing.
Before lubricating oil reaches the lube reduction
valve, it is metered through an orifice to the transmis-

sion low pinion and to the clutch operating needle
bearings.
The lube reduction valve assists shifts (particularly

with cold oil) by reducing lube oil flow when the clutch
is not engaged. This reduces the possibility of clutch

drag.
R28206N
AFrom PTO Op. Piston EPTO Clutch Valve

B Pin FTo Sump
C-To PTO Brake ;v: System Pressure Oil
DLock Piston KI Pressure Free Oil
Fig. $~PTQ Brake Engaged
the brake position, the PTO clutch valve (E, Fig. 6)

In
is held by
its cross pin (B). Oil at system pressure is
routed to the PTO brake (C). The passage to the PTO

clutch operating piston opens
to sump. This permits
the springs to return the PTO
operating bearing to the
disengaged position. Oil from the lock piston also
returns to sump.

LUBE REDUCTION VALVEContinued Transmission Clutch Disengaged/PTO

Transmission Clutch Engaged/PTO Clutch Engaged (C, Fig. 7)
Clutch Disengaged (A, Fig. 7) The piston (G) moves up to stop pin (F). Therefore
the lube reduction valve spring (D) holds the valve
Pressure oil from the dutch valve pushes the lube
reduction valve up against spring force. This routes
against the piston. Some oil goes to lube and the rest
lube ffow to the dutch lube passage (K). Metering

goes to sump.
The reduced all the dutch disk
flow allows nearly
holes in the PTO clutch hub allow the lube oil to cool
the PTO lubrication escape through the PTO clutch hub
oil to
clutch disks.
metering holes. Very little oil goes to the transmission
The remaining lube flow goes to the transmission
clutch.
clutch disks, through the large hole in the PTO dutch
hub.
The PTO clutch is not engaged and the drag created
Transmission Clutch Engaged/PTO
Clutch Engaged
by lubrication flow is not detrimental since the PTO
brake is engaged. The piston may move up against the stop pin, or it
may assume an intermediate position between the two

Transmission Clutch Disengaged/PTO clutch passages. Lubrication flow is not affected to
Clutch Disengaged (B, Fig. 7) either clutch.
The spring forces the lube reduction valve down to

the stop pin (F). Lubrication oil is routed to sump rather
than to clutch disks. Clutch drag is reduced easing the
shift.
R Z9092N
AClutch Engaged, PTO Disengaged G Piston

BClutch Disengaged, PTO Disengaged HTo PTO Clutch Piston # System Pressure Oil
CClutch Disengaged, PTO Engaged IAdapter Inlet | Lubrication Oil

D Valve Spring JTo Clutch Piston and Pressure- Free Oil
E Lube Reduction Valve Quad-Range Shift Valve

F Stop Pin KClutch Lube Passage
Fig. 7-Lube Reduction Valve Operation

NOTE: The Syncro-Range transmission and its
have a low and high

variations synchronizer package
on the transmission drive shaft (9, Fig. 8). Since this
permits shifting between low and high speeds within
any one of the four shift stations (by disengaging the
clutch and moving shift lever), an additional speed
range is created.
On the Syncro-Range, this range is called the

"speed range." Therefore the gears and on the collars
transmission drive shaft are described as "range"
components.
Since the collar shift of the differential drive shaft is

not synchronized; differential shaft components (18)
are considered speed "change" parts.
The QUAD-RANGE Transmission (QRT) consists of

four ranges on the differential drive shaft so those parts
are considered speed "range" components, even 1First and Third-Speed Countershaft Gear
though a collar shift is provided. 2Sixth and Eight-Speed Countershaft Gear
3Second and Fifth-Speed Countershaft Gear
Therefore the synchronized and collar shifts of the
4 Fourth and Seventh-Speed Countershaft Gear
transmission drive shaft and the two-speed Power
5 Countershaft
6 Reverse Range Pinion
Shift planetary are referred to as "speed selector" 7 Reverse Range Shifter Collar
shifts. 8Low Range Pinion
9 Low and High Range Synchronizer
HOW THE SYNCRO-RANGE 10 High Range Pinion
11Transmission Drive Shaft
TRANSMISSION WORKS 12 Fourth and Seventh-Speed Differential Drive Shaft Gear
The Syncro-Range transmission is the standard;
13Transmission Shifter Collar (Front)
14Second and Fifth-Speed Differential Drive Shaft Gear
eight speed, siiding-collar transmission of the 4040 15Sixth and Eighth-Speed Differential Drive Shaft Gear
and 4240 tractors. The Creeper planetary is an option 16Transmission Shifter Collar (Rear)
added to the basic transmission. 17First and Third-Speed Differential Drive Shaft Gear
18 Differential Drive Shaft
The following illustration and chart show the gear 19Differential Drive Shaft Bevel Pinion
combinations to obtain each tractor gear speed. The Fig. 8-Transmission Shafts and Gears
speeds are listed in the order they appear in the shift SHIFT STATION NO. 1
quadrant in each of the four shift stations. Gears and
pinions on the chart are engaged with their respective 1ST Power in 8 2 1 17 Power out
shaft, with the exception of the and
first third speed 3RD Power in 10 4 1 17 Power out
differential drive shaft gear which is an idler in fifth
3REV Power in 6 17 Power out
reverse speed. SHIFT STATION NO. 2
2ND Power in 8 2 3 14 Power out

5TH Power in 10 4 3 14 Power out
5REV Power in 6 17 13 14 Power out
SHIFT STATION NO. 3

7TH Power in 10 4 12 Power out
SHIFT STATION NO. 4


HOW THE SYNCRO-RANGE

TRANSMISSION WORKS^Continued
Synchronized shifts between Jow and high, and re-
verse range shifts are controlled by the speed range
selector collars.The collars operate a disk clutch as-
sembly which synchronizes gear and shaft rotation
before engagement. This shift makes it possible for a
low and high speed range in any one of the four shift
stations by disengaging the dutch and moving the shift
lever.
The speed change shifters, on the differential drive Fig.

V
9-Creeper in Direct Drive
shaft, can slide to engage any one of the four differen-

tial drive shaft gears with the differential drive shaft. All In the direct drive position (Fig. 9), the shifter collar
tractor speeds in any one shift station can be obtained (at the rear of the planetary) locks to the rear sun gear.
without shifting the differential drive shaft gears. The planetary carrier rotates as a unit.
Park is obtained by engaging the first and third, and

fourthand seventh speed differential drive shaft gears !;.'.*.':
V
with the differential drive shaft. These gears are in
constant mesh with the first and third, and fourth and
seventh-speed countershaft gears (which cannot ro-
ililUllfillliiilPs"
tate independently of each other). The differential drive ! 'Ivw
shaft can not turn, and the tractor wheels are locked.
The gear-type oil pump (mentioned

transmission
earlier) forces under pressure through the trans-
oil ?:!&: )$s ,.
mission shafts to lubricate gears, synchronizers and H 2*431 fc'Vs i
bearings. For further information on the pump; see

Fig. 10-Creeper in Underdrive
Section 270, Group 15.
Underdrive (Fig. 10) is produced by engaging the

CREEPER TRANSMISSION shifter collar with a locking plate which is secured at the
transmission drive shaft front bearing quill. The rear

HOW THE CREEPER WORKS sun gear is locked to the transmission case causing the
The Creeper transmission is an eight-speed Syn- on their axes. Power flows to
planet pinions to rotate
cro-Range transmission with a collar-shifted planetary sun gear which is splined to the output shaft.
the front
ahead of it. The Creeper is an option on Syncro-Range The reduction is approximately 78%, creating speeds
transmissions. For information on the Creeper eight- as low as 0.4 mph (0.64 km/hr).
speed, see the preceding page.
The Creeper may be engaged in gears first through
Planetary Operation fifthforward, and first and second reverse. A mechan-
ical interlock on the shifting mechanism prevents en-
The Creeper control lever is located between the
gagement in sixth through eighth speeds forward. A
transmission shifter lever and throttle control lever.
mechanical interlock also prevents the transmission
Moving the Creeper control lever forward slides a
from being placed in the park position unless the
shifter collar to engage the Creeper (underdrive). Pull-
Creeper lever is in the direct drive position.
ing the lever rearward slides the collar to the direct
drive position.
In the tow position, both the shifter collars on the
differential drive shaft are in the neutral position.
The tractor must be stopped and the clutch disen-

gaged to move the Creeper planetary collar. A snubber
brake in the planetary helps stop the carrier when the
clutch is depressed to permit shifting transmission
gears.

Power Train Operation and Tests Perma-Clutch Systems Operation 250-05*11
Lubrication Oil Flow
=M,
rt29Z93N
1Transmission Drive Shaft 5Planet Carrier 9 Front Sun Gear Lubrication O'rf
2Shifter Collar GHex Bushing 10Output Sun Gear
i
3 Shifter Yoke 7PTO Gear 11Shifter Plate

4Planet Pinion 8 Snubber Brake 12 Bearing Quill
13Transmission Input Shaft
Fig. 1 1-Oreeper Planetary Lubrication
Oil from the transmission oil pump flows through the

transmission drive shaft to the sun gear bushings. The
hex. bushing at the front of the input shaft allows some
oilthrough the notch in the bushing to lubricate the
dutch shaft pilot bushing. The remainder of the oil is
directed to the planet pinion roller bearings.

250-05-1 2 Perma-CIutch Systems Operation Power Train Operation and Tests
General Information The input sun gear (BB) is spiined to the clutch shaft.
The Quad-Range transmission is comprised of two Since the input (front) sun gear is integral with the
major components: the Quad-Range two-speed power clutch hub, it rotates at the same speed as the clutch
shift planetary, and the Quad-Range eight-speed hub. The input sun is also in mesh with the front planet
transmission. pinion gears (J).
The two-speed planetary located

The rear (output) sun gear (DD) is in mesh with the
is in the clutch
housing and is attached to rear planet pinion gears and splines with the transmis-
the rear of the clutch
operating piston housing. sion input shaft (D).
The Quad-Range eight-speed transmission The front sun gear is in mesh with the larger (24
is lo-
cated behind the planetary in the transmission case, it teeth) planet pinion gears. This allows underdrive
is a combination synchronized and collar-shifted power flow through the smaller rear planet pinion
transmission. gears.
How the Quad-Range Planetary Works Direct Drive Power Flow Clutch Applied
The Quad- Range planetary is a hydraulically-shift- With the Perma-CIutch engaged, the clutch shaft is
ed, two-speed unit consisting of a compound plane- driven at engine speed.
tary, a direct drive clutch, an underdrive brake, and a

and During a direct-drive shift, pressure oil from the shift
control shift valve. The brake assembly provides
underdrive shaft output. valve causes the clutch piston to compress its disks
and plates forming a solid unit.
Lateral movement of the speed selector (inner) lever
produces a power between and
The clutch hub is welded to the front sun gear. Since
shift 1 2, 3 and 4, and 1
and 2 reverse. the disks are spiined to the hub and the plates are
tanged to the clutch drum, the clutch pack and drum
The compound planetary provides rotates with the clutch shaft. Since the planet pinion
the difference
between gear speeds. carrier is attached to the clutch drum, it also rotates
with the clutch shaft.
The direct drive clutch (M, Fig. 12 or 13) contains

paper-faced disks alternated with
The front planet pinion gears are in mesh with the
steel separator
plates packed on a clutch hub (BB) which clutch shaft sun gear. Therefore, the sun gear is locked
is spiined to
the transmission clutch shaft (J). The separator plates to the planet pinion carrier.
have outer tangs which fit into slots in the clutch drum
The Carrier rotation is transmitted through the rear planet
(AA). clutchdrum is attached to the planet pinion
carrier (EE) by cap screws. The clutch hub is integral pinion to the output sun gear.
with the front planetary sun gear (input sun) (BB).

The power flows from the output sun gear through
The underdrive brake also contains paper-faced the transmission input shaft and to the transmission.
disks alternated with steel separator plates. The brake
disks have tangs on the inside diameter which engage
the clutch drum. (AA). The separator plates have outer
tangs which engage the brake housing (Y).
Both the clutch and brake packs are engaged by

annular hydraulic pistons (R and Q) and are disen-
gaged by springs acting on the piston.
The planetary assembly consists of a planet pinion

carrier, three planet pinions, and two planetary sun
gears.

R 29404N
ATransmission Drive Shaft MDirect Drive Clutch Z Brake Backing Plate

BTransmission Pump Hex. NUnderdrive Brake AADirect Drive Clutch Drum
Drive Shaft OSpring BBInput Sun Gear
C Bearing p Spring Pin CCThrust Washers
DTransmission input Shaft QUnderdrive Brake Piston DDPlanetary Sun Gear
E Bushing R Direct Drive Clutch Piston EE Planet Pinion Carrier
F Bushing SThrust Washer FF Thrust Washer
GPlanet Pinion Shaft T Spring Washers GGBushings
HThrust Washer U Transmission Clutch Shaft W& System Pressure Oil
VPTO Clutch Shaft with Gear
Mi Lubrication Oil
I Needle Bearing Assembly
JPlanet Pinion WBushing Pressure-Free Oil
Clutch Housing
.:;
K XSealing Rings 7$ Power Flow

LBall YUnderdrive Brake Housing
Fig. 12-Quad-Range Two-Speed Planetary Power Flow and Oil Flow
(Direct Drive Clutch Applied)

250-05-14 Per ma-Clutch Systems Operation Power Train Operation and Tests
PLANETARY Continued
R 294Q6N
ATransmission Drive Shaft M Direct Drive Clutch Z Brake Backing Plate

BTransmission Pump Hex. N Underdrive Brake AADirect Drive Clutch Drum
Drive Shaft OSpring BBInput Sun Gear
C Bearing P Spring Pin CCThrust Washers
DTransmission Input Shaft Q Underdrive Brake Piston DD Planetary Sun Gear
E Bushing R Direct Drive Clutch Piston EEPlanet Pinion Carrier
F Bushing S Thrust Washer FF Thrust Washer
G Planet Pinion Shaft T Spring Washers GGBushings
HThrust Washer U Transmission Clutch Shaft
I Needle Bearing Assembly V PTO dutch Shaft with Gear
HH System Pressure
^Lubrication Oil
Oil
J Planet Pinion W Bushing iHi Pressure-Free Oil

K Clutch Housing
X Sealing Rings HU Power Flow
LBall
Y Underdrive Brake Housing
Fig. 13-Quad-Range Two-Speed Planetary Power Row and Oil Flow (Underdrive Brake Applied)

Power Train Operation and Tests Perma-CIutch Systems Operation 250-05-15
Underdrive Power Flow Brake Applied Underdrive Brake Application

The brake housing (Y, Fig. 13) is attached to the
clutch operating bearing housing which is attached to
the clutch housing. Therefore, brake engagement
stops any component controlled by the brake.
The brake disks are tangedto the clutch drum (AA)

which attached to the planet pinion carrier (EE). The
is
separator plates are tanged to the brake housing.
When the shift valve is moved to engage the brake

piston, disk rotation stops. The disks form a solid unit
with the separator plates. Planet pinion carrier rotation
also stops with the dutch drum.
Now the planet pinions (J) act as countershafts

(rotate on their shafts). Power flows from the front sun
gear to the planet pinions and output sun gear (D). The
different gear ratio creates the speed reduction, since
the larger sun gear is at the input end.
From the output sun gear, power flow is the same as R 29095N
direct drive.
AControl Valve P System Pressure Oil
BFrom Operating Piston (from operating piston)
Hi-Lo Planetary Oil Flow C Detent Pin t: System Pressure Oil
DOil Tube (from adapter inlet)
Lube oil to the two-speed planetary is supplied from
EShift Valve ? Return Oil
the transmission pump through the operating piston F Detent Ball
housing. GFrom Clutch Piston
HTo Brake Piston
Control and Shift Valve Assembly
Fig. 14-Underdrive Oil Flows
The control and shift valve assembly is located at
the front of the hi-lo unit brake housing. The control The control valve is shifted down (A, Fig. 14) by
valve is manually operated by lateral movement of the lateralspeed selector movement. This allows oil to
speed selector lever. force the shift valve (E) down.
Oil is routed so the shift is controlled with oil from the Pressure oil from the inlet adapter is now routed past
traction clutch operating piston. The second oilsource the shift valve into the brake passage (H). At the same
isused to apply the clutch or brake through the long time, oil from the direct drive dutch (G) is routed to the
adapter on the hi-lo unit. main hydraulic reservoir.
Oil that was previously at the bottom of the shift

valve is also routed to the reservoir via an external oil
line (D) through a passage in the control valve bore.

250-05-1 6 Perma-Clutch Systems Operation Power Train Operation and Tests
Control and Shift Valve Assembly- How The Quad-Range Eight-Speed Works
Continued
The Quad-Range eight-speed is located behind the
Direct Drive Clutch Application hi-lo planetary. Itconsists of three gear shafts which
are housed in the transmission case.
Speed selection is controlled by two levers on the

control console. The outer lever (range selector) con-
trols collar shifts of the differential drive shaft gears to
provide four speed ranges labeled A, B, C, and D. A
"park" position is located behind A, and a tow position
between C and D.
The inner lever (speed selector) controls the two-

speed power-shift planetary, and the synchronized and
collar shifts of the transmission drive shaft. The high
and low pinion shifts are synchronized while the re-
verse pinion shift is a collar shift.
This arrangement provides four forward speeds in

each of the A through D ranges. A mechanical interlock
on the lever prevents D-range reverse.
Lateral movement of the speed selector lever pro-

R 29096N vides power shifts between first and second, third and
fourth, and first and second reverse.
AControl Valve %% System Pressure Oil
B From Operating Piston (from operating piston)
movement of the lever between second
C Detent Pin ^ZM System Pressure Oil
Longitudinal
DOil Tube (from adapter inlet)
and third causes a combination power shift and low
EShift Valve *.&: Return Oil pinion high pinion synchronized shift requiring
F Detent Ball clutching. Longitudinal movement from first-forward to
GTo Clutch Piston first-reverse causes a collar shift (the tractor must be
H From Brake Piston stopped). A first-reverse to first-forward shift is
Fig. 15-Direct Drive 08 Flows synchronized.
In direct drive the control valve (A, Fig. 15) is moved The following charts and illustration show the gear
up by speed selector lateral movement. Oil is allowed combinations to obtain the various tractor speeds.
from the traction clutch through the control valve bore
and external line to the bottom of the shift valve (E).
The shift valve is forced up.
This allows system pressure oil past the shiftvalve

to the direct drive clutch piston (G) while oil from the
brake piston (H) returns to the main reservoir.

2-Speed Transmission Differential

Power-Shift Drive Drive
Speed I Planetary Shaft Shaft
Selection Element Pinion Gearset
A-1 Underdrive Brake Low A-Range

A-2 Direct Drive Clutch Low A-Range
A-3 Underdrive Brake High A-Range
A-4 Direct Drive Clutch High A-Range
B-1 Underdrive Brake Low B-Range

B-2 Direct Drive Clutch Low B-Range
B-3 Underdrive Brake High B-Range
B-4 Direct Drive Clutch High B-Range
C-1 Underdrive Brake Low C-Range

C-2 Direct Drive Clutch Low C-Range
C-3 Underdrive Brake High C-Range
R25998N C-4 Direct Drive Clutch High C-Range
AA-Range Countershaft Gear
BB-Range Countershaft Gear D-1 Underdrive Brake Low D-Range
CC-Range Countershaft Gear D-2 Direct Drive Clutch Low D-Range
D D-Range Countershaft Gear D-3 Underdrive Brake High D-Range
E Countershaft D-4 Direct Drive Clutch High D-Range
FReverse Pinion
GReverse Shifter Collar A-1R
H Low Pinion Underdrive Brake Rev. A-Range
I Low and High Synchronizer A-2R Direct Drive Clutch Rev. A-Range
J High Pinion B-1R Underdrive Brake Rev. B-Range
KTransmission Drive Shaft B-2R Direct Drive Clutch Rev. B-Range
LC-Range Differential Drive Shaft Gear C-1R Underdrive Brake Rev. C-Range
MB- and C-Range Shifter Collar C-2R
NB-Range Differential Drive Shaft Gear Direct Drive Clutch Rev. C-Range
OD-Range Differential Drive Shaft Gear
PA- and D-Range Shifter Collar Gears listed are engaged with their respective shaft,
QA-Range Differential Drive Shaft Gear with the exception of the A-range differential drive shaft
RDifferential Drive Shaft gear which acts as an idler in B-range, reverse speeds.
SDifferential Drive Shaft Bevel Pinion
Fig. 16-Transmission Shafts and Gears Park position is obtained by engaging both the A-
SHIFT STATION A Range and C-Range differential drive shaft gears (Q
and L, Fig. 16) with the differential drive shaft (R) the
A1/A2 Power in H D A Q Power out same time. Since these gears are in constant mesh
A3/A4 Power in J C A Q Power out A-Range and C-Range countershaft gears (A
with the
A1 R/A2R Power in F Q Power out and C) which cannot rotate independently on each
SHIFT STATION B other, the differential drive shaft is prevented from
turning and locks the rear wheels of the tractor.
B1/B2 Power in H D NB Power out
B3/B4
B1R/B2R
Power in J CBN
Q
Power out A mechanical interlock assures that the speed se-
Power in F A B N Power out lector lever is in a neutral position when the range
SHIFT STATION C selector lever is moved to park. The starter safety
switch permits starting the tractor only in neutral.
C1/C2 Power in H D C L Power out
C3/C4 Power in J C L Power out
In the tow position, both the differential drive shaft
C1R/C2R Power in F Q A C Power out
shifter collars are in neutral.
SHIFT STATION D
D1/D2 Power in H B o Power out

D3/D4 Power in J C D Power out

Dual-Speed PTO
The PTO on Perma-Clutch Tractors has its own
clutchand gear train and runs only when its clutch is
engaged. The clutch is hydraulically applied and
4
operates independently of the transmission. Refer to
Rg. 2 for more information on PTO clutch and lube
flow.
Torque from PTO engagement causes the

clutch
PTO clutch shaft and turn. The PTO shaft gear
gear to
is in mesh with the large PTO shaft drive gear and
turns the PTO shaft at 1000 rpm at rated engine rpm.
The operating assembly houses a PTO brake piston

which stops drive gear motion resulting from PTO
RS9093
clutch drag when the PTO is disengaged. The large
drive gear is shielded to conserve power by preventing A-^540 RPM Stub Shaft EIdler Shaft
the gear from churning the oil. B Rear Bearing Quill F PTO Shaft and Gear
C540 RPM Drive Gear GSleeve
DPTO Countershaft
Fig. 18-540 RPM PTO Power Flow
When the shorter 540 rpm stub shaft (A, Fig. 18) is
inserted through the rear bearing quill (B), only the
front idler gear (D) contacts the PTO shaft gear (F),
Since the gear meshes with the shaft gear,

idler
power flows through the idler assembly to the 540 rpm
drive gear at a reduced speed. The stub shaft (A) turns
with the drive gear (C).
E29Q9?
A1000 RPM Stub Shaft DPTO Shaft and Gear

BRear Bearing Quill ESleeve
C540 RPM Drive Gear
Fig. 17-1000 RPM Power Flow
The large drive gear transfers power through the

PTO shaft which is integral with gear (D, Fig. 1 7) at the
rear of the transmission case.
When the 1000 rpm stub shaft (A) is inserted

through the rear bearing quill (B) f it is connected to the
drive shaft gear (D).
The stub shaft then rotates at the same speed as the

PTO drive shaft. The idler shaft and reduction gear
idles with the 540 rpm gear (C).

Power Train Operation and Tests Perma-Clutch Systems Tests and Diagnosis 250-1 0-1
Group 10
PERMA-CLUTCH SYSTEMS TESTS AND DIAGNOSIS
TESTING HYDRAULIC SYSTEM 1. Check oil level and condition.
Tractors that have just had a clutch, hydraulic or

a) Note any external leakage with tractor running
transmission repair should be thoroughly tested to be
and at rest.
sure the cause of failure has been corrected. b) Burned oil could indicate mechanical over-
heating.
Preliminary System Checks c) Foreign matter in the oil could indicate parts
deterioration.
fkCAUTION: Escaping fluid under pressure
*^ can have sufficient force to penetrate the 2. Inspect entire tractor.
skin, causing serious persona! injury. Before dis- a) Inspect oil filter noting any parts fragments.
connecting lines, be sure to relieve all pressure. b) Check for any hot return lines orpassages that
Before applying pressure to system, be sure all could indicate the source of a high-pressure internal
connections are tight and that lines, pipes and leak.
hoses are not damaged. c) With control valves in neutral, listen for any
Fluid escaping from a very small hole can almost unusual noises at 1000 rpm that could indicate an
be invisible. Use a piece of cardboard or wood, internal high-pressure leak.
If injured by escaping fluid, see a doctor at once. 3. See Section 270 for special tools required for
Serious infection or reaction can develop if proper testing, and for instructions on proper procedure to use
medical treatment is not administered immediate- to systematically isolate the component or circuit
ly. causing a hydraulic problem.
IMPORTANT: If an operator complains of trans-
mission malfunction, ask the operator about all
related operations. For ALL transmission mal-
functionsbefore any further diagnosis is at-
tempted, FIRST:
DIAGNOSING MALFUNCTIONS
(General)
SYMPTOM/COMPLAINT PROBLEM SOLUTION
Clutch Slips Operator riding clutch pedal Instruct Operator (See OM)
Partial loss of pressure Test Clutch Pressure (See 10-4)
Clutch vaive not completely engaged Test Clutch Pressure (See 10-4)
Worn facing Repair Clutch Pack (See 50-5-9)
Engaging levers improperly adjusted Adjust Clutch Pack (See 50-5-11)
Clutch Drag Clutch valve not completely disengaged Test Clutch Pressure (See 10-4)
Lube reduction valve stuck or spring broken Test Lube Pressure (See 10-5)
Very cold oil Instruct Operator (See OM)
Clutch disks warped or bent Repair Clutch Pack (See 50-5-9)
Aggressive Clutch Engagement Incorrect lower clutch valve spring Repair Clutch Valve (See 50-5-1)
Sticking clutch valve Repair Clutch Valve (See 50-5-1)
Noisy Engagement Separator plate drive lugs not located on pins Repair Clutch Pack (See 50-5-9)
Oil Temperature Indicator Glows Oil level low Replenish
Clogged side grille screen Clean
Faulty temperature switch Electrical Testing(See Section 240)
Dirty oil cooler core Clean (See Section 70)
Restricted oil filter Replace if questionable
Oil cooler relief valve stuck open Repair Oil Cooler Relief Valve (See 50-
5-3)
Oil filter relief valve stuck open Repair Oil Filter Relief Valve (See 50-5-
3)
Transmission pump discharge tube clamp loose Repair as necessary (See 70-15)

250-10-2 Perma-Clutch Systems Tests and Diagnosis Power Train Operation and Tests
DIAGNOSING MALFUNCTIONSContinued
SYMPTOM-COMPLAINT
PTO Lacks Power
or Fails to Operate
Worn or burned clutch facings
(General)
Hydraulic control system defective

PROBLEM
Repair
SOLUTION
PERMA-CLUTCH (See 50-5-9)
Diagnosing Malfunctions (Section 270-

10)
Clutch operating levers out of adjustment Adjust Clutch Pack (See 50-5-11)
Low pressure Test and Adjust (See 10-4}
Noisy PTO Engagement Clutch separator plate not indexed correctly Repair Clutch Pack (See 50-5-9)
on the square drive pins
Loose clutch cover assembly Repair Clutch Pack (See 50-5-9)
Excessive gear train backlash Remove and Repair (See 50-30-1)
Damaged or worn clutch operating bearing Remove Operating Assembly (See 50-
5-3)
Noisy PTO Operation Cracked or broken clutch plate Repair Clutch Pack (See 50-5-9)
Loose clutch cover assembly Repair Clutch Pack {See 50-5-9)
Damaged or worn gears or bearings Remove and Repair (See 50-30-1)
PTO Will Not Stop Low PTO brake pressure due to Test and Repair (See 10-7)
incorrect PTO valve rod adjustment, as required
low system pressure, or leak in PTO
brake oil circuit
Excessive PTO clutch drag due to in- Adjust PTO Lever (See 50-30-4)
correct clutch lever adjustment
Brake piston stuck or brake facing Remove and Repair (See 50-30-1)
damaged
Defective clutch disk or plate Repair Clutch Pack (See 50-5-9)
PTO lever spring not installed Install spring (See 50-30-8)
Excessive Gear Clash When Shifting Operator not fully disengaging dutch Instruct Operator (See OM)
Operator shifting too fast Instruct Operator (See OM)
Transmission clutch drag Repair as required (See 10-1)
QUAD- RANGE Only Incorrect two-speed rod adjustment Adjust (See 50-20-13)
Synchronizer disks excessively worn Replace (See 50-10-4)
Shift lever and cam detent not in proper relation Adjust (See 50-10-8)
Cold oil causing transmission clutch drag Instruct Operator (See OM)
Creeper Only Shifting collar in Neutral when Repair (See 50-15-2)
beginning shift
Shifter control parts dry Lubricate

Hard Shifting
Shifter quadrant binding Inspect and Repair (See 50*20-10)
QUAD- RANGE Only Inner lever; Neutral-Park interlock Adjust interlock latch (See 50-20-10)
improperly adjusted
Shffter cam shaft end play incorrect Adjust (See 50-20-10)
Shifters worn or damaged Replace (See 50-10-1)
Cold oil causing transmission clutch drag Instruct Operator (See OM)
Lube reduction valve stuck (May also jump out of Test and Repair (See 10-6)
gear or shift by itself)
Control lever guide slot interference Adjust (See 50-20-10)
Creeper Only Snubber brake failure -
shifts in underdrive
end not square Rebend so spring yoke will slip onto

Hard Shifting from Park (on level Shift rod
ground) Fever arm without deflecting rod.
Incorrect shifter cam shaft end play Adjust cam shaft arm to 0.002-0.007
in. end play (See 50-20-10)
Excessive Transmission Noise Transmission parts worn or damaged Repair (See 50-10-1)
Transmission low on oil Correct
Transmission oil pump rrtalf unction Test to verify and repair as
required (See 270-15)
Creeper Only Planetary parts worn or damaged

Creeper OnlyLow planetary lube flow

Creeper Only Snap ring missing from
planetary shifter plate

Power Train Operation and Tests Perma-Clutch Systems Tests and Diagnosis 250-1 0-3
DIAGNOSING MALFUNCTIONS Continued

(General)

Jumps out of Gear Incorrect range or speed selector rod adjustment Adjust Range and Speed Selector
(See 50-10-15 or 50-20-13)
QUAD-RANGE ONLY In A-range; 1, 2, 3, and 4: weak range shifter Replace (See 50-10-1)
detent spring
Slippage in First and Third Speed Seal leaking on planetary brake piston Replace Seal (See 50-20-6)
Plug leaking or missing from brake housing Inspect and Repair (See 50-20-4)
Planetary brake disks excessively worn Replace Disks (See 50-20-6)
Slippage in Second and Fourth Speed Seal leaking on planetary clutch piston Replace Seal (See 50-20-6)
Clutch drum sealing ring leaking Replace (See 50-20-6)
Plug leaking or missing from brake housing Inspect and Repair (See 50-20-4)
Planetary clutch disks excessively worn Replace Disks (See 50-20-6)
No change in Speed When Moving Linkage broken, disconnected, or out of adjustment Repair and Adjust (See 50-20-11)
Speed Selector Laterally ShiftValve stuck Repair (See 50-20-5)
Low system pressure Test and Repair as Required
External leak on planetary (See 250-10-4)
Repair (See 50-20-4)
Shifts by Itself or Will Not Shift, Hi-Lo control valve rod out of adjustment Adjust to center shifts of power-shift
1-2 or 3-4
lever (See 50-20-13)
Sound-Gard only; planetary control rod boot in- Push boot down on rod
terference (especially over rough ground)
D-Range - Reverse Interlock Not Interlock latch unhooked or bent Rebend latch tab so it will not slip past
Effective lever arm flange (See 50-20-1)
Incorrect interlock latch adjustment Adjust (See 50-20-13)
4-3, 2-1 Downshift Hesitation, Oil Outer seal on low brake piston leaking Replace seal and inspect carrier pinion
Light may blink, PTO lever may Dis- bearings (See 50-20-8)
engage, and low RPM loss of Hydrau-
lics (All ranges, no problem with
cold oil)
TM-1181 (Sep-77) Litho in U.S.A. Tractors 4040 and 4240

250-10-4 Perma -Clutch Systems Tests and Diagnosis Power Train Operation and Tests
COMPONENT AND CIRCUIT TESTING

Testing Clutch Pressure 3, With the transmission in "Park" position, check
clutch oil pressure for the following specifications:
4040
1000 rpm 125-135 psi (8,62-9.31 bar) (8.79*9.49 kg/cm*)
1500 rpm 130-140 psi (8.97-9.66 bar) (9.15-9.85 kg/cm*)
2000 rpm 135-145 psi (9.31-10.0 bar) (8.79-10.2 kg/cm*)
4240
1000 rpm U0-150 psi (9.6-10.3 bar) (9.9-10.5 kg/cm*)
1 500 rpm 150-160 psi (10.3-11.0 bar) (10.5-11.2 kg/cm^)
2000 rpm 155-165 psi (10.7-11,4 bar) (10.9-11.6 kg/cm*)
4. If pressure is not within specifications, adjust

pressure regulating valve by adding or deducting
shims.
5. To check clutch valve modulation, depress clutch

peda! and note gauges.
a) Pressure should drop to zero.

b) As pedal is gradually released, the pressure
should gradually rise.
6. Interpret test results as given in the following

Fig. 1 -dutch Pressure Gauge
diagnostic chart.
2
1. Install a 0-300 psi (0-20 bar) (0-20 kg/cm )
pressure gauge at the dutch pressure test plug in the

pressure regulating valve housing.
2. Warm oil to operating temperature.
TEST RESULT PROBLEM SOLUTION
Low clutch pressure Transmission oil level low Correct

Restricted oil filter Inspect and Replace
Pressure regulating valve out of adjustment Add shims under regulating valve
spring
(one shim equals approximately 5 psi)
(0.35 bar) (0.35 kg/cm*)
Pressure regulating valve spring weak or broken Replace (See 50-5-1)
OH filter relief vaJve stuck Repair Oil Fitter Relief Valve (See Section
70-5)
Gaskets behind dutch valve housing leaking Clutch Valve Removal (See 50-5-1)
Adapter O-rings behind clutch valve housing Remove Pressure Regulating Valve
leaking and replace O-rings (See 50*5-1)
Operating piston leakage Test Lubrication Pressure for Vesication
Element being checked not completely engaged Test Lubrication Pressure for Verification
Low transmission oil pump output Test Lubrication Pressure and See Section
270
Large pressure increase with rpm Leakage in charge circuit Test Lubrication Pressure and See Sec-
increase, and large pressure tion 270
decrease with rpm decrease Low transmission oil pump output Test Lubrication Pressure and See Section
270
TM-1181 (Sep-77) Litho in U&A Tractors - 4040 and 4240

Power Train Operation and Tests Per ma-Clutch Systems Tests and Diagnosis 250-10-5
Testing Lubrication Pressure 2. Check lubrication pressure with the engine run-
ning at 1500 and at 2000 rpm. Specifications are given
in the following chart.
LUBRICATION OIL PRESSURE
Engine Speed 110T(43C)Oil 1S0F (66C) ON
1 500 rpm 25 psi 17 psi

(1.7 bar) (1.2 bar)
(1.8 kg/cm*) (1.2 kg/cm*)
2000 rpm 43 psi 28 psi

(2.9 bar) (1.9 bar)
(3.0 kg/cm*) (2.0 kg/cm*)
3. Interpret test result as given in the following

diagnostic chart.
Fig. 2-Lubrication Pressure Gauge
1. Install a 0-60 psi (0-5 bar) (0-5 kg/cm 2 ) pressure

gauge at the lube test plug on the oil filter relief valve
housing.
TEST RESULT PROBLEM SOLUTION
Lew Lubrication Pressure Pressure regulating-to-dutch valve housing Repair Pressure Regulating Valve (See 50-5-1}
gasket leak
Adapter tube O-rings leaking Remove Pressure Regulating Valve and Replace
(See 50-5-1)
Quad-Range OnlyShift valve (on two-speed) leaking Repair Shift Valve (See 50-20-5)
Charge circuit malfunction Test as instructed in Section 270

250-10-6 Perma-CIutch Systems Tests and Diagnosis Power Train Operation and Tests
Testing Lubrication Reduction Valve Circuit Leakage Isolation Test

1. Install destroking screw in main hydraulic pump,
(See Section 270.)
2. Adjust engine rpm to obtain 10 psi (0.7 bar) (0.7

kg/cm 2 lube pressure. (See Fig. 3)
)
3. Destroke main hydraulic pump. (Turn destroking

screw in.)
a) Lubrication pressure should not increase

more than 3 psi (0.2 bar) (0.2 kg/cm 2 ).
b) If pressure does increase more than 3 psi (0.2
bar) (0.2 kg/cm 2); see Group 10 of Section 270. (There

is probably a high pressure leak to the hydraulic res-
ervoir.)
pressure increases 0-3 psi (0-0.2 bar) (0-

c) If
2
0.2 kg/cm ), and load decreases; there is a high pres-
sure leak to return.
iLpgl
Fig. 3-Lubrication Pressure Gauge

4. Back out main pump destroking screw,
1. Adjust engine speed to get 10 psi (0.7 bar) (0.7 5. With engine running at slow idle, depress the
kg/cm 2
lubrication pressure.
clutch pedal.
)
2. Depress clutch pedal, 6. Apply both brake pedals.
3. Watch lube pressure gauge for a dip in pressure 7. Shift Quad-Range shifter lever to D-Range.
as the clutch is engaged very slowly.
8. Pull the shift lever rearward to the "TOW" posi-
tion,
a) If there is no dtp in pressure, the lubrication
reduction valve probably stuck, (Complete hydraulic
is
9. Slowly release the clutch pedal.
test procedure of Section 270-10 before repairing.)
10. Adjust engine speed to get 10 psi (0.7 bar) (0.7

b) If lubrication pressure does dip, the lube re-
kg/cm 2) lubrication pressure.
duction valve is operating properly.
TM-1181 (Sep-77) Litho in USA. Tractors -4040 and 4240

.
Power Train Operation and Tests Ferma-Clutch Systems Tests and Diagnosis 250-10-7
Testing PTO Clutch and Brake
AClutch Pedal CSpeed Selector Lever

BPTO Lever D Range Selector Lever
(Brake Position)
Hg, 4-Transmission Controls A PTO Clutch Test Plug &PTO Brake Test Plug
1 1 Note lubrication pressure after the PTO clutch Fig. 5-Oil Pressure Regulating Valve Test Plugs
and brake (B, Fig. 4) are engaged.
1. Install a pressure gauge, 0-300 psi (0-20 bar)
a) If lubrication pressure changes more than 3 (0-20 kg/cm 2 ), at the PTO CLUTCH test plug and at
psi (0.2 bar) (0.2 kg/cm2 ), there is excessive leakage in
the PTO BRAKE test plug on the oil pressure regulat-
the circuit with lower pressure. ing valve housing.
b) Position PTO control lever to get the higher 2. Observe clutch and brake pressure at 2000 en-
lubrication pressure and continue test procedure. gine rpm:
12. With range selector lever (D) in "TOW\ shift a) 4040 pressure should be 135-145 psi (9.31-
speed selector (C) to first gear. Note any change in 10.0 bar) (8.79-10.2 kg/cm 2),
lubrication pressure.
b) 4240 pressure should be 155-165 psi (10.7-
13.With the clutch pedal (A) released, note any 11.4 bar) (10.9-11.6 kg/cm 2 }.
change in lubrication pressure in second gear.
c) DO NOT load PTO until any low pressure
a) If pressure changes more than 3
lubrication condition has been corrected (see Hydraulic Diagnosis
psi (0.2 bar) (0,2 kg/cm 2), there is excessive leakage in and Testing).
the circuit with lower pressure.
3. Engage PTO brake; PTO clutch pressure should
b) Shift the transmission to the "PARK" position.
drop immediately to zero. Brake pressure should jump
to system pressure,
NOTE: if leakage
excessive in the hi-io circuit,
is
the hi-lo control valve should be positioned to obtain 4. Engage PTO clutch gradually; clutch pressure
the higher lubrication pressure. Then, continue with should rise gradually to 130 psi (8.9 bar) (9.1 kg/cm 2),
test procedure given in Section 270, then jump to system pressure.

250-10-8 Perma-Clutch Systems Tests and Diagnosis Power Train Operation and Tests
Quad -Range Transmission Cycle Test 2. Place the tractor in first speed, C-Range (under-
1. Place the tractor

(direct drive).
in second speed, C-Range
drive),
a)
b)
Brake the tractor to simulate a load.
Note any slippage.
i
a) Brake the tractor to simulate a load.
b) Note any sKppage.
3. Interpret test results as given in the following
diagnostic chart.
CYCLE TEST RESULT PROBLEM SOLUTION
Tractor Slips in all Speeds Low oil pressure See Diagnosing Malfunctions (10-4)
Unequal Slippage between Under- Two-speed planetary mechanical failure Remove and Repair Planetary (See 50-10-1)
drive and Direct Drive Gears
Testing Oil Pressure Switch 3. Slowly pump hand pump (A) while watching
pressure gauge (B) and ohmmeter.
1. Remove oil pressure switch from oii filter relief
valve housing.
4. Switch should open when pressure is raised to
115-125 psi (7.9-8,6 bar) (8.1-8.8kg/cm 3).
5. Switch should close as pressure is released to

90-100 psi (6,2-6.9 bar) (6.3-7.0 kg/cm 2 ).
/
NOTE: Switch operates with an audible click when
it opens and closes.

A Hand Pump COhmmeter
B 0-300 psi Gauge DPressure Switch
Fig. 6-Testing Oil Pressure Switch
2. Connect Switch (D, Fig. 6) to a hydraulic hand

pump and connect an ohmmeter (C) across the switch
leads.

Power Train Operation and Tests Power Shift System Operation 250-15-1
Group 15
POWER SHIFT SYSTEM OPERATION
HOW THE SYSTEM WORKS Clutch Pack Power Flow
The Power Shift transmission (Figs. 1 and 2) con- Engine power is transmitted from the torsional
tains two compound planetary sets controlled by three damper to the clutch pack. The pack contains three
clutches and four brakes. Eight forward speeds and hydraulically operated clutches (C1, C2, and PTO). C1
four reverse speeds are obtained by various combina- is the low-range clutch and C2 is the high-range clutch.
tions of these components. The PTO clutch (at the rear of the pack) transmits
The transmission oil pump supplies hydraulic pres- power to the PTO gear train when applied. The inter-
sure to control clutches and brakes. The operator can nal-gear transmission pump (H) is located at the front
shift the transmission into any speed while the tractor is of the clutch pack.
standing or in motion. The clutches operate independently of each other.
A mechanical disconnect disengages
sliding-collar and C2) may be engaged or
Either or both clutches (C1
the tractor wheels for (short) towing. The disconnect is disengaged at any time. The PTO clutch can be en-
controlled by a hand lever on the left-hand side of the gaged or disengaged any time regardless of transmis-
transmission case. sion operation.
A pawl-type mechanical parking lock, controlled by When a clutchis disengaged, the control system
the shift lever engages the transmission reduction gear relieves oil pressure on the clutch piston (E). The
behind the planetary pack to prevent gear train rota- clutch piston return spring (J) returns the piston to its
tion. disengaged position, and power flow through the disks
A torsional damper (G, Fig. 1 ) absorbs engine power to the output shaft is interrupted. Oil from the clutch
impulses ahead of the transmission. piston cavity returns to the reservoir.
R28212N
AC1 Shaft CDisks E Pistons GTorsional Damper I Clutch Drum

BC2 Shaft DPlates F Oil Passages HPump JReturn Spring
KPTO Gear Shaft
Fig. 1-Power Shift Clutch Pack

250-15-2 Power Shift System Operation Power Train Operation and Tests
Power Flow Continued

i
R28213N
A Planet Pinions C Ring Gear ECompound Planetary Set

BSun Gears O Planet Pinion Carrier FOverdrive and Reverse Planetary Set
Ftg. 2-Power Shift Planetary Pack
Planetary Pack The planetary pack contains four disk-type brakes

for the planetary system as follows:
The planetary pack mounted
(Fig. 2) is in
mission case, it contains four planetary systems com-

the trans-
B1 1st planetary reduction brake
bined into two sets of two each (E and F). AH the
B2 2nd planetary reduction brake
pinions are mounted on
B3 Reverse brake
which rotates as a solid unit
shafts in a single carrier (D)
B4 Overdrive brake
Engine power from the clutch pack output shafts is
A clutch (C3) is provided for direct drive applications.
This clutch operates independently of the dutches in
transmitted by the planetary pack at different speeds
the clutch pack.
and direction of rotation to the reduction gear train.

Torque Paths Through Transmission
R28216N
& System Pressure Oil I Power Row
Fig. 3-Power and Oil Flow in First Speed Forward (PTO Parts Not Shown)
The following chart shows the clutches and brakes First Speed Forward
which must be engaged to obtain the transmission
speeds. The transmission hydraulic control system CLUTCH PLANETARY
controls the engagement of each clutch and brake. PACK PACK
SPEED CLUTCHES OR BRAKES ENGAGED 1stFORWARD@ C2 @ B2 B3 B4 @

Park B2 Fig. 5-Clutches and Brakes Engaged
Neutral B1 for 1st Speed Forward
Neutral Fwd. B1 C3
1st Fwd. C1 B1 C3 When the transmission control lever is placed in the
2nd Fwd. C1 B2 C3 firstspeed forward position, the hydraulic transmission
control system engages C1 in the clutch pack and B1
3rd Fwd. C2 B1 C3
C2 and C3 in the planetary pack (Fig. 3).
4th Fwd. B2 C3
Engine power flows from the torsional damper to C1
5th Fwd. C2 B1 B4
in the dutch pack. The C1 clutch shaft transmits power
6th Fwd. C2 B2 B4
from C1 to the B1 sun pinion in the planetary pack.
7th Fwd. C1 C2 C3
8th Fwd. C1 C2 B4 Since B1 restrains its ring gear from turning, the
Neutral Rev. B1 B3 planet pinions "walk around" the ring gear, forcing the
1st Rev. C1 B1 B3 planet pinion carrier to rotate in the same direction as
2nd Rev. C1 B2 B3 the sun pinion, but at a slower speed. The planet pinion
3rd Rev. C2 B1 B3 carrier transmits power to the overdrive and reverse
4th Rev. C2 B2 B3 planetary set.
Fig. 4-Ciutch and Brake Engagement When C3 is engaged, both sun pinions in the over-
drive and reverse planetary set are locked together.

Since the planet pinions cannot rotate at different
speeds the planetary set rotates as a solid unit and
acts as a direct drive to the transmission reduction
gears.

Torque Paths Through TransmissionContinued
IW R28215N
f
System Pressure Oil I Power Flow
Fig. 6-Power and Oil Row in Third Speed Reverse (PTO Parts Not Shown)
Third Speed Reverse pinion, which is driven by the planet pinions, drives the
transmission reduction gears.
When the transmission control lever is placed in the
third speed reverse position, the hydraulic transmis-
sion control system engages C2 in the clutch pack and
Transmission Hydraulic System
B1 and B3 in the planetary pack (Fig. 6), The transmission hydraulic system generates,
directs,and controls the pressure and flow of oil within
CLUTCH PLANETARY the transmission. Hydraulic system oil lubricates and
PACK cools the transmission parts and applies the clutches
and brakes.
3rd REVERSE C1
Oil isdrawn from the transmission sump, through a
Fig. 7-Qutches and Brakes Engaged mesh A priority lubrication flow of 2 gpm
strainer.
for 3rd Speed Reverse
(7.6 l/min) at operating speed is orificed directly to the
Engine power flows from the torsional damper to C2 lubrication circuit and the remainder of the transmis-
in the clutch pack. The C2 clutch shaft transmits power sion output is delivered to a full-flow filter.
at engine speed from C2 to the C2 sun pinion in the
planetary pack. The transmission system (see Fig. 11) con-
control
Since B1 restrains its ring gear from turning, the sists of the following components: transmission oil
planet pinions "walk around" the ring gear, forcing the pump, o\\ pressure regulating valve assembly, trans-
planet pinion carrier to rotate in the same direction as mission control valve assembly, shift valve assembly
the sun pinion, but at a slower speed. The planet pinion and pedal valve.
carrier transmits power to the overdrive and reverse
planetary set. When the selector lever is moved from one trans-
When B3 is engaged, its ring gear is restrained from mission speed to another, control is achieved by these
turning. As the planet pinion carrier rotates, the planet components; which are described on the following
pinions in mesh with the ring gear are forced to rotate pages.
on their axes, driving the inner planet pinions, which in
turn forces the sun pinion to rotate in the opposite
direction from the planet pinion carrier. The sun
TM-1181 (Feb-78) Lftho in U.S.A. Tractors - 4040 and 4240

Transmission Oil Pump 2. Transmission Lube Relief Valve

Oil relieved from the filter relief valve or oil cooler
relief valve is routed to this valve. When oil pressure is
high enough at the lube relief valve, the valve opens to

dump oil to the main reservoir.
3. Oil Pressure Regulating Valve
This valve maintains pressure oil to the transmission

controlsystem at transmission operating system pres-
sure. Excess oil is directed to the oil cooler and the
4. Oil Cooler Relief Valve
This valve limits oil pressure to the oil cooler and

R28505N If the oil pressure in the valve housing is excessive,

the valve opens to route oil to the transmission lube
AInlet v8'$ System Pressure Oil circuit.
BTo Filter fill Lubrication Oil
CTo PTO ;SS: System Pressure Oil
DPriority (To B and E) (to filter)
5. Return Pressure Check Valve
E From Cooler to ; v^ Pressure-Free Inlet
oil from the hydraulic func-
This valve allows return
Transmission Shafts Oil
F To C1 go to the cooler and reservoir, while preventing
tions to
GToC2 pressure from entering the hydraulic return system and
"backing up" through the hydraulic filter.
Fig. 8-Transmission Oil Pump Manifold Passages
Transmission Control Valve Assembly

The internal-gear type transmission oil pump locat-
ed in the front of the dutch pack supplies pressure oil
The transmission control valve consists of the
to operate the transmission and circulates oil to lubri-
transmission control valve housing, accumulators, and
cate the transmission clutch pack, planetary pack, the shift valve housing which are assembled together
gears, and bearings. It also lubricates and charges the and located on the right-hand side of the transmission
main hydraulic pump and forces through the oil oil

case (Fig. 11).
cooler to cool the entire hydraulic system.

1. Transmission Control Valve Housing
Oil Pressure Regulating Valve Assembly The transmission control valve housing receives oil
The oil pressure regulating valve housing is located
from the transmission pump and routes it to the proper
on the left-hand side of the clutch housing. The valve valves in the shift valve housing to engage the clutches
housing receives oil under pressure from the trans- and brakes for the selected transmission speed.
mission oil pump and performs the following functions:
The direction selector valve (Fig. 1 1 ) has a forward,
1. Oil Filter Relief Valve neutral, and reverse position.
Pressure differentia! created by filter restriction The speed has nine detented posi-
selector valve
moves the valve to direct oil to the lubrication relief tions. Five positions (neutral and first-through-fourth)
valve and to the lube circuit. are common for forward and reverse speeds. The
fifth-through-eighth positions are forward speeds only.
>

Transmission Hydraulic System-

Continued
i
2. Accumulators
The accumulators are spring-loaded pistons located
in
oil
the transmission control vaive housing. They control
pressure during a shift as follows:
&
A. Maintain a supply of oil to provide oil to assist in
moving the clutch or brake pistons rapidly toward en-
gagement during a shift (other than a C1 or C2 shift). o
B. Provide a low system pressure at the time of R28218N
initial clutch or brake engagement. This provides
smoother shifting just as "slipping" the clutch does AFrom B1 or B2 Brake System Pressure Oil
BFrom C1 Clutch (Gaining Pressure)
when operating a dry disk clutch.
CFrom C2 Clutch System Pressure Oil
C. Give a gradual pressure build-up as the shift is
DFrom Accumulator (Losing Pressure)
accomplished, and a low restriction when the shift is EFrom B4 or C3 ; Pressure-Free Oil
completed and the tractor is in motion, to reduce the Fig. 10~Dump Valve (During a Shift, Accumulator Discharging)
pressure drop in the hydraulic control system. The front
accumulator supplies B1 and B2, and the rear accu- During a shift, accumulator oil pressure is reduced
mulator supplies B3, and B4 and C3. because of the volume of oil required for the engage-
ment of the C3 clutch and/or brakes. As accumulator
3. Shift Vaive Housing pressure is reduced, the dump valve spring forces the
dump valve closed. When the valve is closed, the
The shift valves direct pressure oil to the selected return oil passage from the released clutch or brake is
brake and clutch pistons. Each valve has two positions closed except for an orifice in the dump valve. This
and is actuated in one direction by oil pressure from the permits the pressure on the released clutch or brake to
speed selector valve, and in the opposite direction by a bleed off slowly while pressure is increasing on the
return spring. Each shift valve works independently.
elements being engaged.
The dump valve (Fig. 9) is located in the shift valve Accumulator pressure returns to normal as clutch or
housing. The dump valve controls the oil flow returning brake engagement is completed. The dump valve is
from the clutches and brakes during a
to the reservoir
returned by accumulator pressure to its normal open
shift (except when shifting into seventh or eighth
position, and the released elements are permitted to
speed). The valve is controlled by oil pressure from the complete their cycle by quickly releasing oil to the
B1, B2 accumulator.
reservoir through the dump valve.
Pedal Valve
Afoot-controlled pedal valve (Fig. 1 1) is provided for
emergency stops and for inching the tractor. This vaive
controls the supply of pressure oil to the C1 and C2
clutches. When the pedal is depressed, oil pressure is
cut off to the clutch elements.
ATransmission Filter NTransmission Pump

BFilter Relief Valve OSpeed Selector Valve
CPTO Valve P-Ortfice
DPedal Valve Q Accumulator
ELube Relief Valve R Direction Valve
R28217N F Pressure Regulating SSump Strainer
Valve TShift Valves
AFrom B1 or B2 Brake &$ System Pressure Oil G-Return Check Valve UDump Valve
BFrom C1 Clutch (From Accumulator) HCooler Relief Valve = System Pressure Oil
;;
CFrom C2 Clutch ffrtS Pressure-Free Oil I To Main Pump (Element Engaging)
DFrom Accumulator J From Function ' System Pressure Oil
EFrom B4 or C3
Fig. 9-Dump Valve (Prior to Shifting)

Return
LLube Test Plug

Filter
KCooler Check Valve I
&$
(Charge)
Lubrication Oil
Pressure-Free Oil
MPump Orifice System Pressure Oil
(Shift Valve Operating) i
Legend for Fig. 11

>
)
Fig. 11-Hydraulic Control and Lube Row, First Speed - Forward Position

Hydraulic Control System Flow (Figs. 12- Dual-Speed PTO

23)
PTO operation is independent of the Power Shift
The on the following pages show the
illustrations Transmission. The transmission pump supplies oil to
(
transmission control system elements engaged for engage the PTO clutch piston. Piston springs disen-
each of the twelve tractor speeds. gage the PTO when oil is shut off.
The accumulators, pedal valve, and oil pressure When the control lever is pushed forward, the con-
regulating valve housing are not illustrated as their trol valve directs oil from the transmission oil pump to
function in the transmission control system is constant the clutch piston to engage the PTO clutch.
relative to tractor speed and direction.
When the control lever is pulled to the rear, the
For example: To speed forward,
obtain the first control valve directs oil to the brake piston to apply a
clutches C1 and C3, and brake B1 must be engaged wet-cone brake to the PTO shaft.
(Fig. 12).
The transmission case has a baffle on the front to

The direction selector valve routes pilot oil to the No. prevent the helical gears from throwing oil into the
4 shift valve. Pilot oil pressure against the valve head clutch pack area. This prevents oil heating and power
compresses the valve spring opening the C3 port to loss.
allow pressure oil to flow to the C3 clutch piston and
engage the C3 clutch. When the PTO clutch is engaged, power from the
compressed clutch is transmitted to the PTO clutch
Pilot oil is also routed to the head of the No. 2 shift gear (located between the clutch housing and trans-
valve, allowing pressure oil from the pedal valve to mission case).
pass through the ports in shift valves No. 1 and No. 2 to
engage the C1 clutch. A four-gear arrangement at the front of the trans-
mission case delivers power from the PTO clutch to the
Pressure oil from the accumulator is routed through power shaft.
valve No. 2 to continue through shift valve No. 3 to
shift
engage the B1 brake. The PTO shaft and drive gear are one piece. Power
flows to the same dual-speed reduction gear assembly
Flow Diagram Pressure Gauge Readings described in Group 5, Pages 15 and 16.
(Figs. 12-23)
Gauge readings in each shift are given as an aid

Warning System
in
diagnosing transmission problems. A temperature warning switch is located in the oil
pressure regulating valve housing. This switch lights a
Gauge readings in oil flows which followshow nee- warning light on the instrument panel if the transmis-
dle response during an upshift.Readings are approx- sion fluid overheats.
imate and are specified at 2000 engine rpm.
Later models are also equipped with a low pressure
The black gauge needle indicates the gauge reading warning switch located in the pedal valve housing. This
after the shift is complete. The broken arrows show switch illuminates the same warning light as the tem-
needle action during the shift due to proper accumula- perature switch if transmission operating pressure is
torand dump valve operation. too low.
The dashed gauge needle indicates pressure prior

to the shift or pressure that the appropriate elements
drop to as the accumulator is discharging.
may have an
Later style control valve housings
each control element. On late
individual test port for
housings, the tests may be performed using either the
4-gauge reference (I) and hookup, or the 7-gauge
reference located at the top of each page.
(

R32375C
A From PedaJ Valve E Accumu lators I4-Gauge Reference
BSpeed Selector Valve F Direction Selector Valve
CFrom Transmission Filter @; Element Engaging Pressure Oil
GShift Valves $&< Constant Pressure Oil
DOrifice HDump Valve Shift Valve Operating Oil
Fig. 12-Hydraulic Control System Flow and Pressures - First Speed Forward

Tractors 4040 and 4240
Hydraulic Control System Flow Continued

i
R32376C
A From Pedal Valve E Accumulators 4-Gauge Reference

I
B Speed Selector Vaive F Direction Selector Valve gg Element Engaging Pressure Oil
CFrom Transmission Filter GShift Valves gg* Constant Pressure Oil
D Orifice H Dump Valve S^ Shift Valve Operating Oil \
Fig. 13-Hydrautic Control System Flow and Pressures - Second Speed Forward

R32377C
A From Pedal Valve E Accumulators I4-<3auge Reference

B Speed Selector Valve F Direction Selector Valve &? Element Engaging Pressure Oil
C From Transmission Filter GShift VaJves
DOrifice H Dump S* Constant Pressure Oil
Valve %&& Shift Valve Operating Oil
Fig. 14-Hydrautic Control System Flow and Pressures - Third Speed Forward

R32373C
AFrom Pedal Valve E Accumulators [ 4-Gauge Reference

BSpeed Selector Valve F Direction Selector Valve -
; Element Engaging Pressure Oil
CFrom Transmission Filter GShift Valves Constant Pressure Oil
DOrifice H Dump Valve Shift Valve Operating Oil
<
Fig, 15-Hytfraulic Control System Flow and Pressures - Fourth Speed Forward

R32379C
A From Pedal Valve E Accumulators I 4-Gauge Reference

BSpeed Selector Valve F Direction Selector Valve ;*%^ Element Engaging Pressure Oil
CFrom Transmission Filter GShift Valves >>S Constant Pressure Oil
Fig. 16-Hydrautic Control System Flow and Pressures - Fifth Speed Forward

Hydraulic Control System FlowContinued
R32380C
AFrom Pedal Valve

E Accumulators I 4-Gauge Reference
B Speed Selector Valve F Direction Selector Valve 3&: Element Engaging Pressure Oil
C From Transmission Filter GShift Valves ?& Constant Pressure Oil
Fig. 17-Hydrautic Control System Flow and Pressures - Sixth Speed Forward

N
\ -'2 /no <rX)75\
R32381C
A From Pedal Valve E Accumulators I4-Gauge Reference

BSpeed Selector Valve FDirection Selector Valve gjgg Element Engaging Pressure Oil
C From Transmission Filter GShift Valves ant Pressure Oil
DOrifice H Dump Valve >: Shift Valve Operating Oil
Fig. 18-HydrauHc Control System Flow and Pressures - Seventh Speed Forward

R32382C
AFrom Pedal Valve EAccumulators I4-Gauge Reference

BSpeed Selector Valve FDirection Selector Valve Element Engaging Pressure Oil
CFrom Transmission Filter GShift Valves W Constant Pressure Oil
DOrifice HDump Valve Shift Valve Operating Oil
<
Fig. 19-Hydraulic Control System Flow and Pressures - Eighth Speed Forward

7
Power Train Operation and Tests Power Shift System Operation 250-1 5-1
R32383C
AFrom Pedal Valve E Accumulators I4-Gauge Reference

BSpeed Selector Valve F Direction Selector Valve ^3g Element Engaging Pressure Oil
CFrom Transmission Filter GShift Valves :#$: Constant Pressure Oil
>
Fig. 20-Hydrauiic Control System Flow and Pressures - First Speed Reverse


(
R32384C
A^From PedaJ Valve E Accumu lators l^4-Gauge Reference

B Speed Selector Valve F Direction Selector Valve Element Engaging Pressure Oil
C From Transmission Fitter G ShiftValves v>0 Constant Pressure Oil

D Orifice H Dump Valve Shift Valve Operating Oil (
Fig. 21 -Hydraulic Control System Ftow and Pressures - Second Speed Reverse

R323S5C
A From Pedal Vatve E Accumulators I 4-Gauge Reference

B Speed Selector Valve F-Direction Selector Valve '$M Element Engaging Pressure Oil
C From Transmission Filter G Shift Valves Constant Pressure Oil
*:
DOrifice H Dump Valve ^
J. Shfft Valve Operating Oil
Fig. 23-Hydraulic Control System Flow and Pressures - Fourth Speed Reverse

R32386C
A From Pedal Valve E Accumulators I 4-Gauge Reference

BSpeed Selector Valve F Direction Selector Valve :
>:cl Element Engaging Pressure Oil
C From Transmission Filter G ShiftValves 3&g Constant Pressure Oil
Fig. 22-Hydraufic Control System Flow and Pressures - Third Speed Reverse

Power Train Operation and Tests Power Shift Tests and Diagnosis 250-20-1
POWER SHIFT TESTS AND DIAGNOSIS

Group 20

hoses are not damaged.
Fluid escaping from a very small hole can almost

ly.
A CAUTION: Put main hydraulic pump out of

stroke if tractor is equipped with power
front-wheel drive.
Rg. 2-Late Control Valve Test Plugs (4440 Shown)
NOTE; Refer to Figs. 12 through 15 on page 250-
20-5 to further trace oil flow problems during Repair
TESTING SYSTEM PRESSURE
Fig. 3-Earty Control Vaive Test Plugs
Rg. 1-Tow Disconnect Lever in "Tow" Position

2. Remove system pressure test plug.
1. Place tow disconnect lever in "TOW* position.

250-20-2 Power Shift Tests and Diagnosis Power Train Operation and Tests
TESTING SYSTEM TESTING CONTROL PRESSURE

PRESSURE Continued NOTE: Later style control valve housings may have
an individual test port for each control element On late
housings, the tests may be performed using either the
4-gauge reference and hookup (Fig. 8), or the 7-gauge
i
reference and hookup (Fig. 7).
Fig. 4-300 psi System Pressure Gauge
3. a 0-300 psi (0-20 bar) oil pressure gauge.

Install
4. engine and measure pump pressure at

Start
2000 rpm engine speed and with the transmission oil
temperature at least 100-110F (40-43C).
Fig. 6-Control Valve Pressure Test Points (4-Gauge)
Fig. 5-Adjusting Pressure Regulating Valve

Fig. 7-Testing Control Pressure Test Points (7-Gauge)
5. System pressure should be 175-195 psi (12.0- (4440 Shown)
12.4 bar) (12.3-13.0 kg/cm 2 ).
1 . Remove the four element
test plugs and install a
a) If low, add shims under pressure regulating
0-300 kg/cm 2 ) D-15005 pressure
psi (0-20 bar) (0-20
valve spring to raise system pressure.
gauge at C1, C2, B1B2, and C3B3B4.
b) If high, deduct shims under pressure regulat-
NOTE: On later housings, the tests may be per-
ing valve spring to lower system pressure.
formed using either the 4-gauge hookup (Fig. 8), or the
6. If adjustment does not correct a low pressure
7-gauge hookup (Fig. 9).
condition, see Power Shift Diagnosis.

CLUTCH AND BRAKE ENGAGEMENT
Park
Neutral
Neutral Fwd.
B1
B1
B2
C3
1st Fwd. C1 B1 C3
2nd Fwd. C1 B2 C3
3rd Fwd. C2 B1 C3
4th Fwd. C2 B2 C3
5th Fwd. C2 B1 B4
6th Fwd. C2 B2 B4
* *
fi453 7th Fwd. C1 C2 C3
* *
8th Fwd. C1 C2 B4
Fig. 8-Testing Control Pressure (4-Gauge) Neutral Rev. B1 B3
1st Rev. C1 B1 B3
2nd Rev. C1 B2 B3
3rd Rev. C2 B1 B3
4th Rev. C2 B2 B3
*On 4-gauge test hookup 7th and 8th speed check

shows pressure on gauge at B1-B2 pressure port but
elements are not engaged since pressure is stopped at
shift valve.
NOTE: 01 and 02 pressure is normally 5-10 psi

(0.3-0.7 bar) (0.3-0.7 kg/crrf) below system pressure
because of line restrictions.
3. Place transmission in first speed and depress

inching pedal.
a) Pressure should read zero.
Fig. 9-Testing Control Pressure (7-Gauge) b) If not at zero, see Pedal Valve Repair. (See
(4440 Shown) 50-20-20).
2. Run engine at 2000 rpm with oil temperature at 4. Slowly release pedal.
least 100-110F (40-43C). a) Pressure should rise at a smooth, accelerat-
ing rate until 1/2-1 inch (13-25 mm) from its top
position, where it should be about 1 1 5 psi (5.5 bar) (5.6
kg/cm 2).
b) Further pedal movement should cause pres-
sure to increase to system pressure.

LUBRICATION PRESSURE TEST TESTING PTO CLUTCH AND BRAKE

IMPORTANT: Test should be repeated after re- PRESSURE
pair to check for proper assembly of parts.
1 . Remove lubrication pressure test plug and install

a 0-60 psi (0-5 bar) (0-5 kg/cm 2 ), undamped (no
orifice) pressure gauge.
APTO Clutch Test Port BPTO Brake Test Port

Fig. 10-Testing Lube Pressure
Fig. 11 -PTO Clutch and Brake Test Points
NOTE: The test plug is at the upper right-hand
corner of the clutch housing and is accessible by 1. Install a 0-300 psi (0-20 bar) (0-20 kg/cm2 )
removing the footrest panel. The plug is to the right of pressure gauge at the "PTO CLUTCH" test port (A,
the oil return line. Fig. 1 1 ) on the pedal valve housing.
2. With engine running at 2000 rpm, check lubrica- 2. Engage the PTO clutch with the engine running.
tion pressure with oil at operating temperature and a) At 2000 rpm, clutch pressure should be 1 65-
tractor in "PARK." 185 psi (11.4-12.8 bar) (11.6-13.1 kg/cm2).
a) With oil at 100F (40C), lubrication pressure b) Do not load the PTO until any low pressure
should be 26 psi (1.79 bar) (1.83 kg/cm2*. condition has been corrected.
c) Check system pressure to verify that low
3. Run engine at rpm to obtain 10 psi (0.7 bar) (0.7 pressure condition is in PTO circuit.
kg/cm 2 ) lube pressure.
3. Install a 0-300 psi (0-20 bar) (0-20 kg/cm 2 )
4. Place tow disconnect lever in "TOW" position. pressure gauge at the "PTO BRAKE" test port (B) on
5. Observe lube pressure while shifting through the pedal valve housing.
transmission speeds.
4. Start engine and pull the PTO lever back to the
NOTE: If available, use of a 0-30 psi (0-2 bar) (0-2 brake position.
kg/cm2) gauge with 0.5 psi (0.05 bar) (0.05 kg/cm2) a) At2000 rpm, brake pressure should be 175-
increments will permit more accurate readings to iso- 185 psi (12.0-12.4 bar) (12.3-13.0 kg/cm2 ).
late leakage.
b) Push the control lever forward to the engaged
6. Refer to System Diagnosis. position.
c) Brake pressure should drop to zero.

REFERENCE ILLUSTRATIONS FOR TROUBLE SHOOTING OIL FLOWS
A From Control Valve DTo Filter

Housing to C1 EInlet From Reservoir
APTO Clutch Valve Sump FTo PTO Brake BLubrication Oil OilLine
BPedal and PTO Clutch GTo Bottom of Filter CTo PTO Clutch F From Control Valve
Housing to C2
Valve Sump Relief Valve, Pedal
CPTO Clutch Inlet Valve and PTOValve Fig. 14-Clutch Housing Passages From Control Valve
DUnfiltered Oil to Top H Lube Relief Valve Sump Housing and Transmission Oil Pump
of Filter Relief Valve I From Pedal Valve to
ETo Control Valve Control Valve Housing
Housing From Pedal and C1 and C2 Shift
Valve Valves
Fig. 12-Clutch Housing Passages From Pedal Valve

and Pressure Regulating Valve Housings
*-ToC3 G Pressure Oil Direct

BToC1 From Filter
CToC2 HTo B2 AFrom Control Valve C From Pump to Filter
DFrom Clutch Pedal Valve I To B1 Housing to C1 DTo Clutch Housing
E To Sump JToB4 BFrom Control Valve From Oil Filter
FToB3 KTo Sump Housing to C2 E From Pedal Valve
Fig. 13-Transmission Case and Control Valve Housing Oil Passages Fig. 15-Transmission Case Oil Passages
1
250-20-6 Power Shift Tests and Diagnosis Power Train Operational Tests
POWER SHIFT DIAGNOSIS
General Information ABBREVIATIONS USED IN CHARTS

The following checks and test procedures are pro- FWD Forward
vided to isolate Power Shift transmission problems.
NN Neutral-Neutral
Starting with preliminary checks, each procedure is
PSI Pounds-Per-Square-lnch
designed to isolate the problem to a general area, and
then to a specific component.
PST Power Transmission
Shift
PTO Power Take-Off
Hydraulic Oil Temperature
REV Reverse
RPM Revolutions-Per-Minute
To insure test accuracy, it may be necessary to heat TCV Transmission Control Valve
the hydraulicoil to a specified temperature. Use the
procedure on page 250-20-8 to heat the oil AFTER METRIC EQUIVALENTS-TO-CHART SPECIFICATIONS
performing Preliminary Checks on page 250-20-9.
PSI Bar PSI Bar
0.7 0.05 10 0.7
How To Use Step-By-Step Hydraulic 1 0.07 15 1.0
Diagnosis Charts 2 0.14 60 4.1
The charts that follow provide a step-by-step se- 2.5 0.17 175 12.1
quence to make preliminary checks and test and iso- 3 0.2 195 13.4
late Power Shift problems. 5 0.3 300 20.7
Temperature
The charts on page 250-20-9 are used to make a
preliminary examination of the tractor. Often, a prelim-
100F 40C
inary check will Make these checks
locate a problem.
110F 43C
before installing any test equipment. Pay particular
150F 65C
attention to the "CAUTIONS" on this page.
1. The charts are divided into three sections:

SAFETY INSTRUCTIONS
STEP-SEQUENCE-RESULT. Always
step and
right,
go through the complete sequence from
and top to bottom of page.
start at the first
left to A CAUTION: Escaping fluid under pressure
skin, causing serious injury. Before disconnecting
lines, be sure to relieve pressure. Before applying
2. Each sequence ends witha result. The result will pressure, be sure connections are tight and lines,
tell you what action to take and the next step to which pipes and hoses are not damaged. Use a piece pf
you should go. cardboard or wood, rather than your hands, to
search for suspected leaks.
3. Work through each step of the diagnosis until the
system is repaired. If injured by escaping fluid, see a doctor at once.

4. The procedure is based upon 100F (40 C C)
test medical treatment is not administered immediate-
C
and 150F (65 C) reservoir oil temperature. However, if ly.
there is a specific complaint that can not be isolated at

150F (65C), heat the oil to a maximum of 200F CAUTION: Keep hands away from moving
(90C). parts. Shut engine off before checking
lines near moving parts.
A CAUTION: To avoid personal

hot oil spills when installing test equip-
ment, use the procedure on page 270-10-7 to drain
injury from
auxiliary oil reservoir and oil cooler.
A CAUTION: Securely tie open end of jumper
control valve
hose in the oil filler
when
tube from selective
heating hydraulic oil.

1
CONTENTS OF POWER SHIFT DIAGNOSIS
**
Heating the Hydraulic Oil
Draining Auxiliary Oil Reservoir or Oil Cooler
Page
250-20-8
250-20-8
1 Preliminary Checks 250-20-9
2 Dump Valve Checks 250-20-1
3 Torsional Damper Check 250-20-1
5 Tractor Speed Check 250-20-12
9 C2 Element Drag Check 250-20-15
10 C1 Element Drag Check 250-20-15
11 C3-B3-B4 Element Drag Check ].].[..... 250-20-16
12 B1-B2 Element Drag Check 250-20-16
13 High Pressure System Leakage Test 250-20-17
14 PTO Element Leak Check 250-20-18
17 Transmission Element Circuit Leakage Check 250-20-20
23 Clutch System and Lube Pressure Check 250-20-23
24 Accumulator and Dump Valve Action Check 250-20-24

RW2818 i
ower
y
Train Operation and Tests Power Shift Tests and Diagnosis 250-20-9
R35061

.
PST EQUIPPED TRACTORS STEP-BY-STEP HYDRAULIC DIAGNOSIS

STEP SEQUENCE RESULT
B. Hydraulic Checks: 2. Check oil cooler for
1. Check transmis- restricted air flow.
sion/hydraulic reservoir
oil level.
3. Check transmission oil filter

for restriction.
4. Make sure filter relief valve

(A) is free in its bore.
NOTE: Use JDH-53 Valve

Removal Tool to remove
valve.
OK: IGO TO CI
NOT OK:
REPAIR.
THEN . . . . |GO TO C|
C. Transmission Pressure
Light Check:
NOTE: If clutch pedal valve
housing (A) does not have a
pressure switch (B), GO TO
STEP 2.
Key switch "ON", Engine "STOPPED":

Light should be "ON".
Key switch "ON". Engine "RUNNING":
Light should be "OFF".
OK: |GO TO 2|
^f^ NOT OK: GOTO

SECTION
240-06
(
R35062

PST EQUIPPED TRACTORS

STEP
DUMP VALVE CHECK:

STEP-BY-STEP HYDRAULIC DIAGNOSIS
SEQUENCE
Start engine.
RESULT
Run at 1200 RPM.

Push clutch pedal down.
If engine stalls within 20

seconds at all speeds except
7th and 8th, the dump valve (A)
has been installed upside
down. ENGINE DOES NO T STALL
NOTE: Make sure open end of |GOTQ3l
dump valve is up.
ENGINE STALLS:
INSTALL DUMP VALVE
CORRECTLY.
(REPEAT 2
A
W TORSIONAL DAMPER
CHECK:
Drive tractor in 4th gear at 1 500
RPM.
If clutch pedal valve housing NOTE: If tractor does not
does have a pressure
not move at 4th gear, GO TO step
300 psi gauge
switch, install a 4.
(A) with extension hose at Apply both brakes
clutch system test port. simultaneously to load engine.
Observe engine for pull down

and transmission pressure
light for operation or clutch
system pressure.
<^%
ENGINE STALLS:
DAMPER OK: IGOTOSJ
TRACTOR STOPS, LIGHT

GLOWS or SYSTEM
PRESSURE EXTREMELY
LOW, BUT ENGINE IS
RUNNING:
DAMPER IS SLIPPING.
|GO TO 4|
TRACTOR STOPS, LIGHT IS

OUT or SYSTEM PRESSURE
OK, but ENGINE IS
RUNNING.
DAMPER IS OK.
1GOTQ171
R35063

WTOW".
Place
STEP
tow disconnect at
SEQUENCE
Engine at
RESULT
1500 RPM. Shift

transmission through speeds 1
to 6.
LIGHT STAYS OUT or

Observe transmission system pressure is
pressure light or ok. make note to
clutch system pressure
repair damper.
gauge. continue testing
[gotoIs]
NOTE: Place transmission
disconnect at DRIVE after LIGHT ON, SLOW TO GO
testing or repair. OUT or LOW SYSTEM
PRESSURE: REPAIR
DAMPER.
Then |GO TO 5j
TRACTOR SPEED CHECK: Start at Neutral-
NOTE: Reservoir oil Neutral and shift
temperature must be at least transmission through

100-110 F. all forward and reverse
Engine at 1500 RPM, drive speeds. Observe for a

tractor. speed increase with
each upshift. Reverse
shift sequence to check
down shifting.
NOTE: Shifting from 6th to 8th UP AND DOWN SHIFTING

then to 7th prevents engine OK:
from stalling for a 6th to 7th CONTINUE TESTINO
speed change. IGO TO 91
IMPROPER UP or DOWN
rS SHIFTING: GO TO 6|
TRACTOR DOES NOT MOVE

AT CERTAIN SPE EDS:
IGO TOTS!
R 35064

Q Tractors
STEP
with
accumulator test ports
only dual
GO TO
STEP 7 and STEP 8.
Install 7 gauge bar set at

element test ports.
Engine at 1500 RPM.

Shift to each gear ir
following chart.
Check for: INCORRECT or SLOW
a. Incorrect or slow- ENGAGING ELEMENTS:
engaging elements. OR SHIFTS ERRATICALLY
b. Pressure at any "OFF" 1GO TO"7|
element or excessively slow
dump. CORRECT ELEMENTS
NOTE: See STEP 24 for dump APPLIED, BUT PRESSURE
valve action.
AT "OFF" ELEMEN T OR
IGOTQ8J
R35065
TM-1181 (Apr-81) Litho in U.S.A.

1

Q Inspect the following for

causes of incorrect or slow-
engaging elements:
a. Binding linkage at tran-
missron control valve.
Area (A) or shift quadrant (B).
b. Sticky speed selector valve

(A), direction selector valve
(B), or shifter valve (C).
c. Direction selector valve

detent (A) and speed selector
valve detent (B) interchanged.
INSPECTION
SATISFACTORY:
jGO TO 8
UNSATISFACTORY:
REPAIR.
Then
^___
JGO TQ^
O Inspect the following for a. Sticky dump valve.

causes of pressure at any
"OFF' element:
=5~
b. Excessive leakage by shift

valve gasket (A) or
transmission control valve
gaskets (B).
INSPECTION
SATISFACTORY:
|G0 TO 9
UNSATISFACTORY:
REPAIR.
Then |GO TO 6|
R35066
TM-1181 (Apr-81) Utho in U.S. A Tractors - 404O and 4240

C2 ELEMENT DRAG
CHECK:
IMPORTANT: Reservoir oil

temperature must be at least
100-110 F for drag checks to
be effective. Engine at 2200
RPM. Drive tractor on a level
surface in 2nd gear. J
Depress clutch pedal. NOTE: If speed is same with

Observe tractor ground speed. clutch pedal depressed at 2200
RPM, C1 is not releasing. TRACTOR SLOWS TO A
Repeat check at 1500 RPM. If
C1 releases at 1500 RPM, this
indicates a weak spring at C1
ST0P:
NORMAL.
,
(GO TO
__ 10|
clutch piston. Note for repair SPEED INCREASES: C2

and continue testing. IS DRAGGING. MAKE
NOTE TO REPAIR.
CONTINUE TESTING.
[GO TO 1Q|
CHECK:
ELEMENT DRAG
C1
Engine at 2200 RPM. Drive

tractor on a level surface in 3rd
gear.
Depress clutch pedal. NOTE: If speed is same with

Observe tractor ground speed. clutch pedal depressed at 2200
RPM, C2 is not releasing. TRACTOR SLOWS TO A
Repeat check at 1500 RPM. If STOP:
C2 releases at 1500 RPM, this NORMAL. |gOTQ11)
indicates a weak spring at C2
clutch piston. Note for repair SPEED DECREASES:
and continue testing. C1 IS DRAGGING. MAKE
NOTE TO REPAIR.
CONTINUE TESTING.
1GQTQ11|
R35067

w DRAG CHECK:
ffk C3-B3-B4
STEP
ELEMENT
SEQUENCE
Disconnect
RESULT
yoke from

directional valve arm on
Stop engine. transmission control valve.
Place speed selector lever at
Neutral-Neutral.
Engine at 1500 RPM.

Clutch pedal "UP".
NO MOVEMENT:
NORMAL. IGO TO 121
Place speed selector lever at
1st gear.Observe tractor for
movement.
REVERSE MOVEMENT: B3 IS
DRAGGING. MAKE NOTE TO
REPAIR.
CONTINUE TESTI NG.
|GOTd"l2l
FORWARD MOVEMENT: C3
OR B4 IS DRAGGING.
MAKE NOTE TO REPAIR.
CONTINUE TESTI NG.
IGO TO 12|
ff% B1-B2 ELEMENT Place tow disconnect at

DRAG CHECK: "TOW".
NOTE: If both C1 and C2 were
dragging at steps 9 and 10, do
not perform this check.
GO TO 13.
NO LOADING: IGO TO 13l
Engine at slow idle. NOTE: If C1 was dragging at ENGINE LOADS or STALLS

Observe engine for loading as step 10,move speed selector AT F1 or F3: B2 IS
you: from FN to F1 and FN to F2. DRAGGING. NOTE TO
a. Move speed selector from Reconnect directional valve REPAIR. CONTINUE
FN to F3 for B2 check. yoke after testing. TESTING.
b. Move speed selector from IGO TO 13t
FN to F4 for B1 check.
ENGINE LOADS or STALLS
AT F2 or F4: B1 IS
DRAGGING. NOTE TO
REPAIR. CONTINUE
R35068
TESTING.
|GO TO 131

SYSTEM
STEP
HIGH PRESSURE Install a 60 psi gauge at lube

SEQUENCE RESULT
LEAKAGE test port.

TEST:
Install a destroking screw in Reservoir oil temperature

main pump. must be at least 100-1 10 F.
Rockshaft fully raised. All
other control valves at neu-
tral. Adjust engine to get at
least 10 psi lube pressure.
Turn screw *W
to destroke
main pump. Listen to engine
for a decrease of load.
0-3.0 psi CHANGE :
IN SPEC: JGO TO 14|
MORE THAN 3.0 psi

INCREASE: HIGH PRES-
SURE LEAK TO SUMP.
[*:
Observe lube gauge for a to 3.0 psi CHANGE
pressure change.
BUT ENGINE LOAD DE-
CREASES: HIGH PRES-
SURE LEAK TO RETURN.
* Keep main pump destroked.

Make note to repair. Complete
PST testing. Then see section
270-10 for isolation of leakage
in high pressure system.
R35069
TM-1181 (Apr-81) Utho in US. A. Tractors - 4040 and 4240

(J)
STEP
PTO ELEMENT LEAK
CHECK:
SEQUENCE
Engage PTO
RESULT
clutch.

Adjust engine to get at (east 10
psr lube pressure.
If equipped With hydraulic

seat, position rideadjustment
lever <A) at FIRM to minimize
lube pressure fluctuation.
Engage PTO brake. Observe lube gauge for

pressure change.
to 2.0 psi CHANGE;

IN SPEC. |GO TO 17|
MORE THAN 2.0 psi

CHANGE: OUT O F SPEC.
GO TO
| 15|
R 35070

Power Train Operation and Tests Power Shift Tests and Diagnosis 250*20-19

in

STEP
There is possible leakage

the circuit with the lower
SEQUENCE RESULT
pressure. Install a 300 psi

gauge at PTO clutch (A) or
PTO brake (B) (whichever had
lower pressure) and system
test ports.
Engine at 1500 RPM. Engage Observe PTO clutch (A) or

PTO clutch (A) or PTO brake brake (B) and system pres-
(B). sure difference.
to 10.0 psi CHANGE:

IN SPEC. [GO TO 17l
MORE THAN 10.0 psi

CHANGE: OUT O F SPEC,
|GOTQ16l
The possible areas of leakage are:
PTO BRAKE PTO CLUTCH

a. Pressure regulating and pedal a. Pressure regulating and
valve housing gaskets leaking. pedal vafve housing gaskets
b. PTO valve or pedal valve housing leaking.
scored. b. Transmission pump oil man- POSITION PTO LEVER
c. PTO brake piston seal leaking. Hold gaskets leaking. TO GET HIGHER LUBE
c. Oil rn an if old PTO sealing PRESSURE. MAKE NOTE
ring leaking. TO REPAIR. CON TINUE
d. PTO drum or piston leaking. TESTING. |GOTQ17|
R35071

Q TRANSMISSION
STEP
SEQUENCE RESULT
Adjust engine to get at least 10

ELEMENT CIRCUIT psi lube pressure.
LEAKAGE CHECK:
Reservoir oil temperature must
be at least 100-110 K
Place tow disconnect at
TOW',
Follow the shifting sequence in chart at step 18.

Record lube pressure.
After shifting allow 10 seconds before recording pressure.
If lube pressure drops below 5.0 psi readjust engine to get
10 psi and repeat check.
CONTINUE. JGOTO 181
O LUBE
PRESSURE LUBE SPEC: MAX. LUBE
ELEMENT LUBE WITH CLUTCH PRESSURE PRESSURE CHANGE
GEAR CHECKED PRESSURE DEPRESSED CHANGE B1-B2-B4-C3: 1.0 psi
PARK* B2 C1-C2: 2.5 psi

B3: 0.7 psi
NN* B1
F1* C1
F3* C2
_F3__
" __C3
F5 54
F5 B4
R3 B3
R3 B3
F3 C3
Record tube pres-

sure before and IN SPEC: |GO TO 22|
after depressing
dutch pedal. OUT OF SPEC: m
GO TO 19
L-
R 35072
TM-1181 (Apr-81) Lrtho in U.S.A. Tractors - 4040 and 4240

Power Train Operation and Tests Power Shift Tests and Diagnosis 250*20-21

install a 300 psi gauge
clutch system test port.
at Install a 300 psi gauge at
element test port ot element(s)
found to be out of spec, at step
18.
{GO TO 20l
Engine at 1500 RPM. Shift to gear (in chart below) with leaky
element. Record system
pressure and element {or accumulator) pressure for leaky element(s).
If gauges are
Installed at all test ports, follow shifting sequence in chart. Record system and element
pressures.
NOTE: Subtract element pressure from system pressure to determine
element pressure difference.
ELEMENT SYSTEM ELEMENT PRESSURE SPEC: MAX. ELEMENT

GEAR CHECKED PRESSURE PRESSURE DIFFERENCE PRESSURE DIFFERENCE
F1 C1
F3 C2
B1-B2-B3-B4-C2-C3: 10 psi
C1:15 psi
R35Q73
TM-1181 (Apr-81) Utho in U.S. A, Tractors - 4040 and 4240


STEP
SEQUENCE
Shift to PARK and complete test procedure before repairing the element circuit(s) with
excessive leakage. If B2 circuit is leaking, tie clutch pedal down. When repairing Inspect
RESULT
c
the areas of possible leakage in the following sequence for each element with excessive
leakage.
POSSIBLE AREA OF LEAKAGE C1 C2 B1 B2 B3 B4 C3
Transmission control Valve Gaskets v

A v
A w w
A A A A A
Shift Valve Gaskets a
A a A A A
Allen Plugs In Transmission Case Behind TCV* w *,
A A A A A
Pedal Valve Gaskets V V
Transmission Pump Manifold Gaskets y y
Transmission Pump Manifold Sealina Rinas
*--"* v
A v
A
Clutch Drum or Piston Seals
Clutch Housing to Transmission Case Packings X X
Transmission Case to Planetary Pack O-rings x x X X
Brake Drum or Piston Seals v
A v
A v
A v
A
" Line or Bearing3 Quill
Fitting, '
A
Output Shaft Seals, Clutch Drum or Piston Seals v
*TCV: Transmission Control Valve
MAKE NOTE TO REPAIR
CONTINUE TESTING.
- (GO TO 22|
@
If
If tractor moves in all
element pressures were satisfactory
speeds, GO TO STEP 23
at step 20, but tractor will not move at one of the following
speeds, the possible cause would be:
SPEED or GEAR CAUSE

a. FWD: 1-2-7-8 A has failed between C1 clutch and the
part
REV: 1-2 sun gear of the planetary.
b. FWD: 3-4-5-6-7-8 A part has failed between C2 clutch and the
REV: 3-4 sun gear of the planetary.
c. FWD: 1-3-5 B1 Brake failure.
REV: 1-3
d. FWD: 2-4-6 B2 Brake failure.
REV: 2-4
f. REV: 1-2-3-4 B3 Brake failure.

g. FWD: 5-6-8 B4 Brake failure.
h. No FWD. or REV: 1. Shaft failure between the damper and C1-
C2 clutch assembly.
2. B1-B2 planetary gear failure in brake
REPAIR.
Then |GOT0 3|
R35074


i STEP
CLUTCH SYSTEM AND

LUBE PRESSURE CHECK:
SEQUENCE RESULT
Engine at 2000 RPM. Record
lube and cJutch system
At PA R K, position the PTO and pressure.
clutch pedal to get the higher LUBE PRESSURE SPEC.
lube pressure. AN other control (MfN.)
valves at neutral or main pump 100 F 26 psi
destroyed, if there was high 150 F 22 psi
pressure leakage at step 13.
CLUTCH SYSTEM
PRESSURE SPEC, (MlN.)
175-195 psi
NOTE; H system pressure is
low and lube is OK, add

slightly
shim(s) (A) to pressure
regulating valve (B).
IN SPEC. AND ALL

PREVIOUS CHECKS
SATISFACTORY:
LGOTQ241
IN SPEC, or OUT OF
SPEC. WITH SOME PRE-
VIOUS CHECKS*
UNSATISFACTORY:
REPAIR ALL DISCREP-
ANCIES.
Then |GO TQ 3|
*SEE SECTION 270-10FOR

FURTHER TESTING OF LOW
PRESSURE SYSTEM.
R 35075
TM-1181 (Apr-81) Litho in USA. Tractors - 4O40 and 4240

Q
STEP
ACCUMULATOR and If the PST lest kit
SEQUENCE
Is not Engine at
RESULT
1500 RPM.
i
DUMP VALVE ACTION connected for 7 or 4 gauge test
CHECK: method, connect two 10 ft.
hose extensions to the
transmission control valve
frontand rear accumulator test
ports with two 300 psi gauges.
GAUGE TEST PORT METHOD

7
A. CHECK FOR FRONT ACCUMULATOR ACTfON BY

OBSERVING B1 AND REAR ACCUMULATOR ACTION
BY OBSERVING B4 DURING A 4 to 5 SHIFT,
B- CHECK FOR DUMP VALVE ACTION DURING A
4 to 5 SHIFT.
NOTE: B4 ELEMENT MAY FILL ONE SECOND FASTER
THAN THE OTHER BRAKE ELEMENTS. ON A
5 to 4 SHIFT, C3 WILL TAKE 1-2
SECONDS LONGER TO FILL THAN THE BRAKE
ELEMENTS.
A- Needle hesitates: Dump

valve closes
B- Dump valve opens
C- Element disengaging
D- Needle hesitates: Dump
valve opens
E- Element engaging
NOTE: Shift time rs from
movement of shift lever until
full pressure is applied (3
seconds total time).
4 GAUGE TEST PORT METHOD

A. CHECK FRONT AND REAR ACCUMULATOR ACTION
BY OBSERVING GAUGES DURING A 4 to 5
SHIFT.
B.CHECK FOR DUMP VALVE ACTION DURING A
AND 5 to 4 SHIFT.
4 to 5
NOTE: B4 ELEMENT MAY FILL ONE SECOND FASTER
THAN THE OTHER BRAKE ELEMENTS. ON A 5
to 4 SHIFT, C3 WILL TAKE 1 to 2 SECONDS
LONGER TO FILL THAN THE BRAKE ELEMENTS.
THE DUMP VALVE ACTION IS VERY DIFFICULT
TO OBSERVE.
A- Needle hesitates: Dump

valve opens
B- Accumulator discharging SATISFACTORY:
C- Accumulator charging lGOT0 26|
NOTE: Shift time is from
movement of shift lever until
full pressure is applied (2
UNSATISFACTORY:
seconds total time). FAST or SLOW
ACCUMULATOR ACTION
or IMPROPER DUMP
e
VALVE ACTION.
IGO TO 25l
R35076

STEP
{jl Causes of poor accumulator and/or dump

SEQUENCE
valve action are:

RESULT
SLOW SHIFTING
a. Sticky accumulator piston in transmission control valve housing.
b. Accumulator charging orifice plugged in transmission control valve
housing.
c. (B3-B4-C3 onJy) accumulator shim missing.
d. Restricted oil flow from transmission oil filter to transmission
e. Excessive leakage in transmission control valve housing.
f. Sticky dump valve in shifter valve housing.
g. Missing plate and disk In C3.
FAST SHIFTING
a. (B3-B4-C3 only) accumulator spring broken.
b. (B1-B2 only) accumulator spring broken.
q. Accumulator charging orifice massing in transmission control
valve.
d. C3 air bleed ball stuck closed: 4040-4240-4440 in reduction shaft
bearing quill. 4640-4840 in C3 piston cover.
e. C3 piston return spring broken.
REPAIR.
Then |GO TO 24J
@ Two areas that are very drfficult to determine as the cause of a transmission slippage
complaint are:
A. Leakage past one of the four o-rings located at the
bottom of the transmission case to the planetary pack.
B. Torsional damper slippage at the flywheel.
if checks are normal and any problem that relates

all
to transmission slippage has been corrected
STOP TRANS.
NORMAL
If all checks are normal and no problem was isolated, perform the following:
A. Heat the reservoir oil to 150 F (65 C), (see p 270-10-3)
go to B.
B. Repeat transmission test procedure starting at step 3,
again the checks are normal, go to C.
If
Screws loose:
C. Check the hold down cap screws at the top of the planetary Tighten . RELEASE
pack torque by removing SGB floor
for (if equipped with TRACTOR
SGB) and the transmission cover.
Screws tight:
Repair damper.
|GO TO 3|
R 35077
TM-1181 (Apr-81) Litho in US. A Tractors - 4040 and 4240


Power Train Operation and Tests Differential and Final Drive 250*25-1
Group 25
DIFFERENTIAL AND FINAL DRIVE
R28232N
ADifferential Lock Pedal (Depressed) F Lock Clutch Piston (Lock Inlet) Hydraulic System
BPlunger GBevel Lock Gear Pressure Oil
C Diff. Lock Return OH H Disks and Plates ?$? Lock Engaging Oil (450 psi)
DInlet I Differential Ring Gear 1 Return Oil
EPressure Control Valve J Final Drive Sun Gear
Ftg. 1 -Differential Lock Engaged

250-25-2 Differential and Final Drive Power Train Operation and Tests
Differential Continued

R282ZZ11
A Lock Pedal (Released) F Lock Clutch Piston KPlanet Pinion

B Plunger G Bevel Lock Gear (Lock Inlet) Hydraulic System
C Oiff. Lock Return H Bevel Pinion (2 used) Pressure Oil
[>Inlet (Blocked)
Oil I Planetary Ring Gear .Return Oil
E Pressure Control Valve J Sun Pinion
Fig. 2-Differentiat Lock Disengaged

Power Train Operation and Tests Differential and Final Drive 250-25-3
HOW THE SYSTEM WORKS Hi-Crop Final Drive

The differential transmits power to the final drive. It
allows each drive wheel to rotate at varying speeds
and still pull its own load.
Power to the ring gear from the differential drive

shaft flows through a two-bevel pinion arrangement to
the bevel gears as a unit.
When the tractor turns sharply, one axle is held

stationary. Therefore, the bevel pinions (H, Fig. 2)
rotate on own
axis and "walk around" the sta-
their
tionary axle bevel gear. The turning ring gear transmits
its power through the pinions to the opposite bevel
gear.
Except for the ring gear and pinion, the differentials

are the same on all transmission options.
The Power Shift Transmission is the differentia! ring

gear is on the right-hand side of the differential drive
shaft pinion.
This compensates for a bevel pinion which (com-

pared to Perma-Clutch transmissions) turns in the
opposite direction. R 2S706N
Hydraulic Differential Lock

AInner Drive Shaft Gear F Outer Drive Shaft Gear
Differential speed causes traction loss when one 8 Differential Output GAxle Shaft
wheel is slipping. An optional, hydraulic lock uses
Shaft H Final Drive Gear
pressure oil to lock up the
COutput Shaft Pinion I Final Drive
differential.
DFinal Drive Shaft Gear Housing
When the lock pedal is depressed (Fig. 1), oil flows
E Drive Shaft Housing
to the differential. A piston-clutch arrangement locks
Fig. 3-Hi-Crop Final Drive
the bevel pinions to the differential housing.
When the pedal is released, oil pressure at the Power to the differential output shaft (B, Fig. 3) turns
piston is shut off, releasing the clutch (Fig. 2). the output shaft pinion (C), The pinion is in mesh with
the inner drive shaft gear (A) which is splined to the
A built-in link on the tractor brakes unlocks the final drive shaft (D).
differentia! whenever the brake pedals are used.
The final drive shaft (D) transfers power from the
Final Drive drive shaft housing (E) to the outer drive shaft gear (F)
The final drive planetary gives the drive wheels a in the final drive gear housing (I).
finalspeed reduction and torque increase.

The large final drive gear (H) receives torque for the
The planetary sun pinion (J) rotates with the dif- final speed reduction of the axle (G).
ferential. The three planet pinions "walk around" the
ring gear (I) which is fixed inside the axle housing.
Since the rear axle shaft is connected to the planet

pinion carrier, it rotates \n the same direction as the sun
pinion.

250-25-4 Differential and Final Drive Power Train Operation and Tests
Testing Differential Lock Valve 1. Install a Tee fitting (Nuday 135-5.1) with pressure
i<;<l^H:::<<<nS3-:;
gauge
case oil
in the differential lock valve-to-transmission
pipe.
2. Run engine at 2000 rpm and depress lock pedal.

t
Pressure should be 435-485 psi (30.0-33.4 bar)
(30.6-34,1 kg/cm 2 ) with oil at 100 D F (38C).
a) If pressure is incorrect, disconnect linkage and

add or deduct shims (See 50-35-7).
b) If correct pressure cannot be obtained, disas-

semble and repair valve as instructed on page 50-35-
7.
Fig. 4-Testmg Differential Lock Pressure
Differential Noisy at all Ring gear and pinion adjustment incorrect Adjust (See 50-35-5)
times Ring gear and pinion damaged Remove and Repair (See 50-35-3)
Quill or pinion shaft bearings damaged Repair (See 50-35-3)
Differential Not Working Damaged bevel pinions and shafts Repair (See 50-35-3)
Freely White Turning Damaged bevel pinion bearing surface Repair (See 50-35-3)
Differential Lock Not Low lock vaive pressure setting Add shims (See 50*35-7)
Functioning Plunger spring weak Replace (See 50-35-6)
Control valve spring weak Replace (See 50-35-6)
Oil seals or gasket leaking Repair (See 50-35-6)
Outer Axle Oil Seal Excessive axle end play Adjust (See 50-40-4)
Leaking Worn spacer Replace and adjust (See 50-4r>2)
Bearing cup not seated or worn Repair as required (see 50-40-2)
Retaining cap screw loose Adjust (See 50-4CM)
Excessive lubrication

.
Power Train Operation and Tests Power Front- Wheel Drive 250-30-1
i POWER
Group 30
FRONT-WHEEL DRIVE
HOW THE SYSTEM WORKS Clutch Pedal Switch
The power front-wheel drive system consists of an The clutch pedal switch is located on the pressure
electrical actuating system, a directional and torque regulating valve housing. When the clutch is disen-
control valve, and a hydraulic front wheel drive motor in gaged, clutch engagement pressure to the switch is
each front wheel housing. shut off and the front wheel drive is disconnected.
A double planetary gear system gives a speed re- Gear Shift Lever Switches
duction of 40 to 1
On Quad-Range and Syncro-Range tractors, these
The front-wheel drive can be switched from high to switches synchronize solenoid pilot valve action. The
low torque, low to high torque, or engaged and disen- switches are located in the shift quadrant so they work
directly with shift lever position.
gaged, ali while the tractor is moving.
The front-wheel drive can be engaged in any field On Power Shift tractors, the switches are located on
the transmission control valve housing.
condition, but is designed to be used under marginal
traction conditions.
The following chart shows proper switch operation.
Control System The asterisk (*) indicates that the drive is automatically
switched into low torque.
Drive Operating Switch
Trans- Low Torque High Torque
mission Forward Reverse Forward Reverse
Power
Shift 1,2,3,4,5,6 1,2,3,4 1,2,3,4 1,2,3,4
Syncro-
Range 1,2,3,4,5,6 1,2 1,2,3,4 1,2
Quad-
Range A-1, 2,3,4 A-1R,2R A-1 ,2,3,4 A-1R,2R
B-1,2,3 B-1R B-1,2*,3* B-1R*
C-1,2,3 (MR C-1\2*,3* C-1R*
Fig. 1-PFWD Operating Switch
A three-position switchallows the system to operate

in high or low torque, or shuts the system off.
The switch does not have to be moved when shifting

to higher gears, reversing the tractor, or clutching.

250-30-2 Power Front-Wheel Drive Power Train Operation and Tests
Control System Pilot Valves

Power Front-Wheel Drive Control Valve Housing
The control valve housing is located under the trac-
tor and slightly behind the main hydraulic pump. The
The three small pilot valves (H) are controlled by
their solenoids. Electrical current to the solenoids ac-
tuate the pilot valves which in turn actuate the direction
i
valve (D) or torque spool valve (G).
control valve receives and directs oil flow as follows:
The pilot valves are marked "FWD". "REV", and

"TRQ" indicating each valve function.
Direction Valve
Oil from the pressure control valve (B) is routed to

the direction valve (D) bore. The has
direction valve
three possible positions (forward, reverse, and neu-
tral), and is controlled by solenoid pilot valve position.
Torque Valve
The torque valve (G) receives oil from the direction
The valve allows oil flow to either connect the
valve.
drive motors in parallel for high torque or in series for
low torque drive.
Return Flow Check Valve
This spool-type check valve (C) is located in the

E28Z258 hydraulic pump inlet tee.
ARelief Valve ENeutral Bleed Valve

BPressure Control Valve F Regenerative Check During front-whee! drive operation, the valve allows
O-Return Check Valve Valve returnoil from the front wheel drive circuit to re-enter
DDirection Valve GrTorque Valve the main hydraulic pump.
H Pilot Valves
Fig. 2-Controt Valve Components When the front-wheel drive is disengaged, spring
force closes the valve preventing charge flow from
Relief Valve entering the control valve and "backing up" into the
front- wheel drive circuit.
The valve (A, Fig. 2)
relief is located on the iniet side
of the control valve housing.It absorbs pressure peaks
from the main hydraulic pump and limits possible

pressure buildup to 2700 psi (186.2 bar) (189.9 kg/
cm 2 ). Such a buildup of pressure could result from a
rapid change of vehicle direction.
Pressure Control Valve
The pressure oil from the

control valve (B) receives
main hydraulic pump. The valve pressure controlled;
is
therefore, when other hydraulic functions require near

maximum pump output, the pressure control valve

meters oil to the front wheel drive giving priority to the
other functions.
Pilot Solenoids

The three electrical solenoids are located on top of
the control valve housing. They actuate the pilot valves
below them in the control valve housing.
If electrical power fails, the valves move to their off
position.

Power Train Operation and Tests Power Front-Wheel Drive 250-30-3
Neutral Bleed Valve Regenerative Check Valve
The neutral bleed valve (E) allows

wheel drive circuit to "bleed
drive is disengaged.
off"
oil
when the
in the front-
front-wheei
When the front-wheel drive is engaged in series
torque), and the tractor is
(low
turned; the outside wheel
motor pumps oil (especially during a right-hand, for-
ward turn or a left-hand, reverse turn).
This pumping action occurs because the outside

wheel is turning faster than the inside wheel Also the
front-wheel drive control valve maintains oil flow to the

wheel motors.
iiii To prevent excessive oil pressure between the

wheels, a regenerative check valve (F, Fig. 2) is locat-
*zzz?i ed in the common passage between the wheels (in the
control valve housing).
7
777?^ The check valve relieves oil pressure in the front-
wheel drive circuit to the hydraulic system pressure oil
line when oil pressure between the wheels exceeds
hydraulic system pressure.
k////A
R 28192N
ANeutral EReverse Only

BEngaged '
System Pressure Oil

CThrough Bleed Manifold (REV)
DDirection Valve :::'-".;
Bleed or Pressure-Free
(Forward)
Fig. S-Neutrai Bleed Valve Operation
allowed past a check ball through an external

Oil is
oil the bleed oil manifold. The bleed oil manifold
line to
directs the bleed oil to the hydraulic reservoir.
This prevents secondary brake drag and oil backing

through the control valve.
When the front-wheel drive is engaged, the valve

seats blocking any flow from the control valve housing.
The valve seats when oil pressure in that portion of
the valve housing is from 143-187 psi (10-13 bar).
forward gears with the front wheel drive engaged,

In
the check
ball is seated mechanically by the direction
valve. In reverse gears, the ball is seated hydraulically
since front-wheel drive pressure oil is routed past the
inner end of the valve.

WHEEL OPERATION
Oil Manifold and Check Valve

R 2B324N
AForward Operation FCheck Ball KTo Top Pivot Pin

B Reverse Operation G Lower Motor Plate Area System Pressure OH
CCheck Passage HTo Lower Pivot Pin &" Motor Return Oil
DTo Brake Pistons I -flelief Valve
ECheck Valve Body J Upper Motor Plate Area
Fig. 4-Wheel Manifold Oit Flow (High Torque)
Oil from the control valve housing enters the oil Reverse Operation (B, Fig. 4)
manifold (which located on the inside of each wheel
is
When enters through the bottom pivot pin, the
oil
motor housing). Depending on the position of the di-
lower manifold port (H) receives inlet flow. The wheel
rection valve, oil enters the oil manifold through either
motor receives oil at the lower portion of the valve plate
the top or bottom pivot pin.
(Q).
The check ball (F) moves and seats toward the
Forward Operation (A, Fig. 4)
center of the manifold. This allows motor inlet oil to flow
When oil enters through the top pivot pin, the upper through the check valve assembly in the opposite
manifold port (K) receives inlet flow. The wheel motor direction of forward operation. Oil is routed to the brake
receives oil upper portion of the valve plate (J).
at the pistons through the same passage as in forward
A free-floating check ball (F) moves and seats away operation.
from the center of the manifold. Motor inlet oil is Motor oil returns through the top pivot pin from the
allowed through the check ball assembly and motor upper portion of the valve plate (J), and on to the
housing to the brake pistons (D). control valve housing.
Motor oil returns at the lower portion of the vaive
Relief Valve
plate (G), through the bottom pivot pin, and on to the
If there is excess leakage in the unit due to poor
sealing, pressure will build in the wheel housing. A
relief valve (I) in the manifold relieves pressure greater
than 55 psi (3.8 bar) (3.9 kg/cm 2) to the outside of the
wheel unit.
TM-1181 (Sep-77) Lftho in U.S.A. Tractors - 4040 and 4240

Wheel Housing
R 28325N
A Brake Pressure Plate HOil Manifold 0 Brake Piston VFirst Planet Ring Gear
BTo Brake Pistons I Pivot Pin PPiston Housing WSecond Planet Ring Gear
C Pivot Pin Oil Tube J Return (Forward) QBacking Plate X Planetary Housing
DBleed Oil Line KSJipper Piston R-^Second Planet Pinion W$$i System Pressure OH
EPressure Line (Forward) LSwash Plate SMotor Shaft 8$ Motor Return Oil
FTo Brake Pistons MMotor Housing Tfirst Planet Pinion iff! Bleed Oil
G-ReHef Varve NCylinder Block U^First Planet Sun
Fig. S-Front-Wheel Assembly - Forward Operation
Wheel Motor the pistons are forced outward against the swash plate
The axial piston wheel motor contains nine pistons (L). As down the angled swash plate,
the pistons slide
(K, Fig. 5) which work inside a revolving cylinder block the cylinder block rotates. As each piston completes
The this cycle and moves up the thick side of the swash
(N), pistons contact a fixed-angie swash plate (L)
plate, oil discharges. Oil flow determines the speed the
as they revolve.
The motor is located inside the wheel motor hous- pistons revolve and the motor drive shaft (S) rotates
ing (M). As pressure oil enters t he cylinder bores, accordingly.

$
250*30*6 Power Front-Wheel Drive Power Train Operation and Tests
Planetary and Brake Assembly Neutral

There are two planetary units in each wheel hous-
ing. The wheel motor drive shaft is located in the center
of the wheel motor. This shaft rotates with the motor.
Another shaft with an integral spur gear splines into the
In neutral,
and none
not routed by any of the
valve (AA, Fig.
the operating switch
of the solenoids are activated.
6).
pilot
The front-wheel
is in the off position
Pressure
valves to the direction
drive
oil is
does not

motor drive shaft. The spur gear on this shaft is the function.
outer planetary sun gear.
Charge main hydraulic pump cannot enter
oil to the
The inner planetary sun gear splines with the outer the control valve housing since the return flow check
planetary carrier. The inner planetary carrier is at- valve (I) is closed.
tached by cap screws to the outer hub.
Excess wheel bleed and lubrication pressure oil is
The ring gear of the outer planetary is pressed into bled off by the neutral bleed valve (J) to the bleed oil
the outer hub. The inner planetary ring gear is (ocked to manifold (G) and on to the main hydraulic reservoir.
the motor housing by the brake assembly.
As the moves forward, the wheel housing (O)
tractor
When pressure oil at the nine brake pistons (B) rotates asshown. Since the brake pistons (R) are not
moves them out to lock the ring gear to the wheel engaged, the motor shaft gear system is not affected.
motor housing, rotation stops.
The motor drive shaft transfers power to the outer

planetary sun gear. The planet pinions must rotate on
their axes.
Power flows to the outer carrier which is splined to

the inner planetary sun gear. The inner sun gear turns
its planet pinions. Since the inner planetary carrier is
attached to the wheel housing (X, Fig. 5) power flows

at a reduced speed through the carrier to the wheel
and tractor tire.
Internal leakage inside the wheel housing returns to

the reservoir through a bleed line (D, Fig. 5) which runs
through the center of the pivot pin.

OPERATION AND OIL FLOWS
NOTE: References to "left-hand" and "right-hand"
jefer to the illustrations which are viewed from the front
of the tractor
Also, whenever a forward gear" is referred to dur-

ing the following descriptions of valve operation, that
forward gear is subject to switch operation as de-
scribed on page 1 of this Group.

R28328N
ATo Junction Manifold JNeutral Bleed Valve UTo Lower R.H. AADirection Valve
BOH Cooler K Torque Valve Pivot Pin BBSurge Relief Valve
C Main Hydraulic Pump LL.H. Bleed Oil Line VWheel Housing CCSolenoids and Pilot
(4 cu. in.) MTo Upper LH. Pivot Pin Relief Valve Valves
DBleed Oil Manifold NSecond Planet Ring Gear WOil Manifold and
DD Pressure Control Valve
Return Line OPlanetary Housing . Check Valve gggg System Pressure Oil

E To Main Reservoir P First Planetary Assembly X To Upper R.H. ^| Charge Oil
F Pressure Regulating Q Second Planetary Assembly Pivot Pin |gj Lubrication Oil
Valve Housing R Planet Brake Pistons YR.H, Bleed Line lilt Pressure-Free or
G Bleed Oil Manifold SWheel Motor Drive Shaft Z Regenerative Bleed Return Oil
H Neutral Bleed Oil Line TTo Lower LH. Pivot Pin Check Valve
1 Return Flow Check Valve
Fig. 6-Power Front-Wheel Drive Power and Oil Rows - Neutral

Forward -Low Torque Excess leakage in the wheel unit passes through a
tube the center of the pivot pin. From the pivot pin
in
When the operating switch is moved to "Low
cap, the bleed oil lines (L and Y, Fig. 6) route bleed oil
Torque" and the a forward gear, the
tractor is in
through the bleed oil manifold (G) to the main hydraulic
electrical solenoids marked "FWD" and "TRQ" are
reservoir.
activated.
During a right-hand turn, the left-hand wheel motor

The "FWD" solenoid pulls its pilot valve up and
shaft (S) turns faster than the right-hand motor shaft.
allows oil to flow through it to the left end of the
Since the left-hand motor receives oil from the control
direction valve (A A, Fig. 7). Oil forces the direction
valve first, that motor pumps oil.
valve to the right to open an oil passage to the torque
valve (K).
The control valve receives this oil before the right-
hand wheel motor. When oil pressure is excessive
Since the "TRQ" solenoid is activated, its pilot valve
opens
during the turn, the regenerative check valve (Z)
moves up through the valve to the right end
allowing oil
before the right-hand wheel motor receives excess
of the torque valve. This forces the torque valve to the
pressure oil
left, connecting the wheel motors in series.
Since the direction valve is in its right-hand position,

The torque valve blocks oil from the direction valve
the bleed oil check valve (J) is mechanically seated
to the right-hand wheel Oil flows to the left-hand wheel
preventing any oil flow to the reservoir.
(0), returns to the control valve, and passes through
directly to the right-hand wheel
Return oil from the lower right-hand wheel (U) is
routed through the control valve to the charge circuit
Since the wheels are operated in series, a "dif-
since return oil pressure is greater than charge pres-
wheels displace the
ferential lock" action results. Both
sure.
same oil. Therefore, neither wheel can slip without the
same slip on the opposite wheel Since oil flow is
one-half of parallel operational flow, the resulting
torque is also one-half of when each wheel receives
individual oil flow.
TM-1181 (Sep-77) Lftho in USA. Tractors - 4040 and 4240

Power Train Operation and Tests Power Front-Wheel Drive 250*30-9
A To Junction Manifold JNeutral Bleed Valve V Wheel Housing CCSotenoias and Pilot
B Cooler
Oil KTorque Valve Relief Valve Valves
C Main Hydraulic Pump L^L.H. Bleed Oil Una W Oil Manifold and DD Pressure Control Valve
(4 cu. in.) MTo Upper L.H. Pivot Pin Check Valve System Pressure Oil
DBleed Oil Manrfofd N Second Planet Ring Gear X To Upper R.K Series Wheel Pressure
Return Line 0Planetary Housing Pivot Pin Oil
E To Main Reservoir P First Planetary Assembly Y R.H. Bleed Line $M Charge Oit
F Pressure Regulating OSecond Planetary Assembly 2 Regenerative Lubrication Oil
Valve Housing RPlanet Brake Pistons Check Valve -$$0. Pressure-Free or
G Bleed Oil Manrfold SWheel Motor Drive Shaft AA Direction Valve Bleed Return Oil
H Neutral Bleed OH Line TTo Lower L.K Pivot Pin BBSurge Relief Valve
I Return Flow Check Valve UTo Lower R.H. Pivot Pin
7-Power Front-Wheel Drive Power \nd Oil RowsForward-Low Torque
TM-1181 (Sep-77) Litho in US. A, Tractors - 4040 and 4240

Forward-High Torque Since the direction valve (AA) is in its right-hand
When the
position
operating switch
and the
is set at the high torque
a forward gear; the "FWD"
tractor is in
solenoid is activated. Its pilot valve moves up and oil
flows through it to the left end of the direction valve
position, the neutral bleedcheck valve (J) is mechani-
cally seated preventing any return oil flow to the res-
ervoir. 4
Return oil from the lower pivot pin of each wheel (U
(AA, Fig. 8). This moves the direction valve to the right
and T) is routed through the control valve to the return
opening a passage to the torque valve (K). The torque
oil check valve. Since wheel motor return oil is greater
vaive is held in high torque position by spring force.
than charge oil pressure, the check valve opens to the
charge circuit.
Oil flows through the torque valve to the top of the
pivot pin on each wheel (M and X). Since pressure oil is
received by each wheel simultaneously (parallel flow),
high torque operation results and more pulling force is
attained.
Excess leakage in the wheel unit passes through a

tube the center of the pivot pin. From the pivot pin
in
reservoir.

R28328H
ATo Junction Manifold J Neutral Bleed Valve UTo Lower R.H. AADirection Valve
BOH Cooler KTorque Valve Pivot Pin BBSurge Relief Valve
CMain Hydraufic Pump LL.H. Bleed OU Line VWheel Housing CCSolenoids and Pilot
{4 cu. in.) MTo Upper L.H. Pivot Pin Relief Valve Valves
D Bleed Manifold
Oil N Second Planet Ring Gear WOil Manifold and DD Pressure Control Valve
Return Line 0 Planetary Housing Check Valve SeS: System Pressure Oil
E To Main Reservoir P First Planetary Assembly XTo Upper R.H. ^5^ Charge Oil
F Pressure Regulating QSecond Planetary Assembly Pivot Pin 1 Lubrication Oil
Valve Housing R Planet Brake Pistons YRH. Bleed Line i|f Pressure-Free or
GBleed Oil Manifold SWheel Motor Drive Shaft Z Regenerative Bleed Return Oil
HNeutral Bleed Oil Line TTo Lower L.H. Pivot Pin Check Valve
i Return Row Check Valve
Fig. 8-Power Front-Wheel Drive Power and Oil Flows - Forward-High Torque
TM-1181 (Sep-77) Utho in Ll&A Tractors - 4040 and 4240

250*30*12 Power Front-Wheel Drive Power Train Operation and Tests
Reverse-Low Torque Excess leakage in the wheel unit passes through a

tube in the center of the pivot pin. From the pivot pin
With the operating switch in low torque position, and
the tractor in reverse; the "REV" solenoid pulls its pilot
valve up to allow oil flow through the valve to the right
reservoir.
end of the direction valve (moving the direction valve to
the left).
During a left-hand turn, the right-hand wheel motor
shaft turns faster than the left-hand motor shaft (S).
The "TRQ" pilot valve directs oil to the right end of
Since the right-hand motor receives oil from the control
the torque valve (K, Fig. 9), moving the valve to left Oil
valve first, that motor pumps oil.
from the direction valve (AA) is directed to the bottom
of the right wheel (U).
The control valve receives this oil before the left-
hand wheel motor. When oil pressure is excessive

Oil flow through the right wheel returns to the control
during the turn, the regenerative check valve (Z) opens
valve, is routed directly to the bottom of the left wheel,
before the left-hand wheel motor receives excess
and returns to the control valve.
pressure oil.
Since both wheels displace the same oil, series

Since pressure oil is routed past the inner end of the
operation results. One wheel cannot spin more than
neutral bleed valve (J), its ball is hydraulically seated
the other, and torque is one-half that of parallel opera-
preventing any flow to the hydraulic reservoir from the
tion.
wheel motors.
Return oil from the upper left-hand wheel is routed

through the control valve to the charge circuit since
return oil pressure is greater than charge pressure.

ATo Junction Manifold J Neutral Bleed Valve V Wheel Housing COSolenoids and Pilot
BOil Cooler KTorque Valve Relief Valve Valves
CMain Hydraulic Pump L LH. Bleed Oil Line W Oil Manifold and DDPressure Control Valve
(4 cu. in.) MTo Upper L.H. Pivot Pin Check Valve Hydraulic System
DBleed Oii Manifold NSecond Planet Ring Gear X To Upper R.H. Pressure Oil
Return Line O Planetary Housing Pivot Pin ! Series Wheel
E To Main Reservoir PFirst Planetary Assembly Y RH. Bleed Line Pressure Oil
FPressure Regulating OSecond Planetary Assembly Z Regenerative Charge Oil
Valve Housing RPlanet Brake Pistons Check Valve | Lubrication Oil
G Bleed Oil Manifold SWheel Motor Drive Shaft AA Direction Valve 1 Pressure-Free or
HNeutral Bleed Oil tine TTo Lower LH, Pivot Pin BBSurge Relief Waive Bleed Return Oil
IReturn Row Check Valve UTo Lower R.H. Pivot Pin
Fig, 9-Power Front-Wheel Drive Power and Oil Flows - Reverse-Low Torque

Reverse-High Torque Excess leakage in the wheel unit passes through a

tube in the center of the pivot pin. From the pivot pin
With the shift lever in reverse and the operating
cap, the bleed oil lines (Land Y, Fig. 10) route bleed oil
switch in high torque, the "REV" solenoid pulls the pilot
through the bleed oil manifold (G) to the hydraulic
valve up to allow through the valve to the right end of
oil
reservoir.
the direction valve (AA, Fig. 10), pushing it left.
Since pressure oil is routed past the inner end of the

Oil flows through the direction valve. Since the
neutral bleed valve (J), its ball is hydraulically seated
torque valve is held to the right by spring force, oil flows
preventing any return oil flow from the wheel motors to
equally to each wheel (at the bottom of each pivot pin).
the hydraulic reservoir.
Since the oil flows in the opposite direction of for-

Return oil from the upper pivot pin of each wheel (M
ward, the wheel motors also turn in the opposite di-
and X) is routed through the control valve to the charge
rection of forward motion.
circuit since return oil pressure is greater than charge
pressure.

R2819QH
ATo Junction Manifold J Neutral Bleed Valve UTo Lower R.H. AADirection Valve
BOil Cooler K Torque Valve Pivot Pin BBSurge Relief Valve
CMain Hydraulic Pump LL.K Bleed Oil Line VWheel Housing CCSolenoids and Pilot
(4 cu. in.) MTo Upper LH. Pivot Pin Relief Valve Valves
DBleed Oil Manifold NSecond Planet Ring Gear WOil Manifold and
DD Pressure Control Valve
Return Line OPlanetary Housing Check Valve Wk System Pressure Oil
ETo Main Reservoir P Planetary Assembly
First X To Upper R.H. W0i Charge OH

F Pressure Regulating QSecond Planetary Assembly Pivot Pin fflB Lubrication Oil
Valve Housing RPlanet Brake Pistons YR.H. Bleed Line III! Pressure-Free or
G Bleed Oil Manifold SWheel Motor Drive Shaft Z Regenerative Bleed Return Oil
H Neutral Bleed Oil Line TTo Lower L.H. Pivot Pin Check Valve
IReturn Flow Check Valve
Fig. 10-Powe r Front-Wheel Drive Power and OH Flows - Reverse-High Torque

DIAGNOSING MALFUNCTIONS (GENERAL)

Front-Wheel Drive Not Engaging In Any Position Forward, Reverse, Low or High
Key off or key switch not working (See Section 240}
Circuit breaker not working (See Section 240)
Clutch pedal depressed Instruct operator
Clutch pedal switch not working (See Section 240)
Drive operating switch not working (See Section 240)
Shift lever switches not working (See Section 240)
Direction control valve stuck or (See 50-45-3)
spring missing or broken
Brake piston packings leaking (See 50-45-2)
Pressure control valve spring (See 50-45-3)
broken, weak, or assembled wrong
Transmission oil filter plugged Replace
Excessive motor leakage (See 50-45-11)
Low hydraulic pump output (See Section 270)
Front-Wheel Drive Engages In Forward But Not In Reverse, Or In Reverse But Not Forward
Electrical circuit malfunction (See Section 240)
Solenoid-operated pilot valve (See 50-45-3)
stuck or blown Oring
Direction valve stuck or spring (See 50-45-3)
broken
Front-Wheel Drive Operates Continuously In Forward Or Reverse, Regardless Of Shift Lever Position
Shift lever switch linkage discon- (See Section 240)
nected or switch not working
Blown O-ring or stuck spool on (See 50-45-3)
solenoid operated pilot valve
Direction valve stuck or spring (See 5CM5-3)
broken
Bent or mrssing coil return spring (See 50-45-3)
on top of solenoid valve plunger
No Or Low Torque In Reverse NeutraJ bleed valve stuck or check (See 50-45-4)
ball missing
Front- Wheel Drive Operates In High Torque "(Parallel) Only

Torque solenoid malfunction (See Section 240)
Electrical switch malfunction (See Section 240)
Torque solenoid-operated pilot (See 5<M5-4)
vaive or torque valve stuck
Front-Wheel Drive Operates In Low Torque (Series) Only

Torque solenoid malfunction (See Section 240)
Blown O-ring on torque solenoid (See 50-45-3)
valve sleeve
Bent or missing coif return spring (See 50-45-3)
on top of torque solenoid valve plunger
Torque solenoid valve or torque (See page 50-45-3)
control valve stuck

Power Train Operation and Tests Power Front Wheel Drive 250-30-17
DIAGNOSING MALFUNCTIONSContinued
Front-Wheel Drive Engages But Has Low Or No Torque

Plugged transmission oil filter Replace filter
Planetary brake slipping (See 50*45-2)
Piston slipper sealing rings leaking (See 50-45-11)
Exoessive wheel motor leakage (See 50-45-11)
Low pump output (See Section 270)
Pressure control valve pressure low (See 50-45-4)
or spring weak
Operating in low torque instead of Instruct operator
high torque (or possible switch malfunction)
Manifold check valve missing (See 50-45-11)
Hub Seal Leaks Or Relief Valve In Oil Manifold Blows (Pressure Buildup In Planetary Brake Housing)
Relief valve packing defective Replace packing (See 50-45-11)
Excessive wheel motor leakage (See 50-45-11)
Pivot pin drain tube seals leaking (See 50-45-6)
Bleed lines restricted Inspect and repair as necessary
Drive motors overspeeding inspect regenerative check valve
and check control valve pressure
Excessive valve plate leakage (See 50-45-11)
Brake piston packings leaking (See 50-45-2)
Front-Wheel Drive Continuously Engaged In Forward Or Reverse Regardless Of Switch Position

Electrical malfunction (See Section 240)
Cut O-ring on forward or reverse pilot valve cage (See 50-45-3)
Direction valve stuck (See 50-45-4)
Regenerative check valve bail missing (See 50^45-4)
External Leakage From Upper Or Lower Wheel Pivot Pin
Pivot pin tube sealing rings damaged Replace (See 50-45-6)
Excessive pivot pin or bushing wear (See 50-45-6)
Front Wheels Will Not Pull At High Speeds Defective hydraulic pump (See Section 270)
Pressure control valve setting high (See 250-30-18)
Pressure control valve orifice cocked (See 50-45-4}
invalve (spring not square)
Excessive internal leakage (See 50-45-11)
Valves Do Not Shift Electrical circuit open (See Section 240)
Rockshaft Raises Slowly Or Steering Is Hard

Pressure control valve sticking (See 50-45-3)
Pressure control valve improperly Adjust (See 250-30-18)
adjusted
TM-1181 (Sep-77) Ltiho in U.S.A. Tractors - 4040 and 4240

250-30-18 Power Front Wheel Drive Power Train Operation and Tests
TESTING

IMPORTANT: Do not overspeed PFWD wheels
while elevated. Damage to the motor pistons, valve
plate and bearing plate could result.
connecting lines, be sure to relieve ail pressure.
Before applying pressure to system, be sure all 1 . Check for leakage at the wheel oil manifold check
connections are tight and that lines, pipes and valve,
hoses are not damaged. Fluid escaping from a
small hole can almost be invisible. Use a piece of wheels off the floor, operating
a) With front
card board or wood, rather than hands, to search switch in and engine running at 2000
neutral position,
for suspected leaks. rpm; the wheels should turn freely by hand.
If injured by escaping fluid, see a doctor at once. locking or dragging

b) If is felt, excessive leak-
Serious infection or reaction can develop if proper age is suspected.
ly.
Refer to Section 240 for electrical system testing

procedure. The solenoids operate with an audible
"click" when they are operating properly,
A CAUTION: Always be extremely careful

when making tests around running ma-
chinery. Operate engine only during test. Block
tractor up sufficiently to prevent it from faffing
while making tests.
Testing Pressure Control Valve

1 - Run tractor to allow oil to heat to operating tem-
perature.
2. Install a 0-5000 psi (0-340 bar) (0-350 kg/cm a )

pressure gauge at the junction manifold plug (located
on the right-hand side of the clutch housing).
3. Check pressure control valve setting wrth front-

Fig. 1 1-Checking Bleed Leakage
wheel drive engaged and engine running at 1500 rpm.
2. Check for motor leakage. If the relief valve plug
Pressure should be 1930 to 1970 psi (133.1
a) -
frequently relieves pressure, excessive motor leakage
135,9 bar) (135.7-138.6 kg/cm 2 ).
is suspected.
b) If necessary, add or deduct shims in front-

a) Disconnect a bleed hose at the bleed man-
wheel control valve to obtain proper pressure,
and cap the
ifold fitting it was connected to using OTC
0030 Cap Nut.

Testing Bleed Leakage
A CAUTION: Be sure to observe all safety

precautions. Use a hoist (or a heavy-duty
splitting stand), not a jack, to raise the front of the
b)
c)
Route bleed
With the tractor

oil into
in
a container (Fig. 11).
3rd gear (Syncro-Range or

tractor. Place transmission in park position and Power Shift) or A-4 (Quad-Range), road test the tractor
use a jumper wire to engage the high torque sole* with power front-wheel drive engaged in high torque
noid. and measure leakage of each wheel bleed line.
d) Leakage should not exceed 3/8 gpm (1-1/2

qt./rrtin) (1.4 !/min) per wheel.

Steering/Brakes Operation and Test Specifications and Special Tools 260-00-1
Section 260
STEERING/BRAKES OPERATION
AND TESTS
Page Page
GROUP 00 SPECIFICATIONS AND Operation 260-05-4
SPECIAL TOOLS Neutral 260-05-4
Right Turn - Power 260-05-6
Special Tools 260-00-1 Left Turn - Power 260-05-8
Making Special Tools 260-00-2 Manual Turns 260-05-10
Left Turn 260-05-10
GROUP 05 - POWER STEERING Right Turn 260-05-12
Make-up Valves . . 260-05-12
Power Steering Components 260-05-1 Diagnosing Malfunctions 260-05-14
Metering Pump Assembly 260-05-2 Metering Pump Leakage Test 260-05-15
Steering Valve Assembly 260-05-2
Steering Motor Assembly 260-05-2 GROUP 10 - POWER BRAKES
Control Circuit 260-05-3
Pressure Oil Circuit 260-05-3 How The Brakes Work 260-10-1
Return Oil Circuit 260-05-4 Dual (Equalized) Braking 260-10-2
Individual Braking 260-10-3
Accumulator and Manually
Assisted Braking 260-10-4
SPECIAL TOOLS
TOOL NUMBER USE
\JDG-85 Used to perform Steering metering

Air Pressure pump leakage test
Test Kit
*Order From
Service Tools
Box 314
Owatonna, MN 55060
R80136A1
Fig. 1-Air Pressure Test Kit

260-00-2 Specifications and Special Tools Steering/Brakes Operation and Tests

*D-0120SAA Used to hold metering pump seal
Gear Puller during metering pump leakage test.
*::S^
Ir .
.i^'"".^.,'^..:-
; H|HHHi
IBP
;i |^.'
R800H?!
Fig. 2-D~Q120$AA Gear Putter
MAKING SPECIAL TOOL

1. Cut ends of 25 mm (1 in.) I.D. pipe with pipe
cutter to obtain a length of 180.97-182.56 mm (7.125-
15.88 mm 7.187 in.). File ends free of burrs.
f 9 (0.625 in.) I
2. Spot weld a 3.18 mm (0.125 in.) washer to one

end of pipe.
3. Cut a 15.88 mm (0.625 in.) square slot on other

end of pipe. File free from burrs.
3.18 mm (0.125 in.)
15.88 mm
{0,625 in.)
m
180.77-1 82.56 mm_
(7.125*7.187 in.)
R34594
A25.4 mm (1.0 in.) I.D. Pipe B^-3.1$ mm (0.125 in.)
Washer
Fig. 3-Metering Pump Seat Holding Too!
'Order From
Service Tools
Box 314
Owatonna, MN 55060
TM-1181 (Jun-80) Litho in USA Tractors - 4040 and 4240

Steering/Brakes Operation and Test Power Steering 260-05-7
Group 05
POWER STEERING
POWER STEERING COMPONENTS
R 29113N
A Metering Pump B Steering Valve C Steering Motor
Fig. 1-Power Steering System
The power steering system consists of a metering There are no mechanical linkages between the three
pump (A, Fig. 1) steering valve (B), and steering motor assemblies. Three hydraulic oil circuits provide control
(C). and power to the system.

260-05-2 Power Steering Steering/Brakes Operation and Test
Metering Pump Assembly The steering valve is a spool-type valve matched

with the valve housing (Fig. 3) to close tolerance. The
vaive, itself, contains seats, balls, and a spring to
provide for manual steering. An inlet check valve in the
housing traps oil in the steering circuits to also permit
ap manual steering when pressure oil is not available.
Check valves between return oil and control circuits
provide make-up oil for the control circuit to replace

"lost" oilin both power and manual steering opera-
tions. In manual steering operation, check valves allow

return oil to flow into the control circuit.
Three filters in the control circuit fittings and pres-

R 28305N sure oil circuit fitting maintain necessary clean oil into
the valve assembly.

A Metering Pump B Steering Wheel Shaft
Steering Motor Assembly
Fig. 2-Metering Pump
The metering pump (A Fig. 2) is an external gear-

T
type pump. is mounted and splined to the end of the

It
steering wheel shaft (B). The pump consists of a base,

body with gears, and cover. The body and gears are
matched together to provide closely fitted parts. Four
special fittings in the pump cover connect the pump to
the control and return oil circuits.
Steering Valve Assembly
A Spindle Arm C Feedback Piston

B Steering Motor Cylinder
Piston Cylinder
Fig, 4-Steering Motor Shown
The steering motor consists of a spindle, piston with

rack and a feedback piston. The feedback piston is
pinned to the steering motor piston with a spring-load-
ed pin and moves with the piston during a turning
operation.
X Fig. 3-Steering Vaive

Control Circuit Pressure Oil Circuit
Pressure oil from the main pump (D, Fig. 6) enters

the steering valve (B) and is directed to the steering
motor (C) to make a right or left turn. Pressure oil circuit
lines between vaJve and motor are alternate return
lines as turning direction is reversed.
R 29114N
AMetering Pump C Steering Motor

BSteering Valve
Fig. S-Controt Circuit
R2911S
Control trapped oil, Pressure and flow
circuit oil is
are generated within the circuit by turning the steering AMetering Pump D From Main Hydraulic
wheel and meshing metering pump (A, Fig. 5) gears. B Steering Valve Pump
This pressure and flow positions the steering valve (B) CSteering Motor
to direct pressure oil to the steering motor (C). The Fig. 6-Pressure Qit Circuit
feedback piston supplies oil to reposition or neutralize
the steering valve when steering wheel rotation is
stopped.

Return Oil Circuit OPERATION
R 29116N
A Metering Pump C Steering Motor

B Steering Valve DTo Oil Pressure R 29112N
Regulating Valve
Housing
Afeedback Piston CSpindle
Ftg. 7-Return Oil Circuit
BSteering Motor
Piston
Return oil from the steering motor (C, Fig.

circuit flow Fig, 8-Steermg Motor
passes through the steering valve (B)
7) piston cylinder
and metering pump (A) back to the hydraulic system Neutral
charging circuit. Return oil Is intentionally routed
In a neutral or no-turn situation, the steering valve
through the metering pump to warm control circuit oil
(A, Fig. 9) is held in the center of the valve housing by
and the metering pump.
the trapped non-flowing control circuit oil. Passages (C
and D) between valve housing (B) and steering motor

(E) are blocked by the centered valve. This prevents
pressure circuit oil flow to the steering motor. It also
traps oil between steering valve and motor and this
trapped oil on each end of the steering motor piston (F)

holds the piston and tractor front wheels in position.

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TM-1181 (Sep-77) Utho in USA, Tractors - 4040 and 4240

Right-Turn Power Oil in the right-hand of the piston cylinder is

through passage (D) to the steering valve housing. It
forced
As the steering wheel is turned to the right, gears (G flows through return oil gallery (P) and the return oil
and H, Fig- 10) in the metering pump (l) move control
T
circuit, out to the metering pump. The oil enters the
circuit oil out passage (J) to the steering valve housing
center of the gear (G) passes through the pump base
T
<B).
and out the center of gear (H). It unseats check valve
(R) and returns to the oil pressure regulating valve
The control circuit passes through the valve
oil
housing in the hydraulic system charging circuit.
housing to the left-hand end of the feedback piston (K).
At thesame time, flows through orifice (L) in the valve

oil in the right-hand end of the feed-
it
Control circuit
housing and moves the steering valve (A) to the left.
back cylinder is forced out by the feeback piston (F) as
Passage (C)opened to the pressure circuit inlet (M)
is
moves with the steering motor piston. The oil returns
it
and the left-hand end of the steering motor piston (F). through the left-hand side of the steering valve housing
Passage (D) is opened to the return circuit outlet (N) and into the metering pump at passage (S).
and the right-hand end of the steering motor piston.
When the right turn has been completed, or when
Pressure oil from the main hydraulic pump flows steering wheel rotation has stopped, control circuit
through inlet (M) out passage (C) to the left-hand end pressure in passage (J) on the right-hand end of the
of the piston (F), moving the piston to the right. In
steering valve (A) drops. Control circuit pressure in
moving to the right, the piston turns the steering motor
passage (S) caused by feedback piston movement,
spindle (O) clockwise and the spindle turns the tractor
acts through orifice (T) against the left-hand end of the
front wheels to the right.
steering valve. The valve moves to the right to a neutral
position, closing passages (C and D), and thereby
stopping the turning movement.

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TM-11&l1Gep=ZZlJ-ithin USA. Tractors - 4040 and 4240

260-05*8 Power Steering Steering/Brakes Operation and Test
Left Turn Power Return circuit oil from the left-hand end of the piston
movement
(F) is forced through passage (C) by piston
Turning the steering wheel to the left reverses the
and enters the valve housing return oil gallery (P), it
rotation of the metering pump gears (G and H, Fig. 11)

flows from the gallery to the center of metering pump
so that control circuit oil flow is through passage (S) to
gear (G) through the pump base and the center of gear
the left-hand side of the steering valve housing and
(H). The oil opens check valve (R) and flows out
right-hand end of the feedback piston (K). Control
through the return line to oil pressure regulating valve
circuit pressure through orifice (T) moves the steering
housing and the hydraulic system charging circuit.
valve (A) to the right, opening passages (C and D).
Control circuit oil at the left-hand end of the feed-
Passage (D) is now a pressure circuit passage to the
back piston (K) is forced out by feedback piston
right-hand end of the steering motor piston (F). Pas-
movement through the right-hand side of the steering
sage (C) is now a return circuit passage from the
valve, into the metering pump at passage (J).
left-hand end of the steering motor piston.
When the left-hand turn has been completed or

Pressure oil from the main pump passes through
when steering wheel rotation has stopped, control cir-
pressure inlet (V) out passage (D) to the right-hand
cuit pressure drops in passage (S) on the left-hand
end motor piston, moving the piston to
of the steering
side of the steering valve. Control circuit pressure in
the The piston turns the spindle (O) counterclock-
left.
passage (J), caused by feedback piston movement,
wise which turns the tractor front wheels to the left.
acts through orifice (L) to move valve (A) to the left to a
neutral position. This closes passages (C and D),
trapping oil between the valve housing and steering
motor, thereby stopping the left turn.

Outlet
Feedback Spring
Return Passage fnlet
Valva Valve
Valve Steering
Steering
of
Circuit i
Valva Circuit
Orifice Circuit
Circuit
Pump Steering
Circuit
i
Circuit
End Oil Valve anual
Ball anual
ake-Up ake-Up
leering
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Steerln
Housing
Piston Drive
Idler
Passage
c Inlet
Outlet
L.H. 2 Valve
to to
Gallery
to 0. Piaton Circuit
Motor Motor Orifice

Valve Valve Cylinder Cylinder Circuit
Pump Pump Pump ircult
o < >rlng
II
CD
Passage Passage
Pump
Stat
C C
Faedb
-Pressure
-Metering -Cuntrof -Feedbac -Spindle
-Metering -Metering
-Steering -Steering -Steering -Steering Housing
-Return -Return
Piston Piston
From
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Manual Turns and D), but also unseats manual steering check valve
This permits control circuit oil to flow through
ball (X).
When there is no inlet pressure oil to the steering
the center of the valve (A), out passage (D) to the
valve housing (B Fig, 12), the tractor can stili be turned
T
right-hand end of the steering motor piston (F). The

manually. The turn is still made with hydraulic pres-
force of the oil on piston (F) and feedback piston (K)
sure, but that pressure is generated by the physical
moves the piston to the left, turning the steering spindle
effort of turning the steering wheel.
(O) counterclockwise and the tractor front wheels to
the left.
The absence of inlet pressure oil allows inlet check
valve ball (V, Fig. 12) to be seated, thereby preventing
Control circuit oil in the left-hand end of the feedback
any oil in the steering system from entering the hy-
piston cylinder is forced out by piston movement to
draulic system pressure circuit.
return through the steering valve housing, through
passage (J) to the metering pump.
Left Turn
Just as in a power left turn, turning the steering Oil in the left-hand of the steering piston cylinder is
wheel to the causes metering pump gears (G and
left forced out to return through passage (C) to the return
H) to force control circuit oil out passage (S) to the oil gallery (P). in a manual turn operation, the oil does
left-hand end of the steering valve (A) and right-hand not return through the metering pump to the hydraulic
end of the feedback piston (K). system charging circuit Instead, it opens the right-
hand make-up valve (Z) and joins with control circuit oil
However, the force of the control circuit oil not only in passage (J). This insures a recirculating oil supply in
moves valve (A) to the right, opening passages (C the control circuit
TM-U81 (Sep-77) Litho in U.S.A. Tractors - 4040 and 4240

Steering/Brakes Operation and Test
Power Steering 260-05-11
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Right Turn Manual Oil in the right-hand end of the steering piston
A manual right turn is simitar to a manual left
except that control circuit oil flow direction is reversed

as are the movement directions of the parts of the
system.
turn
cylinder
return oil
joins returning
is forced out through passage (D) into the
gallery (P),
back piston for control

oil
opens make-up valve (ZZ) and
from the right-hand end of the feed-
circuit supply.
<
A "Make-Up" Valves
manual right turn on the steering wheel causes
metering pump gears (G and H, Fig. 13) to force The "make-up" valves (Z and ZZ) are not only
control circuit oil out passage (J) to the right-hand end needed in the manual steering operation. Hydraulic oil
of the steering valve (A) and left-hand end of the could be "lost" from the trapped control circuit during
feedback piston (K). power steering turn. In that event, return oil circuit
pressure is slightly higher than returning control circuit
The steering valve (A) moves to the left, opening pressure. This higher pressure opens either valve
passages (C and D). The control circuit oil also opens (depending on turning direction) and replaces the
the right-hand manual steering check valve (W) and "lost" oil. The make-up valves also admit oil to the
flows through valve (A) out passage (C) to the left- initial fill or after lines have been
control circuit for
hand end of the steering motor piston (F). The force of disconnected and re-connected.
the oil on piston (F) and on feedback piston (K) moves
both pistons to the right The steering spindle (O) is
turned clockwise and turns the tractor front wheels to
the right.

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TM-1181 (Feb-78) Lithe in USA. Tractors - 4040 and 4240

260-05*14 Power Steering Steering/Brakes Operation and Test
Slow Steering Response Or Hard Power Steering Wheel Creeps (Requires
Steering constant steering to maintain straight

travel) Creeps At Locks Excessively
Tractor not in motion Creeps In Manual Steering
Low hydraulic system pressure
Check hydraulic system pressure Steering motor feedback piston O-ring failure
Steering valve filters plugged or damaged Replace O-rings
Remove and clean or replace filters Metering pump shims torn, wrinkled or folded
Steering vafve feedback orifices plugged, eroded, or Replace shims
damaged
Remove and clean or replace filters Front Wheels Lock To One Side
Cold control circuit oil due to lack of return oil circula-
tion through metering pump Steering valve manual steering vaive seats, balls, or
Check steering vaive housing and return lines for spring failure
plugged or leaking conditions Replace vafve parts as necessary
Steering valve scored or damaged Steering valve scored or damaged
Remove valve and examine valve and valve bore Replace valve and valve housing
Internalleakage in metering pump
Disassemble and examine parts for wear or damage Steering Wheel Continues To Turn With
Steering motor piston slipper seal failure Wheels In Lock Position
Check steering motor piston and bore
Steering motor feedback piston pin stuck in steering Steering valve make-up oil valves or seats failure
motor piston or feedback piston pin spring failure Replace make-up valve(s) or steering valve housing
Check steering motor assembly if make-up valve seat{s) failure
Improper Pressure Hose Connection at Steering Wanders

the Attenuator
Steering motor feedback piston pin stuck in steering
Pressure line should be connected to the non-orificed motor piston
side of the tee Repair
Steering motor feedback piston pin spring failure
Loss Of Manual Steering Replace spring
Metering pump return oil check valve does not seal or Front Wheels Turn To A Sharper Angle
is missing In One Direction
Check valve for damage or foreign material
Internal leakage in metering pump due to wear or Steering motor spindle indexed incorrectly
damage Re-index spindle with front support
Disassemble and check pump parts for wear or
damage Up And Down Motion Of Steering Wheel
Steering valve inlet check valve seat, ball, or spring With Engine Running
failure
Remove steering valve inlet elbow and check valve Metering pump return oil check valve does not seat
assembly Check and replace if necessary
Steering valve manual steering vaive seats, balls, or
spring failure Erratic Steering Wheel Effort Feels Like
Remove steering valve and manual valve seats to "Lumpy" Oil
check
Steering valve make-up oil valves or seats failure Metering pump return oil check valve does not seat
Remove and examine Check and replace if necessary
Steering valve manual steering valve balls, seats, or
spring failure
Remove steering valve and manual valve seats to
check

Steering/Brakes Operation and Test
Power Steering 260-05-15
No Steering Feel METERING PUMP LEAKAGE TEST
Metering pump
Replace spring
Metering
friction
Pump Hose
spring failure
Failure
1.
described
Remove
in
steering column
Section 60, Group 05.
and metering pump as
Metering pump return oil check valve failure or missing

Check and replace if necessary
Damaged Metering Pump Return Oil

Check Valve
Metering pump friction spring failure
Replace spring
Oil Leakage In Control Support Or Out

Steering Column
Metering pump oil seal failure
Replace oil seal
Metering pump shims torn, wrinkled or folded
Replace shims
Internal Metering Pump Leakage

Shims torn, wrinkled or folded
Replace shims
A Nut E Retaining Ring
B Washer F Plate
Pump gears, body, base or cover worn or damaged C-Retaining Ring GWasher
Replace parts as necessary D Plastic Bushing H Oil Seal
* installation
Leakage Through Steering Motor Fig. U-Speciai Pipe
Bleed-Line
2. Remove plate (F, Fig. 14). Reinstall cap screws
Steering motor piston slipper seal failure and tighten to 35 ft-lbs (47 N*m}.
Check for cause of failure, repair and replace

3. Remove bushing (D), retaining ring (E) and
washer (B) from lower steering shaft.
Front Wheels "Twitch" On Start Up
Air in steering system 4. Use washer (B) to hold washer (G) and oif seal
Check (H) in place. Install Sower steering shaft.
for loose or damaged line connections
" Jerky" Steering *See "Making Special Toots" on page 260-00-2,
Air in steering system

Check for loose or damaged line connections

METERING PUMP LEAKAGE 9. Install hose from air nozzle to metering pump
TESTContinued connector.
CAUTION: DO NOT EXCEED 200 psi (13.8

bar) air pressure.
10. Apply air pressure to pump. Submerge pump in
clean solvent for five minutes or until air bubbles ap-

pear
11. If bubbles are seen, but source cannot be lo-
cated, cover pump with liquid soap and again apply air
pressure. This should make leaks easier to isolate.
12. Replace leaking parts and repeat test.
mm^M
A 1/2-20(F) JIC 7/16-20(M) JIC
Adaptor (0723) 0-16 Air Inlet
B9/1 6-1 8(F) JIC (0030) Cap (2 used)
C 1/2-20(F) JIC (6674) Cap
D Air Nozzle Connection
E Pressure Hose
F Special Pipe*
G D-01205AA Gear Puller
Fig. 15-Air Nozzle Hookup
5. Install special pipe (F, Fig, 15) over lower steer-

ing shaft. Use D-01205AA Gear Puller (G) to hold pipe
in place.
6. install 1/8 in. (M) NPT X 7/16-20(M) JIC D-1

connector on an air nozzle with a 1 /8 in. (F) NPT fitting.
7. Attach a 30-inch R-12 Pressure Hose to air noz-
zle and steering metering pump connection.
8. Place metering pump on clean, well-lighted

bench.
*See "Making Special Too!" on page 260-00-2.

Steering/Brakes Operation and Tests Power Brakes 260-10-1
Group 10
POWER BRAKES
HOW THE BRAKES WORK 0\\ pressure in the cylinders forces the brake pistons
(D) outward. Each piston forces its brake pressure
plate (B) outward forcing the brake disk (G) against the
brake backing plate (F).
Since the backing plate also has frictional facing and

the disk is splined to the sun pinion (E), wheel rotation
is braked.
ABrake Cylinder E Sun Gear

Pressure Plate F Backing Plate
C Brake Line G Brake Disk
DBrake Piston Pressure Oil
Fig. 1-Brake Operation
The brake valve assembly directs priority oil from the

main hydraulic pump to the three brake cylinders (A,
Fig. 1) which are located on either side of the trans-
mission case.

260-10*2 Power Brakes Steering/Brakes Operation and Tests
Dual (Equalized) Brakina
FB84S5S
A Left-Hand Rod FTo Right-Hand Brake KEqualizing Valve Pins

B Operating Valve G Operating Valve L Left-Hand Return Passage

C Equalizing Valve HInlet Check Valve MTo Sump
DTo Left-Hand Brake I Right-Hand Rod Jjy. Pressure Oil
E Equalizing Valve JOperating Rod Guide 01 Pressure-Free OH
Fig, 2-Equalizecf Braking (left-hand brake valve

opens stightfy before right-hanG valve)
Oilfrom the main hydraulic pump and accumulator with oil. Inlet oil is allowed past the valve (B) to the
overcomes iniet check valve spring pressure (H, Fig. 2) equalizing valve (E). Since that equalizing valve is
to enter the brake valve. Oil flow stops at each operat- open, oil is allowed to the other equalizing valve (C),
ing valve assembly (B and G). (This non-working
phase is not illustrated.) Since that equalizing valve was also opened by its
allowed past the late operating valve (G) to
pin, oil is
As both brake pedals are applied, uneven pedal that valve's brake (F).
pressure or adjustment could cause uneven braking-
However, during the first 3/4 inch (19 mm) of pedal If both operating valves are opened simultaneously,
travel; the operating rod guides (J) push the equalizing oil will each operating valve to its
flow directly from
valve pins (K) forward. respective brake. The equalizing valve passage will
also be open.
Then, if one operating valve (B) opens before the
other (G); the first valve will supply the second When the pedals are released, oil is allowed to
return to the reservoir through the return passage (L).

Steering/Brakes Operation and Tests
Power Brakes 260-10-3
Individual Braking
R28566N
A Left-Hand Rod Applied ETo Left-Hand Brake J Check Valve (open)

BOperating Rod Guide F Equalizing Valve (closed) K Brake Valve Plunger
COperating Valve GCheck Valve (closed) LTo Sump
D Equalizing Valve (open) H Oil Screen Pressure Oil
r inlet Check ffiBPressure-Free Oil
Fig. 3-tndividual Braking (Left-hand Brake Applied)
As one brake isapplied, its operating rod guide (B, the brake valve plunger (K) forward to open the brake
Fig. 3) pushes equalizing valve pin forward to open
its valve (C), Oil then allowed to flow to the left-hand
is
its equalizing valve (D). This occurs during the first 3/4 brake and to the right-hand equalizing valve. (Check
inch (19 mm) of pedal travel. valve [J] is forced open against spring pressure by the
pressure oil.)
Further pedal travel approximately 1/8 inch
(of
[3 mm]) causes the operating rod guide (B) to move Since the right-hand equalizing valve is closed, no
flow is allowed to that brake.

260-10-4 Power Brakes Steering/Brakes Operation and Tests
Accumulator and Manually Assisted Braking
RBB567S
AOperating Valve (open) EOperating Guide Trapped Oil

BCheck Valve (closed) F ManualBrake Piston I Pressure Free Oil
CPlunger GFrom Accumulator
D4nfet Check
F\g. 4-Accurnulator and Manually Assisted Braking
pressure to the brake valve is lost, the accu-

If oil Additional pressure on the brake pedal causes the
mulator inlet check valve closes. The accumulator operating guide (E) to move the brake valve plunger
contains a volume of trapped oil under pressure which (C), brake valve (A), and manual brake piston (F)
is available for brake operation. forward.
This oil provides normal power brakes for the first The brake valve seats at the rearward end of the
few applications. However, this pressure will gradually brake valve, stopping flow of oil to the reservoir. The
diminish, requiring more manual pressure to achieve manual brake piston then has the ability to manually
any braking action. increase the pressure of the trapped oil in the brake
valve to the brake cylinders.
With the accumulator oil supply partially depleted,
spring pressure closes the inlet check valve (D, Fig. 4).
The reservoir check valve (B) is also dosed. Oil is
trapped in the operating valve.

Steering/Brakes Operation and Tests Power Brakes 260-10-5
DIAGNOSING MALFUNCTIONS No Manual Brakes

Brake Pedal Settles in Right or Left Manual Brake valve plunger or plunger packing failure (See
60-10-2)
Brake disk piston leak (See 60-10-1) Brake valve piston or piston packing failure (See 60-
Brake valve plunger or plunger packing failure (See 10-2)
60-10-2) Inlet check valve failure (See 60-10-2)
Brake valve piston, seat, or piston packing failure (See Reservoir check valve failure (See 60-10-2)
60-10-4) Air in brake system (See 60-10-10)
Equalizer valve leakage (See 60-10-2) Brake piston packing failure (See 60-10-1)
Inlet check valve failure (See 60-10-2) Brake disk warpage (See 60-10-1)
Reservoir check valve leaking (See 60-10-2) Bleed screws open or leaking (See 60-10-10)
Air in brake
system (See 60-10-10)
Bleed screw open or leaking (See 60-10-10) Brake Facing Deteriorated
Accumulator pre-charge lost (See 60-10-6)
Warped brake disk (See 60-10-1) Contaminated oil (Flush and replenish)
Improper oil (Flush and replenish)
Poor or No Turning Brake
BRAKE ACCUMULATOR
Operating rod guide stuck down on opposite brake
(See 60-10-2) Testing
Equalizer valve leakage (See 60-10-2)
Brake piston packing failure (See 60-10-1) 1, With the engine stopped for no less than 15
Water in oil (Flush system with oil and replenish) minutes, apply the brakes five times at five second
intervals.
Improper oil (Rush system with proper oil and replen-
ish)
Bleed screws open or leaking (See 60-10-10) 2. If there are no power brakes in five applications
or less, there is a malfunction in the accumulator.
Individual Brake Won't Release
Right inlet valve leaking (See 60-10-2)

Left inlet y/a)ve leaking (See 60-10-3)
Orifice (12, Fig. 6) plugged (See 60-10-4)
Both Brakes Engage When

individual Brake is Applied
Operating rod guide stuck down on opposite brake

(See 60-10-2)
Equalizing valve or packing failure (See 60-10-2)
Brake Pedal Kick
Air insystem (See 60-10-10)

Brake disk warpage (See 60-10-1)
Brake operating valve orifice restricted (See 60-10-2)

260-10-6 Power Brakes Steering/Brakes Operation and Tests
Wt-1181 (Sep-77) Utho in USA, Tractors - 4040 and 4240

31 1
Hydraulic Operation and Tests Specifications and Special Tools 270-00-1
Section 270
HYDRAULIC OPERATION AND TESTS
GROUP 00 - SPECIFICATIONS AND Preliminary Checks (Power Shift
SPECIAL TOOLS Transmission) 270-1 0-29
Specifications 270-00-2 Power Transmission Charts
Shift 270-10-32
Special Tools 270-00-3 Test Data Sheet 270-10-48
Making Special Tools 270-00-8
GROUP 15 - MISCELLANEOUS HYDRAULIC
GROUP 05 - HYDRAULIC SYSTEM OPERATION COMPONENTS
How The Hydraulic System Works 270-05-1 HYDRACUSHIONED Seat 270-15-1
QUAD-RANGE Transmission 270-05-2 Checking Discharge Flow Rate 270-15-5
Power Shift Transmission 270-05-5 Testing Pressure Regulating Valve.., 270-15-5
Hydraulic System Valves 270-05-7 Adjusting Pressure Regulating Valve . 270-15-5
Valves In QUAD-RANGE Main Hydraulic Oil Reservoir 270-15-5
Transmission 270-05-7 Hydraulic Oil Reservoir 270-15-6
Oil Cooler Lube Check Valve 270-05-7 Hydraulic Oil Filter 270-15-6
Oil Filter Relief Valve 270-05-7 Hydraulic Oil Cooler 270-15-6
Return Oil Check Valve 270-05-8 Hydraulic Oil Attenuator 270-1 5-7
OilPressure Regulating Valve 270-05-8
OilCooler Check Valve 270-05-9
GROUP 20 - HYDRAULIC PUMP
Valves In Power Shift Transmission TransmissionPumps 270-20-1
Equipped Tractors 270-05-9
How The Pumps Work 270-20-1
Hydraulic Function Oil Filter
Operation of External Gear Pump
Relief Valve 270-05-9 (QUAD-RANGE)
Transmission Oil Fifter Operation of internal Gear Pump
Relief Valve 270-05-1
(Power Shift) 270-20-1
Oil Cooler Relief Valve Testing The External Gear Pump
270-05-12
Lube Relief Valve 270-05-12
(QUAD-RANGE) 270-20-2
Oil Pressure Regulating Valve 270*05-12
Testing The Internal Gear Pump
Return Oil Check Valve (Power Shift) 270-20-5
270-05-12
Pressure Circuit Valves Diagnosing Malfunctions 270-20-7
270-05-1
Pressure Control Valve Main Hydraulic Pump 270-20-8
270-05-14
Directional Control Valve 270-05-15
How The Main Pump Works 270-20-8
How The Directional Control Valve
Works 270-05-16 GROUP 25 - ROCKSHAFT AND
GROUP 10 - HYDRAULIC SYSTEM TESTS IMPLEMENT HITCHES
General Information 270-10-1
How The Rockshaft Works 270-25-1
How To Use Diagnosing Malfunctions 270-25-6
Step-by-Step Hydraulic
Diagnosis Charts Adjustment Checks 270-25-9
270-10-1
Safety Instructions Testing 270-25-14
270-10-2
Guide For Hydraulic Testing Rockshaft Air Leakage Tests 25-17
Fitting 270-10-3
Contents For Syncro-Range and Lift-Assist 270-25-21
QUAD-RANGE Transmission Power Weight-Transfer 270-25-22
270-10-6
Heating The Hydraulic Oil 270-10-7 GROUP 30 - SELECTIVE CONTROL VALVE
Preliminary Checks (QUAD-RANGE AND REMOTE CYLINDER
Transmission) 270-1 0-8 How The System Works 270-30-1
QUAD-RANGE Transmission Charts . . 270-10-10 Diagnosing Malfunctions 270-30-10
Test Data Sheet 270-1 0-27 Testing 270-30-1
Contents For Power Shift Selective Control Valve Air
Transmission Diagnosis 270-1 0-28 Leakage Test 270-30-14

270*00-2 Specifications and Special Tools Hydraulic Operation and Tests
SPECIFICATIONS
FTEM MEASUREMENT WEAR TOLERANCE
Hydraulic System Operation

Hydraulic system operating pressure 2000 psi (137.9 bar) (140.6 kg/cm 2 )
Hydraulic system standby pressure
With 3.0 cu, in. (49 mL) pump 2200 to 2300 psi (151.7 to 158.6 bar) (154.7 to 161.8
kg/cm 2 )
With 4.0 cu, in. (66 mL) pump 2250 to 2300 psi (154.7 to 158.6 bar) (158.2 to 161.8
kg/cm 2 )
QUAD-RANGE Transmission Valves

Oil filter relief valve 70 kg/cm 2 )first stage (differential)
psi (4.8 bar) (4.9
91 psi (6.3 bar) (6.4 kg/cm 2 )
second stage (differential)
Oil cooler relief valve 1 15 psi (7.9 bar) (8.0 kg/cm )
2

(to lube)
135 psi (9.3 bar) (9.5 kg/cm 2 ) (to sump)
4040 135-145 psi (9.3-10.0 bar) (9.5-10.2 kg/cm 2 ) (a 2000 rpm
4240 155-165 psi (1 1.0-1 1 ,3 bar) (1 1 .2-1 1 .5 kg/cm 2 ) & 2000
rpm
Power Shift Transmission Valves

Transmission oil filter relief valve 70 psi (4.8 bar) (4.9 kg/cm 2 ) differential
Oil cooler relief valve 1 1 5 to 135 psi (7.9 to 9.3 bar) (8.0 to 9.5 kg/cm 2 )
Lube relief valve 40 psi (2.8 bar) (2.8 kg/cm 2)
Oil pressure regulating valve 175 to 185 psi (12.1 to 12.8 bar) (12.3 to 13 kg/cm 2 )
Function oil filter relief valve 40 to
50 psi (2.8 to 3.4 bar) (2.8 to 3.5 kg/cm 2 ) differential
General Hydraulic System Tests and Diagnosis

Specifications for tests and diagnosis are given in Group 10 of this Section

Seat pressure regulating valve 290 to 320 psi (20.0 to 21 A bar) (20.4 to 21.8 kg/cm 2 )
Pressure Control valve operating pressure 1600 to 1700 psi (110.4 to 117.2 bar) (112.5 to 119.5
kg/cm 2 )
Hydraulic Pumps
Internal gear pump (Power Shift)
Operating Pressure 175-195 psi (12.1-13.4 bar) (12.3-13.7 kg/cm 2 )
External gear pump (QUAD-RANGE)
Clutch pressure test 4040 135-145 psi (9.3-10.0 bar) (9.5-10.2 kg/cm 2 ) < 2000 rpm
4240 155-165 psi (11.0-11.3 bar) (11.2-11.5 kg/cm 2 ) (a 2000
rpm
Main hydraulic pump
3 cu. in. pump (49 mL) Flow 23 gpm (87 L/min)
Standby pressure 2200-2300 psi (151.7-158.6 bar)
(154.7-161.8 kg/cm 2 )
4 cu. in. pump (66 mL) Flow 26.5 gpm (100 L/m)
Standby pressure 2250-2300- psi {155.2-158.6 bar)
(158.2-161.8 kg/cm 2 )

Hydraulic Operation and Tests Specifications and Special Tools 270-00-3
SPECIFICATIONS Continued
ITEM MEASUREMENT WEAR TOLEHANCE

Rockshaft Time Cycle Test
4240 2.5 to 2.75 seconds (75 rotation)
4040 2.39 to 2,68 seconds (75 rotation)
Rockshaft flow control va\ve flow;

4240 standard 10-11 gpm (37.85-41 ,64L/m)
with lift-assist 12-13 gpm (45.42-49.21 L/m)
Hi-Crop 8-9 gpm (30.28-30,07L/m)
4040 standard 8-9 gpm (30.28^30.07L/m)

with lift-assist 10-1 1 gpm (37.85-41. 64L/m)
Surge relief valve opening pressure 2650 to psi (182 J to 206.8 bar)
3000
(186.43 to 211.02 kg/cm )
Thermal relief vafve opening pressure 3550 to 3950 psi (244.8 to 272.4 bar)
(249.80 to 277.96 kg/cm a )
Remote Cylinder
Selective control valve Flow 3-16 gpm (1 1-60 l/min)
Remote cylinder extension Time 1 ,5-2.0 sec.
Stroke 8 in. (203 mm)
SPECIAL TOOLS
TOOL NUMBER USE
Hydraulic System Tests
*D-15017NU Hydraulic To check hydraulic fiow and

Flow Meter pressure
(NOTE; D-1074AA Hydraulic Flow Meter may also be

used)
ft 26977K Order From

Service Tools
Fig. 1-Hydrautic Flow Meters Box 314
Owatonna, MN 55060

270-00*4 Specifications and Special Tools Hydraulic Operation and Tests
TOOL NUMBER USE
*D-15027NU Universal To check hydraulic pressures.

Pressure Test Kit
*^f"*\*
flS^ *>
B%$42$
Fig. 2-Untversai Pressure Test Kit
D-15022NU Master To make hose and gauge con-

Hydraulic Fitting nections for hydraulic tests.
Flow Test Kit
$%&4$l^
Fig. 3-Master Hydraulic Fitting Row Test Kit

*Qrder From
Service Tools
Box 314
Owatonna, MN 55060

Hydraulic Operation and Tests Specifications and Specia Tools
l 270-00-5
TOOL NUMBER USE
A-100-240F (38-1 20*C) To check hydraulic

ature
oil temper-
Temperature Gauge
(Automotive type)
B-R-2 Hose - 1/2x48'

(Jumper Hose)
C-JD-293-5 and 6 To hold filter relief valve on its

seat during charge circuit ca-
pacity test. (Power Shift only).
\SB3S09t
Fig. 4-Misceflaneous Special Test Equipment
*JDH-53
XS
To remove filter relief valve.
Fitter Relief
Valve Removal Tool
R 28510N
Fig. 5-Fitter Relief Valve Removal Tool
Used for power shift transmission charge pump flow te$t r
*AJDH-58 Fitter Diverter Plate

**BAR75601 25 Micron Filter
**C R34766 Retaining Ring
**D R65892 Filter Retainer
**E R394 O-Ring (Two Used)
**F24H1227A Washer (Three Used)
**G R66064 1-7/8 in. Spring (Two Used)
**H 28H1656 1/2x1-1/4 in. Spacer
**l R65894 Micron Filter Screw
*\J T31170 Ported Filter Cover
*K 1365 Connector
*Order From *John Deere Service Parts

R34691
Service Tools
Box 314
Fig. 6-Housing and Filter Assembly for Charge Owatonna MN 55060
Pump Test

270-00-6 Specifications and Special Tools Hydraulic Operation and Tests
SPECIAL TOOLS^Continued
TOOL NUMBER USE
To test seat pressure regulating valve.
A0-600 psi (0-41.4 bar) Gauge*

BTest Hose*
C D-11 Fitting*
*From Universal Pressure Test Kit (See Fig, 2)
<i
r zbsitk
Fig. 7-Seat Pressure Regulating Valve

Test Tools
Hydraulic Pumps
See Fig. 1 page 270-00-3 D-15017IMU To check hydraulic flow and
Hydraulic Flow pressure.
Meter
See Fig. 2 page 270-00-4 D-15027NU To check hydraulic pressures.

Universal Pressure
Test Kit
See Fig. 3 page 270-00-4 D-15022NU To make hose and gauge con-
Master Hydraulic nections for hydraulic tests.
Fitting Flow Test
Kit

See Fig. 3 page 270-00-4 D-15022NU To make hose and gauge con-
Fttting Flow Test Kit
See Fig. page 270-00-3 D-15017NU To check hydraulic flow and

Hydraulic Row pressure.
Meter

Hydraulic Operation and Tests Specifications and Special TooJs 270-00-7
TOOL NUMBER USE
; .,
/
-&*
'^^'^'^''^"''''v.
.'v:--f^
u
'"Il'yj
jriHk.^^B^ ,-_
'''/#;- :
JDH-43 Rockshafl
Thermal Relief
Valve Test Kit
Test
mal
used to check the ther-
kit
valve, surge relief
relief
valve, and load capacity.
-pidi^ ,.;/ v^"' Ljjo:
PP^f^"
BSpSÊ
fc 27115N
F/g. 8-JDH-43 Rockshaft Thermal Relief Valve

Test Kit
John Deere Used to test surge relief valve.

Part #T37190
* 2SI36N
F/g, 9-Test Fitting
*JDG-B5 Used for rockshaft and selec-

Air Pressure tive control valve air leakage
Test Kit tests.
*Order From
Service Tools
Box 314
Owatonna MN 55060
RS0136A1
fig. 10-Air Pressure Test Kit

270-00-8 Specifications and Special Tools Hydraulic Operation and Tests

TOOL NUMBER USE
Selective Control Valve, Breakaway Coupler and Remote Cylinder

D-15017NU To check hydraulic flow and
See Fig. 1 Page 270-00-3
Hydraulic Flow pressure.
Meter
See Fig. 2 Page 270-00-4 D-15027NU To check hydraulic pressures.

Universal Pressure
Test Ktl
See Fig. 3 Page 270-00-4 D-15022NU To make hose and gauge con-
Fitting Flow Test
Kit
See Fig. 10 Page 270-00-7 JDG-85 Used for SCV air pressure leak
Air Pressure tests.
Test Kit

Obtain a R56741 pressure control valve body
1.
from John Deere Service Parts.

. Braze bleed-off orifice (A, Fig. 11) shut
2.
R80049G1
A Bleed-Off Orifice
Fig. 11 -Special Pressure Control Valve Body

Hydraulic Operation and Tests Hydraulic System Operation 270-05-1
Group 05
HYDRAULIC SYSTEM OPERATION
POWER SHIFT AND QUAD-RANGE TRANSMISSION
HOW THE HYDRAULIC SYSTEM WORKS
The hydraulic system is a closed-center, constant QUAD-RANGE Transmission
pressure system. The primary purpose of the system is
to provide high pressure oil to operate steering, brakes, Transmission Control and Charging Cir-
differential lock, rockshaft, and remote cylinders. The cuit
system is also inter-related with the power train to
lubricate, protect and provide low pressure oil for
When the engine
is running, a fixed-displacement
power train operation.

pump powered by a hex. shaft from the
(C, Fig. 1)
engine crankshaft, pumps oil from the main hydraulic
oil reservoir (transmission case) (A). Part of this
The tractor model, type of power train, and optional oil is
hydraulic equipment dictate hydraulic line routing pumped through a priority lube passage (D) to insure
component location and shape of the components in adequate lubrication transmission shafts and
to the
the system. The remaining oil flows through

differential shafts (U).
internal tubes and passages to the oil filter relief valve
housing (F) and hydraulic oil filter (E).
In general, the hydraulic system can be divided into
five circuits
The oil is filtered, then re-enters housing (F) and
flows on to the oil pressure regulating housing (I). After
1. Transmission pump and control circuit, under
the transmission controls (PTO, PERMA-CLUTCH and
intermediate pressure to operate the power train.
Hi-Lo) (J) requirements are satisfied, the remaining oil
A charge flows on to charge the main hydraulic pump (N),

2. circuit under low pressure to supply the
main pump with oil.
To meet the possible high requirement for the
oil
3. A lubrication circuit under low pressure

pressure circuit, most of the oil that is returned
from the
to lubri-
pressure circuit hydraulic functions, when they are in
cate the power train and coo! the hydraulic oil
use, is routed back into the charge circuit through a
4. A pressure circuit, under high pressure,
function return fine (HH).
to
operate the hydraulic functions: steering, brakes, dif-
ferential lock, rockshaft and remote cylinders and hy-
draulic seat.
5. A return circuit under intermediate pressure to

route function return oil back into the main pump
charge circuit.

270-05-2 Hydraulic System Operation Hydraulic Operation and Tests
Pressure Circuit Lubrication and Return Circuit

If one or more of the hydraulic functions, steering The oil from the charging circuit is then routed
(Z), brakes (CC), differential lock (Y), rockshaft (EE) or through the inlet side of the main pump (N), reservoir
selective control (FF), are in use, a demand for high (O) and the hydraulic oil cooler (P). The oil flows
pressure oil is created. The main pump goes
hydraulic through the oil cooler check valve (Q) and routed to the
into "stroke" (pumps oil) to satisfy the demand. lubrication reduction valve (R) and to lubricate power
train parts.
The main pump is a variable displacement, high
capacity pump that automatically provides as little or as Some oil is returned directly to the main reservoir,
much as required to meet the demands of the high particularly oil that has been bypassed by relief valves
pressure circuit. within the hydraulic system.
If none of the hydraulic functions are in use, there is
no demand for pressure oil and the main pump is in

"standby" (non-pumping condition). Oil to the functions
is "trapped" between functions and pump at a slightly
higher than system operating pressure (standby pres-

sure).
R34846 ,
A Reservoir (Transmission K Pressure Regulating WJunction BLock HH Function Return Line

Case) Valve XAttenuator U Function Return Check
B Sump Screen L Oil Cooler Relief Valve Y Differential Lock Valve
C Transmission Pump M Oil Cooler Relief to Lube ZSteering : High Pressure Oil
D Priority Lube N Main Hydraulic Pump AA Seat Position Valve ffi< Regulated Transmission
E Hydraulic Oil Filter 0 Auxiliary Oil Reservoir Housing Control Oil
F Filter Relief Valve Housing P Hydraulic Oil Cooler BB Brake Accumulator Low Charge Pressure Oil
G Filter Relief Valve QOil Cooler Check Valve CC Brakes Lube Pressure Oil
HFilter Relief to Lube R Lube Reduction Valve DD Pressure Control Valve
I Pressure Regulating Valve SClutch and PTO EE Rockshaft
Housing Operating Piston FF Selective Control Valve
J Transmission Controls T Lube Oil Check Valve GG Directional Control
(Hi-Lo, PTO U Transmission Lube Valves
and PERMA-CLUTCH) V Optional Power Front
Wheel Drive
Fig. 1 -Hydraulic System - Quad-Range Transmission

(System in Normal Operating Condition)

13
C 0]
TO
o
3
c
(0
i
111
Q>
a Lilu
O I
CO
I
f TT
I
I 1
en o
I
I
h
MM i i
00
1 I
II
o
cm s
Mrr
i
1 i
6
\l_
cauD
*~
c
3 5* at
p'JO
I I E E
51
3 =so s S
I 1 15I^
.a
saIIdc CO
83
111 Ig *c
m
""S
fig
!
c
f$ !
Q
I I I I
Qui U. O X a a H => > > > N


Charging Circuit high pressure created. The main hydraulic pump
oil is
When the engine is running, a fixed-displacement goes (pumps oil) to satisfy the demand.
into "stroke"
pump (C, Fig. 3), mounted on the front of the power The main pump is a variable displacement, high
train clutch pack and driven by the clutch shaft, pumps capacity pump that automatically provides as little or as
oil from the main hydraulic reservoir (transmission much as required to meet the demands of the high
case) (A). Part of the oil flows through an orificed pressure circuit.
passage (D) in the pump manifold to lubricate power If none of the hydraulic functions are in use, there is
train gears and parts. The remaining oil flows through no demand for pressure oil and the main pump is in
the transmission oil filter (E) to the oil pressure regu- "standby" (non-pumping condition). OW to the functions
latingvalve housing (F). is "trapped" between functions and pump at a slightly
Within the pressure regulating valve housing (F), the higher than system operating pressure (standby pres-
pressure regulating valve (K) regulates transmission sure).
pump pressure for power train operation. Oil is then
Return or Lubrication Circuit
routed to the main hydraulic pump (M).
from the hydraulic functions, when they are in
Oil
The oil from the charging circuit is then routed
use, returned to the charging circuit through the
is
through the inlet side of the main pump (M), reservoir
return oil filter (EE) and oil pressure regulating valve (N) and the hydraulic oil cooler (O). The oil flows
housing. through the oil cooler check valve (P) and routed to
lubricate transmission (Q).
Pressure Circuit Some oil is returned directly to the main reservoir,
If one or more of the hydraulic functions, steering particularly oil that has been bypassed by relief valves
(V), brakes (Y), differential lock (U), rockshaft (AA) and within the hydraulic system.
selective control valve (BB), are in use, a demand for
^^^^^^^^^^^^^^^^^r^mwm^m^m^^^
A Reservoir (Transmission K Pressure Regulating V Steering EE Function Return Oil Filter
Case) Valve WSeat Position Waive FFFunction Return Relief Valve
BSump Screen L Cooler Relief Valve Housing Housing
C Transmission Pump
M Main Hydraulic Pump
X Brake Accumulator GGFunction Return Check Valve
DPriority Lube N Auxiliary Cooler
Oil Y-Brakes
E Hydraulic niter
F Oil Pressure Regulating
O
P
Hydraulic Oil Cooler
OH Cooler Check Valve
Z Pressure Control Valve
AA Rockshaft
i
%*$ High Pressure Oil
Regulated Transmission
Control Oil
valve Housing Q Transmission Lube BB Selective Control Valve if Low Charge Pressure Oil
G Filter Relief Valve R Optional Power Front CC Directional Control Valve ?? Lube Pressure Oil
H Filter Relief to Lube Wheel Drive DD Function Return Line gtgf Pressure-Free Oil
I Lube Valve
Oil Relief SJunction Block
J Transmission Control T Attenuator
Valve UDifferential Lock
Fig. 4-Hydrauiic System - Tractors With Power Shift Transmission
(System in Normal Operating Condition)

1Lube Oil Check Valve 7-Ott Fitter Relief 11To Warn Reservoir 16Main Reservoir Inlet
2Oil Fitter Relief Valve Valve Housing 12To Lube Reduction Valve Screen
3Return Oil Check Valve 8Oil Fitter 13To Clutch Operating 17 Low Pinion Gear
4Oil Cooler Relief Valve 9 Pressure Regulating
Oil Bearing 18Orifice
5Oil Pressure Regulating Valve Housing 14From Oil Cooler ^t Regulated Pressure Oil
Valve 10Oil Cooler Check Valve 15To Main Hydraulic f Charge Pressure Oil
6Transmission Pump Pump and Oil Cooler ^:C Lube Pressure Oil
:
y
L^. Pressure-Free Oil
Fig. 5-Hydrautic Valves-Tractor with QUAD-RANGE Transmission

HYDRAULIC SYSTEM VALVES

Various valves are placed in the hydraulic system to Oil Filter Relief Valve (Plugged Filter Condition)
insure proper pressure, protect the hydraulic sys-
oil
tem, direct oil to the hydraulic functions and provide oil

for lubrication and cooling.
Valves In QUAD-RANGE Transmission

Equipped Tractors
Oil Cooler Lube Check Valve
R3485I
AOil Fitter Relief VaJve F Oil Cooler Return Line

B Filter Outlet GTo Pressure Regulating
C filter Inlet Valve Housing
DTo Oil Cooler Return H From Transmission Pump
Passage -S3& Charge Oil
E To Main Reservoir Lube Oil
W?M Reservoir Oil
Fig. 7-Oil Filter Relief Valve (Plugged Filter Condition)
The valve (A, Fig. 7) is located in the oil filter relief

valve housing, it operates on a pressure difference
R34850 between the inlet (C) and outlet (B) sides of the oil filter
(8, Fig. 5).
AOil Cooler Lube E Transmission Drive
Check Valve Shaft Lubrication
If a plugged filter or cold oil cause a pressure dif-
BLubrication Oil F Differential Drive
COil Cooler Lube Shaft Lubrication
ference that is 70 psi (5 Bar) (5.1 kg/cm 2 more in the
)
Line filter inlet (C, Fig. 5) than in filter outlet (B), the valve (A)
-ill Intake Oil
D Discharge Oil Lube Oil opens to passage (D) to route oil to the oil cooler return
,& Discharge Oil passage (F). If the difference in pressure increases to
91 psi (6 bar), (6.10 kg/cm 2), the valve opens further
Fig r 6-OH Cooler Lube Check Valve
(E) to route oil to the main reservoir.
The vaiVe (A, Fig. 6} is located in the transmission

pump manifold and prevents lubrication oil (B) from
entering the oil cooler lube line (C) when lubrication to
the transmission (E) and differential drive shafts (F) is
being supplied by the pump discharge (D).
Lube oil to the transmission and differential drive

shafts is supplied by oil when the oil
oii cooler lube
cooler lube pressure exceeds spring pressure and
oii
discharge pressure.
>
TM-1181 (Jun-80) Litho in US, A. Tractors - 4040 and 4240
A
Return OH Check Valve The valve (A, Fig. 9) is located in the oil pressure
regulating valve housing. It is used reduce high
to
pressure surges that couid damage the oil cooler and
If a pressure surge exceeds 1 1 5 psi {6.9 bar) (7,0

kg/cm*), the valve opens and bypasses oil to the
lubrication circuit (B). If pressure exceeds 135 psi (9.3
bar) (9.5 kg/cm 2 ) the valve opens further to bypass oil
to the main reservoir (C).
Oil Pressure Regulating Valve
R34852
A Return OH Check Valve Charge Oil
B Transmission Pump Oil Flow Return Oil

C Function Return Lube OH
Fig. 8-Retum Oil Check Valve
The valve (A, Fig. 8} is closed by spring force if there

is little or no return oil flow from the rockshaft or
selective control valves. This prevents transmission
R34854
pump flow (B) from entering the return circuit.
oil
When the
operation, the return
rockshaft or selective control valves are in
oil (C) from them opens the valve
A Oil Pressure Regulating
Valve
i
gg
Charge Oil
Lubrication Oil
and is added to the charging circuit flow.

BTo PERMA-CLUTCH WM Reservoir Oil
Operation
Oil Cooler Relief Valve Pressure Regulating Valve

Fig. 10-Oif
(Low Charge Pressure Shown)
The valve (A, Fig. 10) remains closed if pressure is

2
not greater than 145 psi (10 bar) (10.2 kg/cm ) on 4040
2
tractors or 165 psi (11.3 bar) (11.5 kg/cm ) on 4240
tractors. This insures oil pressure to the transmission

lubrication system.
The valve opens when pressure exceeds the above

pressures and permits oil flow to the main hydraulic
pump and oil cooler.
R34853
AOil Cooler Relief Valve Hi Control Circuit Oil

BTo Lubrication Circuit IB Charge Oil
CTo Main Reservoir $& Lube Oil
HI Reservoir Oil
Fig. 9-Oii Cooler Relief Valve <
(Pressure Above 1 15 psi)

Oil Cooler Check Valve Valves in Power Shift Transmission

Equipped Tractors
Hydraulic Function Oil Filter Relief Valve

The valve is located in the filter housing in the
transmission case. It operates on a pressure difference

between the inlet and outlet side of the filter.
R34855
AOil Cooler Check Valve ETo Lube Reduction Valve

Ball FTo Cfutch Operating
BUnfiltered Oil From Open Bearing
Filter Relief Valve MBLube Oil R 2B498N
CTo Low Pinion Lube &fi Pressure-Free Oil
D From Cooler Relief Valve AValve DTo Main Reservoir
BIntel Side iM& Charge Oil (From Functions)
Fig. 1 1-Oil Cooler Check Valve (PERMA-CLUTCH Type) COutlet Side SS
Pressure-Free Oil
(Off Fitter Relief Valve in Relief)
Fig. 12-Hydrautic Function Oil Riter Relief Valve
The oil cooler check valve found in both QUAD-
is (Plugged Fitter Condition Shown)
RANGE and Power Shift Transmission equipped trac-
tors. It is in the top of the clutch housing; the left-hand If a plugged filter or cold oil cause a pressure dif-
side on QUAD-RANGE
Transmission tractors, the ference that is 40 to 50 psi (2.8 to 3.4 bar) (2.8 to 3.4
right-hand side on Power Shift Transmission tractors. kg/cm 2 ) more on the inlet side (B, Fig 12) of the filter
than on the outlet side of the filter (C), the valve (A)
During normal operation return oil from the oil cooler
opens and routes function return oil to the main reser-
forces the valve bail (A) off its seat and flows into the
voir.
power train lubrication circuit.
If excessive differentialpressure has opened the oil The function return oil is not added to the charging
filter relief valve, flow to and from the oil cooler is
oil circuitunder these conditions. If a plugged filter is not
interrupted. The valve ball (A, Fig. 1 1) is forced on seat replaced, there could be an inadequate supply of oil to
by spring force. This permits the use of unfiltered oil (B) the main hydraulic pump, resulting in slow or loss of
for lubrication, but prevents unfiltered oil from entering hydraulic functions.
the main hydraulic pump through the oil cooler.

5
O_
o
S c tip ^
S 3
5ft* o i
5*5
.4 CC CO ^
JC CB = c tt r
9 5
s missis* c
.o 2
I I I I I
* _J 2 O
1

o ~ -= >
g a jc ^ o S
o Ua:
s
^ Ô
==
*3>> 5 -
|5g 0|o5
g' J C a c
55o4 *-
g|
h co > 0:0 O tt
II
u-
111
X_ C3 -5
c c
"5 * 5oo|>
c
1C IS E E E a
< ffl OOU1
TM-1181 (Jun-80) Litho in 1/.S.A Tractors - 4040 and 4240

Valves In Power Shift Transmission Equipped Tractors Continued

Transmission Oil Filter Relief Valve
R34857
AOil Cooler Relief Valve ETo Oil Cooler Return HE Charge Oil
BlnJet Side of Filter Lube Passages sgg Lube Oil
COutlet Side of Filter F Lube Relief Valve x?;< Pressure-Free Oil
DOil Cooler Relief
G From Transmission Pump
Valve Outlet HTo Transmission Control Vaive Housing
Fig, 1 ^Transmission Oil Filter Relief Valve
(Plug Fitter Shown)
The valve is located in the oil pressure regulating side, the vaive opens. Transmission pump oil (G) then
valve housing. It is placed
the charging circuit to
in bypasses the filter, passes across the lube relief valve
insure oil for lubrication to the transmission if a plugged (F) and flows through the oil cooler relief vaive outlet
filter or cold oil conditions exist. (D) to the oil cooler return lube passage (E).
The valve (A, Fig. 14) operates on a pressure dif- A plugged transmission oil filter condition must be
ference (caused by a plugged filter or cold oil) be- corrected as soon as possible. Oil flow to transmission
tween the inlet side (8) and the outlet side (C) of contro/ valve and the main hydraulic pump is inter-
the filter. When the difference is 70 psi (5 bar) (5.1 rupted, resulting in slow transmission and hydraulic
kg/cm 2 ) more on the inlet side than on the outlet function operation.
TM-1181 (Jun-80) Utbo in U.SA. Tractors - 4040 and 4240

Oil Cooler Relief Valve A Lube Relief Valve Regulated Pressure Oil
B Transmission Oil Charge Circuit Oil
Valve
Filter Relief Lube Oil
COil Cooler Relief Valve Reservoir or Pressure
D To Main Reservoir Free Oil
The lube relief valve (A, Fig. 16) is placed in the

system to protect the lubrication circuit.
If pressure from either an open transmission oil filter
relief valve (B) or oil cooler relief valve (C) exceeds 40

psi (2.8 bar) (2.8 kg/cm 2 ) the lube relief valve opens
and routes oil to the main reservoir.
Oil Pressure Regulating Valve
R34S58
A Oil Cooler Relief Valve ; Regulated Pressure Oil

B Outlet lit Charge Circuit Oil
C^-To Oil Cooler Hf Lubrication Oil
Return Lube Passage ffl Reservoir or Pressure-
D Lube Relief Valve Free Oil
Fig. 15-Oil Cooler Relief Valve (Pressure Above 135 psi)
The valve (A, Fig. 15) is placed in the system to

reduce high pressure surges that could damage the oii
cooler or main hydraulic pump.

A sudden increase in pressure over 135 psi (6.9 bar)
2
(7.0 kg/cm ) opens the valve and bypasses oil (B) to
the oil cooler return passage (C). The bypassing oii
pressure is also sensed at the lube relief valve (D).
Lube Relief Valve
R34660
AValve Charge Oil From

BTo Transmission Transmission Pump
Control Valves t Reservoir or Pressure-
Free Oil
Fig. 17-Oii Pressure Regulating Valve

(Transmission Pump Output below 1 75 psi)
The oil pressure regulating valve (A, Fig. 17) is

placed in the system to maintainoii pressure from the
transmission pump to the transmission control valve

(B).
If transmission pump oil pressure is below 175 to

185 psi (12.1 to 12.8 bar) (12.3 to 13 kg/cm 2 ) the valve
remains closed allowing oil flow only to the transmis-
sion control valves.
Under most operating conditions, the valve is open,

R34359 allowing oii to charge the main hydraulic pump or be
routed through the oil cooler.

Fig. 16-Lube Belief Valve

Valves In Power Shift Transmission The valve (A, Fig. 18) is held shut by spring force

Tractors Continued when there is little or no return oil flow (B) from the
Return Oil Check Valve rockshaft or selective control valves. This prevents
transmission pump oil flow (C) from entering the return
circuit.
When the rockshaft or selective control valves are in

operation, the return (B) from them opens the valve
oil
and is added to the charging circuit.
R34861
A Return Oil Check Valve 3g Regulated Pressure Oil

B From Hydraulic Function B| Charge Circuit Oil
Return Oil Filter %$ Lube Oil
C Transmission Pump Oil '."..;
Pressure-Free Oil
Flow
Fig. 18-Return Oil Check Valve
PRESSURE CIRCUIT VALVES
R 28495N
APressure Control Valve DOrifice GValve Spring

BValve Body EOrifice ||J| High Pressure Oil
C Function Outlet FFunction Return Oil Passage l Charge Oil
Fig. 19-Pressure Control Valve (Function Outlet Open)
Two valves in the high pressure circuit on both equipped tractors, control and direct oil flow and pres-
QUAD-RANGE and Power Shift Transmission sure to and from the hydraulic functions.

Pressure Control Valve
R 28496N
APressure Control Valve CFunction Outlet EOrifice GValve Spring

BValve Body DOrifice F Function Return &g Pressure Oil
Oil Passage Charge Circuit Oil
l
;-y Pressure-Free Oil
Fig. 20-Pressure Control Valve (Function Outlet Restricted)
The pressure control valve is used in the system to A demand forpressure oil by hydraulic function
insure pressure oil to steering, brakes, and the dif- operation will cause a pressure drop in front of the
ferential lock, regardless of the demands of the other valve. The valve spring (G, Fig. 20) moves the valve
hydraulic functions. forward to restrict the function outlet (C). The main
pump immediately goes into "stroke" to supply pres-
Thevalve (A, Fig. 19) is located in a bore in the sure oil to move the valve rearward, open the function
right-hand side of the rockshaft housing. outlet and pressurize the rockshaft and selective con-
trol valves.
When there are no demands for pressure oil, the
main hydraulic pump is in "standby." Pressure on both if the demand for pressure oil by steering, brakes or
ends of the valve (A) is equal. The valve is toward the hydraulic function is greater than what the main pump
rear of the valve body (B) and the function outlet (C) is can produce, the pressure difference between the rear
open. The rockshaft and selective control valves are of the valve and the front of the valve, moves the valve
pressurized. forward to restrict function outlet (C, Fig. 20). This
insures that pressure oil is available for steering, brake
Orifices (D) and (E) in the valve and in the body and differential lock valves until the pump can rebuild
allow oil to leak-off into the function return oil passage and pressurize all hydraulic functions equally.
(F) to prevent a hydraulic lock.

DIRECTIONAL CONTROL VALVE

The valve assembly (Fig. 21) is used in conjunction
with the lower right-hand selective control valve. When
a single-acting remote cylinder is powered by that
selective control valve, the directional control valve
hydraulically routes return oil from the remote cylinder
to the main reservoir. If a double-acting remote cylin-
der is powered by that selective control valve, the
directional control valve routes the return oil from that
cylinder to the charging circuit.
mimmmmm
A Directional Valve Housing BValve Plug
Fig. 21 -Directional Control Valve Housing
R 2&497N
ASingte-Acting Cylinder* DOrifice J Charge Circuit Outlet ;^: System Pressure Oil
Extend EValve Port Lower System
Slightly
BSingle-Acting Cylinder- F Pressure Oil Land KSpring Pressure Oil
Retract G Pressure Oil inlet Port LReservoir Outlet Port
C Double-Acting Cyfinder- HPressure Oil Outlet Port MSelective Control Valve MM Charge Circuit Oil
:
pij Reservoir or Pressure

Extend or Retract Return Oil Land Return
1
Oil Inlet Free OU
Fig. 22-Df'recHonal Control Valve Operation

HOW THE DIRECTIONAL CONTROL Double-Acting Remote Cylinders

VALVE WORKS Double-acting cylinder hoses are installed in both
Review selective control valve operation in Group 30 breakaway couplers of the right-hand selective control
of this Section. valve.
Single-Acting Remote Cylinder Extend or Retract - (C, Fig. 22)
The single-acting cylinder hose is installed in the Directional control valve operation is the same in the
left-hand breakaway coupler of the right-hand selec- extension or retraction of a double-acting remote cyl-
tive control valve. The right-hand breakaway coupler inder.
remains closed with dust plug in place.
The demand pressure oil to either extend or
for
Extend - (A, Fig. 22) retract the cylinder causes a pressure drop through
orifice (D). This permits inlet system pressure at the
As the selective control valve console lever is moved
bottom of the valve (E) to raise the valve and align
rearward extend the cylinder, the demand for pres-
to
pressure oil land (F) with ports (G and H) and return oil
sure oil creates a slight pressure drop through orifice
land (I) with port (J).
(D). This allows inlet system pressure working on the
bottom of the valve (E) to raise the valve and align
Pressure oil flows through the valve and selective
pressure oil land (F) with ports (G and H). The return oil
control valve to extend or retract the cylinder. Return oil
land (I) is aligned with the return oil charging circuit
from the cylinder flows out port (J) through the return oil
outlet port (J).
gallery in the rockshaft valve housing and rockshaft
housing out to the return oil filter relief valve housing
Pressure oil flows at a slightly lower system pres-
and the charging circuit.
sure through the directional control valve housing and
selective control valve to extend the cylinder.
Since there is no return oil from the cylinder, there is

no return oil flow through the directional control valve
housing to the charging circuit.
Retract (B, Fig. 22)
When the console lever is moved forward to retract

the cylinder, there is no demand for pressure oil.
Without oil flow, inlet system pressure equalizes on
both ends of the valve (E), allowing spring (K) to force
the valve down. Return oil land (I) is aligned with the
return oil reservoir outlet port (L).
Return oil forced out of the cylinder by the weight of

the implement, flows through the directional control
vaive out port (L) through the rockshaft valve housing
and into the reservoir.

Hydraulic Operation and Tests Hydraulic System Tests 270-10-1
Group 10
GENERAL HYDRAULIC SYSTEM TESTS AND DIAGNOSIS
GENERAL INFORMATION 2. Each sequence ends with a result. The result will
tell you what action to take and the next step to which
The following checks, diagnostic and test proce-
dures are provided to isolate hydraulic system and, in you should go.
some cases, power train hydraulic problems,
3. Work through each step of the diagnosis and
trouble shooting charts until the system is repaired.
Starting with preliminary checks, each procedure is
designed to isolate the problem to a general area, a

4. The test procedure based upon 100F (38C)
is
particular hydraulic circuit or a specific hydraulic com-
ponent.
and 150F (66C) reservoir temperature. However, if
oil
thereis a specific complaint that can not be isolated at
Use these procedures when there is a "no hydrau-

150F (66C), heat the oil to a maximum of 200T
(93C),
lics" complajnt, hydraulic functions are slow, hydraulic
oil is over-heated, or when major power train or hy-
draulic system repairs have been made. In all cases,
5.Use the record sheet (or copy of) on pages 27 or
follow the sequence and test specifications as given. 48 The numbers in parentheses
to record test results.
in the test sequence chart corresponds to the numbers
on the record sheet.

Hydraulic Oil Temperature
To insure test accuracy, it may be necessary to heat ABBREVIATIONS USED IN CHARTS
the hydraulic oil to a specified temperature. Use the
procedure on page 270-10-7 to heat the oil AFTER RS Rockshaft
performing Preliminary Checks on page 270-10-8, PCV Pressure Control Valve
SCV Selective Control Valve
HOW TO USE STEP-BY-STEP PTO Power Take-Off
HYDRAULIC DIAGNOSIS CHARTS SRT Syncro-Range Transmission
The charts that follow provide a step-by-step se- QRT QUAD-RANGE Transmission
quence to make preliminary checks and test and iso- PST Power Transmission
Shift
late hydraulic system and power train problems.

PFWD Power Front Wheel Drive
RPM Revolutions-Per-Minute
The charts on page 270-10-8 are used to make a LH Left-Hand
preliminary examination of the tractor. Often, a prelim-
RH Right-Hand
inary check will locate the problem. Make these checks
SPEC Specification
before installing any test equipment Pay particular
QT Quart
attention to the "CAUTIONS" on page 270-10-2.
PSi Pounds-Per-Square-lnch
GPM Gallon-Per-Minute
The next set of charts (pages 270-10-10 through
270-10-27) cover diagnosis of QUAD- RANGE Trans- IMPORTANT: In the test procedures, 1 psi lube
mission-equipped tractors.
pressure is used as a beginning reference for sev-
eral tests.
The third set of charts (page 270-10-29 through

If lube pressure is above 10 psi at slow idle, adjust
270-10-48) cover diagnosis of Power Shift Transmis-
engine speed to get the next higher gauge increment.
sion-equipped tractors.
If lube pressure Isbelow 10 psi at wide open throttle,

1. The charts are divided into three sections;
STEP-SEQUENCE-RESULT. Always start at the first continue to test at wide open throttle.
step and go through the complete sequence from left to
right.

270-10-2 Hydraulic System Tests Hydraulic Operation and Tests
PS1
3
METRIC EQUIVALENTS TO CHART SPECIFICATIONS
Bar
0.20
PSI
135
BAR
9.3
GPM
0.125
L/M
0.42
A
al injury
CAUTION: The
tions MUST be followed
following safety
or damage to test equipment:

precau-
to prevent person-
4 0.27 145 10.1 0.500 1.8 1. Securely tie open end of jumper hose in the oil
5 0.3 170 11.7 1.000 3.6 filler tube from selective control valve when heating
6 0.4 175 12.1 1.500 5.4 hydraulic oil or flow testing transmission pump.
7 0.5 180 12.4 2.000 8.2 2. When checking the transmission oil control cir-
9 0.6 195 13.4 5.000 18.9 cuits for leakage, follow these steps to be sure trans-
10 0.7 300 20.7 9.500 35.9 mission is in "tow."
12 0.8 500 34.5 10.000 37.9 A. At slow idle, depress the clutch pedal.
18 1.2 1500 103,4 10.500 39.7 B. Apply both brake pedals.
19 1.3 1600 110.3 1 1 .500 43.5 C. Shift to "D" Range
22 1.5 1700 117.2 12.000 45.4 D. Pull the shift lever rearward one detent position
25 1.7 2000 137.9 15.500 58.6 to "tow."
28 1.9 2200 151.7 16.000 60,5 E. Slowly release the clutch pedal,
60 4.1 2250 155.1 17.000 64.3 F. The brakes can now be released
for checking the
105 7.2 2300 158.6 18.000 68.1 2-speed oil circuits.
115 7.9 5000 344.7 23,000 87.1 G. After checks are complete, depress clutch pedal
26.500 100.3 and shift to "Park,"
H. Release clutch pedal.
Temperature Dimensions
10OF 38C 3/16 in. 4.762 mm Power Shift Transmission
110F 43C 3/8 in. 9.525 mm
150F 65.5C 10 in. 254 mm
240F 120C
SAFETY INSTRUCTIONS

skin, causing serious personal injury. Ffuid
escaping from a very smalt hole can be almost
invisible. Use a piece of cardboard or wood, rather
than hands, to search for suspected leaks.

medical treatment is not administered immediate- Ftg. W'Tow* Position - Power Shift Transmission.
ly.
1. Place "Tow" Lever in 'Tow" position (Fig. 2).
A
lines
CAUTION: Keep hands away from moving
parts. Shut engine off before checking
near moving parts.
A CAUTION: Before disconnecting lines, re-

lieve all pressure. Before pressurizing sys-
tem, be sure that alt connections are tight
A CAUTION: To avoid personal injury from

hot oil spills when installing test equip-
ment, use the procedure on page 270-10-7 to drain
auxiliary oil reservoir and oil cooler.

CROSS REFERENCE FITTING GUIDE FOR HYDRAULIC FLOW TESTING

No. D-15022NU Master Hydraulic Fitting Row Test Kit consists of the following fittings and hose assemblies.
Master
Kit No. OTC No. Nuday No. Description
MALE J.I.C. FITTINGS
6732 9/16 18M JIC x 9/16 18M JiC (two used)

6729 3/4-1 6M JIC x 3/4-1 6M JiC (two used)
6726 7/8 14M JiC x 7/8 14M JiC
6724 1-1/16 12M JIC x 7/8 14M JiC
0092 1-1/16 12M JiC x 1-1/16 12M JiC (two used)
6667 1-1/16 12M JIC x 3/4 16M JIC
6743 1-1/16 12M JIC 1-3/16 12M JIC
x
6736 45 Elb. 7/8^14MJIC x 7/8 14M O-Ring
2111 D-103 45 Elb. 7/8 14M
JIC x 1-1/16 12M JIC
6741 45 Elb. 1-3/16 12M JIC x 1-1/16 12M JIC
6731 90 Eib. 9/16 18M JIC x 9/16 18M O-Ring (two used)
6730 D
90 Elb. 3/4 16M JIC x 3/4 16M O-Ring (two used)
0017 90 Elb. 1-1/16 12M JIC x 1-1/16 12F JiC Swivel
FEMALE J.LC. FITTINGS
0770 D-96 1-1/16 12F JiC x 1-1/16 12F JIC Swivel (two used)
6676 3/8 24F JIC Cap Nut (two used)
0026 7/1620F JIC Cap Nut (two used}
6674 1/220F JIC Cap Nut (two used)
0030 9/1 & 18F
JIC Cap Nut (two used)
0020 3/4 16F JiC Cap Nut (two used)
1240 7/8 14F JIC Cap Nut (two used)
0022 1-1/16 12F JIC Cap Nut (two used)
1103 1-3/1612 JIC Cap Nut (two used)
MALE PIPE (NPT) FITTING
0007 D-83 1/2M NPT 30 Cham, x 1-1/16 12M JIC

6750 1/2M NPT x 3/4 16F O-Ring (two used)
0764 D-88 3/4M NPT x 1-1/16 12M JIC (two used)
FEMALE PIPE (NPT} FITTINGS
6735 1/2F NPT x 3/4 16M O-Ring (two used)

0763 1/2F NPT x
1-1/16 12M JIC
1747 3/4F NPT x 1-1/16 12F JIC Sw. (two used)
6734 1/2F NPT x 1-1/16 12F JIC Sw.
MALE SAE O-RING FITTINGS
2102 1/2 20M SAE O-Ring x 7/1620M JiC

0760 Y-3005 D-75 3/4 16M SAE O-Ring x 3/4F NPT Sw. (three used)
6749 JDH-46 3/4 16M SAE O-Ring x 3/4 16M JIC (two used)
0765 Y-3021 D-89 1-1/16 12M SAE O-Ring s/Siot x 3/4F NPT
1365 1-1/16 12M SAE O-Ring x 1-1/16 12M JIC
6737 45 Elb. 3/4 16M SAE O-Ring x 3/4 16M JIC
TM-1181 (Jun-80) Litho in US-A. Tractors - 4040 and 4240

CROSS REFERENCE FITTING GUIDE FOR HYDRAULIC FLOW TESTINGContinued

Master
6768 7/8 Spec. Tube 90 Ell w/Off Set

0831 90 Elb. 7/16 20M SAE O-Ring x 7/16 20M JIC
6677 3/824M SAE O-Ring Plug (two used)
6669 7/16 20M SAE O-Ring Plug (two used)
6670 1/220M SAE O-Ring Plug (two used)
6672 3/41 6 M SAE O-Ring Plug (two used)
6673 1-1/16 12M SAE O-Ring Plug (two used)
6863 1-1/16 12M SAE O-Ring x 3/4F NPT (two used)
7020 1-1/16 12M JIC x 3/4 16M ORB (two used)
-
FEMALE SAE O-RING FITTINGS
6744 9/16 18F SAE O-Ring x 7/8 14M JIC

0759 Y-3002 D-73 3/4 16F SAE O-Ring x 1/220F JIC (two used)
0758 Y-3003 D-72 3/41 6F SAE O-Ring x 9/16 18F JIC (two used)
6748 JDH-38 3/4 16F SAE O-Ring x 3/4 16F JIC & SAE O-Rrng (two
used)
6725 Y-3007 3/41 6F SAE O-Ring x 7/8 14F JIC (two used)
0757 Y-3001 D-71 3/4 16F SAE O-Ring x 1-1/16 12F JIC & SAE O-Ring (two
used)
0761 D-76 1-1/16 12F SAE O-Ring x 3/4M NPT (two used)
JJ.C. TEE FITTINGS
0766 1-1/16 12M JIC x 1-1/16 12F JIC Sw. x 1-1/16 12M JIC
SPECIAL FITTINGS
6739 Destroking Screw Short (small bushing) 2.4, 3.0, 4.0 Cu. in.
pump
6740
Destroking Screw Long (large bushing) 1 .38 Cu. in. pump
6568 55 Tube 1-1/16 12F JIC x 1-1/812 Thd.
6745 3/4 Tube 1-1/16 12F JIC x 1-1/8 O.D. x .562 t.D. Plug
6746 1-1/16 12M JIC x (2) 3/4 16F SAE O-Ring
6747 JDH-19A Crank Case Outlet Valve Tool 2.4, 3.0 & 4.0 Cu. in. pump
6752 Metering Steering Relief Valve Test Plug w/O-Ring
6738 Inlet Pressure 7/8 14M UNF x 7/1620F SAE O-Ring 2.4, 3.0
& 4.0 Cu. in. Pump
0714 SCV Plug x 3/4 16F SAE O-Ring (two used)
HOSES
2106 Hose w/Quick Disconnect

0094 Y-21-10 D-91 120" (R2) Hose w/1-1/16 12M JIC x 1-1/16 12F JIC Swivel
(two used)
6733 48" (R2) Hose w/3/4 NPT w/Rev. Hare
6794 6" Straight 3/4 Tube with 1-1/16 12F JIC Both Ends
6751 Comp. Metal Storage Box w/SKde Handles & Tote Tray
2488 90 Elbow - 3/4 Hose Fitting x 1-1/16 x 12M JIC

CROSS REFERENCE FOR CONSUMER PRODUCT TEST KIT

D-05168ST Flow Meter Test Kit, consists of the following:
Master
693-015 Flow Meter with 3000-psi gauge and needle valve

300106-24 24" Hose 1/2M NPT x 3/4 16F JIC
300106-48 48" Hose 1/2M NPT x 3/4 16F JIC
8HTX-5 3/4 16M JIC Union
D-15034NU Row Meter Fitting Kit, consists of the following:
0020 Cap 3/416 JIC (two used)

0022 Cap 1-1/16 12 JIC (two used)
0113 Elbow 90 3/4 16M JIC x 3/4 16F JIC Sw.
0714 Quick Disconnect Plug (two used)
0732 Storage Box
0765 Y-3021 D-89 Bushing 1-1/16 12M SAE x 3/4F NPT (two used)
1105 Plug 3/8 NPT (two used)
1560 Elbow 90 3/4 16M JIC x 9/16 18F JIC Sw.
7320 JDH^58 Oil Filter Diverter Plate
6497 Connector 1/2M NPT x 3/4 16M JIC (two used)
6667 Reducing Union 1-1/16 12M JIC x 3/4 16M JIC (two used)
6729 Union Connector 3/4 16M JIC x 3/4 16M JIC
6732 Union Connector 9/16 18M JIC x 9/16 18M JIC (two used)
6740 Destroking Screw
6745 Tube 3/4", 1-1/16 12F JIC Sw. x 1-1/8 O.D. Plug
6748 JDH-38 Coupling 3/4 16F SAE x 3/4 16F JIC (two used}
6749 JDH-46 Connector 3/4 16M JIC x 3/4 16M SAE (two used)
6794 Tube 6", 1-1/16 12F JIC Sw. x 1-1/16 12F JIC Sw.
6799 Connector 3/8M NPT 3/4 16M JIC (two used)
7126 Bushing 3/4M NPT x 1/2F NPT (two used)
7384 Quick disconnect Plug, 3/8 (F) NPT (two used)

8
1 7
6
1
270*10-6 Hydraulic System Tests Hydraulic Operation and Tests
CONTENTS FOR SYNCRO-RANGE AND QUAD-RANGE DIAGNOSIS

See page 270-10-28 for Contents for Power Shift Transmission Diagnosis
SteP Page
Heating the Hydraulic Oil 270-10- 7
Draining Auxiliary Oil Reservoir or Oil Cooler 270-10- 7
1 Preliminary Checks (SRT-QRT) *
270-10- 8
2 Installation of Test Equipment 270-10-10
3 High Pressure Leak to Sump or High Pressure Leak to Return Test 270-10-1
10 Selective Control Valve Leakage Test 270-10-13
1 Rockshaft Valve Leakage Test 270-10-13
12 Pressure Control Valve Inspection 270-10-14
13 Lube Reduction Valve Test 270-10-14
15 Element Leakage Test 270-10-15
17 Clutch Circuit Leakage Test 270-10-1
1 Clutch and Lube Pressure Test 270-10-1
20 Return to Sump Leak Test 270-10-1
22 Standby Pressure Test 270-10-17
24 Pressure Control Valve Test 270-10-18
27 Cooler Relief Valve Test 27CM0-19
29 High Pressure to Return Leak Test 270-10-20
31 Selective Control Valve Leakage Test 270-10-20
32 Rockshaft Valve Leakage Test 270-10-21
36 Charge Circuit Test (To Main Pump) 270-10-23
38 Transmission Pump Test 270-10-24
41 Lube Circuit Test 270-10-24
43 Main Pump Quick Check 270-10-25
45 Main Pump Test 270-10-26
Hydraulic Testing Record Sheet 270-10-27

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270*10-18 Hydraulic System Tests Hydraulic Operation and Tests
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.
HYDRAULIC TESTING RECORD SHEET
Hour Meter_
_
(For Jorm Oeer*
Hoder/Seriaf Ho.
^Hydraulic Problem _
agricultural tractors with ciosed-center hydraulic system)
Adjust the engine speed to gel 10 PSf Cube or main pump inlet pressure
to check for leakage at a component or clutch element.
Lube or Inlet Flew Meter
Pressure CPM
100T 150 3 F 100F 150F
Main Pump at Standby RPH d) (12)
Destroke Main Pump
(2) (13)
Depress CMeh Pedal (Rewrser: inlet Press. Decrease; Pwma-CUrtch: Lube Dip During Slow Engagement;)
(3) (14)
Engage PTO Clutch
{4} (14)
Engage PTO Brake
(4) (T4)
(Utility) Hi-Clutch (Utility) Forward Clutch
{4} (14)
(Utility) Lo-Brake {Utility) Reverse Brake
(4) (14)
(QRT) Shift to "Tow"* and 1st Gear (Release Clutch Pedal)
(4) (14)
(QRT) "Tow"* and 2nd Gear (Clutch Released)
W
4WD-Shift to Park. Disconnect speed change cable. Shift lo
w (14)
"A*",
(PST) "At Tow", Shift to Each Gear Indicated in Chart To Check Element (E)
Reservoir Oil Temperature Must Be At Least tOtfF
IDOT isrrF
RPM Pressure
Trans/ Clutch Pressure 2000** (5)
Lube or Main Pump Intel Pressure 2000" (6)

Lube or Inlet Pressure (Standby) 1500
X
(7)
Lube or Jnict Pressure (In Stroke) fiead/ust RPM; 1500 (8)
Return to Sump Leak Test: (7) Minus (8)
Main Pump Standby Pressure 2000 (9)

PCV Setting: Steady Pulsating ftOO (10)
Cooler or Surge Relief Valve Pressure 1000 Record lube pressure before and
(11) after
da pressing clutch pedal.
Lube Circuit Pressure Test 1500
07X;
Use the chart below with p$T gauge set
* Post-1980 Utility With Hi-U>:
Use 1500 RPM
PRESSURE
Flow (E) System Element Difference
Charge Circuit Flow to Main Pump
C1
(QRT-SRT 5 PSI Lube: Other Models 10 PSI Lube 2000 (15)
or Inlet Press, with SCV to Sump) F3 C2
FJ+tt C3
Trans/ Clutch Pump Row at Trans /Clutch Press. 2000 tiejxc' F3*i B1
Pump Quick
Main Test (In SCV, At Max. 1500 PSD 1000 Jis)xr F6^t
Main Pump Test (Across Main Pump at 2000 PSI) 2000 fi9><r 84
R3+++
NOTE: NUMBERS PARENTHESES ON RECORD SHEET CORRE-
IN
SPOND TO BOLO FACED NUMBERS IN PARENTHESES THROUGHOUT ff Four Gauge Method:
THE DIAGNOSING SEQUENCES IN THE TRACTOR TECHNICAL MAN- ttFront Accumulator
UAL AND ARE FOLLOWED BY A SPECIFICATION, ^tRear Accumulator
R34739

5
1
CONTENT FOR POWER SHIFT DIAGNOSIS

SteP
Page
Heating the Hydraulic Oil 270-10- 7
Draining Auxiliary Oil Reservoir or Oil Cooler 270-10- 7
1 Preliminary Checks (PST) 270-10-29
2 Installation of Test Equipment 270-10-31
3 High Pressure Leak to Sump or High Pressure Leak to Return Test 270-10-32
10 Selective Control Valve Leak Test 270-10-34
1 Rockshaft Valve Leakage Test !...!!.!!!! 270-10-34
13 Element Leakage Test 270-10-35
1 Clutch and Lube Pressure Test 270-10-37
18 Return to Sump Leak Test 270-10-3Q
20 Standby Pressure Test ][.[['.] 270-10-38
22 Pressure Control Valve Test 270-10-39
\
24 Installation of Flow Meter for Transmission/Charge Pump Test 270-10-40

25 Transmission (Charge) Pump Flow Test 270-10-41
28 Cooler Relief Valve Test ]]]]..] 270-10-42
30 High Pressure to Return Leak Test 270-10-43
32 Selective Control Valve Leakage Test ..]//.][].../.[.. 270-10-44
33 Rockshaft Valve Leakage Test *
270-10-44
]
35 Element Leakage Test *
270-10-44
37 Charge Circuit Capacity Test (To Main Pump) 270-10-45
39 Lube Circuit Test !..!!!!!!! 270-10-46
41 Main Pump Quick Check !..!!!"!! 270-10-46
43 Main Pump Test 270-10-47
Hydraulic Testing Record Sheet 270-10-46

Hydraulic Operation and Tests
Hydraulic System Tests 270-10-29
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.
HYDRAULIC TESTING RECORD SHEET
,
(For John Deere
Model/Serial No.
.Hydraulic Problem ^
agricultural tractors with closed -center hydraulic system)
i
Adjust the engine speed to get 10 P$r tube or main pump fnlet pressure
to check for leakage at a component or clutch efement. Lube or Inlet Flow Meter
Pressure GPM
100 F 150 F 100 F 15D F
Ma ifi Pump at Standby RPM d) (12)
Destroke Main Pump (2) (13)
Depress Clutch Pedal {Reverscr: Inlet Press. Decrease; Per ma -Clutch: Lube Dip During Slow Engagement;) (3} (14)
Engage PTO Clutch (4) (14)
Engage PTO Brake (4) (14)
(Utility) Hi-Clutch (Utility) Forward Clutch (4) (14)
(Utility) Lo- Brake (Utility) Reverse Brake (4) (14)
(ORT) Shift to "Tow"" and 1st Gear (Release Clutch Pedal) (4) (14)
f
(QRT) "Tow" and 2nd Gear (Clutch Released) (4) I (14)
4WD-Shifl to Park. Disconnect speed change cable. Shift to "A",
(PST) ""At Tow", Shift to Each Gear indicated in Chart To Check Element (E)
Reservoir Oil Temperature Must Be At Least 100~F
100 F 150 F
RPM Pressure
Trans/Clutch Pressure 2000" (5)

Lube or Main Pump Inlet Pressure 2000" (6)
Lube or Inlet Pressure (Standby) 1500
X
<7>
Lube or inlet Pressure (In Stroke) Readjust RPM: 1500 (8)
Return to Sump Leak Test: (7) Minus (8)
Main Pump Standby Pressure 2000 O)

PCV Setting: Steady Pulsating BOO (10)
Cooler or Surge Relief VaJve Pressure - Record lube pressure before and
1000 01) j
after
depressing clutch pedaL
Lube Circuit Pressure Test 1500 (")><
I Use the chart below with PST gauge set
* "Pc.it.1M0 Utility Wrfh Hi-Lo:
Use 1500 RPM
PRESSURE
Flow Gear (E) System Element Difference
Charge Circuit Flow to Main Pump F1 CI

(QRT-SHT 5 PSI Lube: Other Models 10 PSl Lube 2000 05)
or Intel Press, with SCV to Sump)
F3 C2
F3-^ C3
Trans/Clutch Pump Row at Trans/Clutch Press. 2000 fiej^cT
Mam Pump Quick Te*t
Main Pump Test (Across Main Pump

(In SCV, At Max. 1500 PSI)
at 2000 PSI)
tooo
2000
WXZ
p9>><r
F3^
*v
F6^
B1
B2
B4
R3-^ B3
NOTE NUMBERS fN PARENTHESES ON RECORD SHEET CORRE-
SPOND TO BOLD FACED numbers in parentheses throughout Nate: If Four Gauge Method:
THE DIAGNOSING SEQUENCES IN THE TRACTOR TECHNICAL MAN- -
-Front Accumulator
UAL AND ARE FOLLOWED BY A SPECIFICATION -Rea' Accumulator
R34739

Hydrauiic Operation and Tests Miscellaneous Hydraulic Components 270-15-1
MISCELLANEOUS HYDRAULIC COMPONENTS

Group 15
HYDRACUSHIONED SEAT
R 31158
APressure Regulating Valve ECylinder
BHeight Adjustment Valve F Dampening Adjustment Valve
CHeight Adjustment Lever GSeat
DAccumulator Pressure Oil
HI 300 psf (20.7 bar) (21.1 kg/cm*) Oil
Fig. 1 -Seat Being Raised
The hydracushioned seat is hydra ulically raised, down past the inlet passage to the hydraulic cylinder.
lowered and cushioned. A pressure regulating valve
Pressure oil then
allowed to flow to the cylinder (E).
is
(A, Fig. 1)reduces inlet pressure oil from 2250 psi to As the seat travels upward, it carries with it the
300 psi.Pressure oil is then directed to the seat height adjustment valve. When the large O.D. at the
position vaJve bore.
bottom of the valve (B) covers the inlet passage to the
When the height adjustment lever (C) is pulled up to cylinder, seat travel stops.
raise the seat, the height adjustment valve (B) is forced

270-1 5-2 Miscellaneous Hydraulic Components Hydraulic Operation and Tests
?- ; '?*'
7777 7TT 7.^?
; ,
R 31159
APressure Regulating Valve F Dampening Adjustment Valve

BHeight Adjustment Valve GSeat
CHeight Adjustment Lever Wf%$ Pressure Oil
DAccumulator 8^300 psi (20.7 bar) (21.1 kg/cm*) OH
ECylinder Kê Pressure Free OH
Fig. 2~Seat Being Lowered
When the height adjustment Jever (C, Fig. 2) is As the seat travels downward, it carries with it the
pushed down to lower the seat, the height adjustment height adjustment valve. When the large O.D. at the
valve (B) is pulled up uncovering the passage to the bottom of the valve covers the passage to the cylinder
hydraulic cylinder. Pressure oil in the cylinder is then seat travel stops.
allowed to discharge through the passage and on to
sump.

Hydraulic Operation and Tests Miscellaneous Hydraulic Components 270-15-3
////;/ /'/ \
R 31160
APressure Regulating Valve FDampening Adjustment Valve

B Height Adjustment Valve GSeat
C Height Adjustment Lever
DAccumulator HB Pressure Oil
ECylinder UK 300 psi (20.7 bar) (21.1 kg/cm2) Oil

Trapped Oil
Fig, 3-Seat in Stationary Position
When the seat is in the stationary position, the large An accumulator dampening adjustment valve (F) is
O.D. at the bottom of the height adjustment valve (B,
located between the hydraulic cylinder and accumula-
Fig, 3) covers the passage to the hydraulic
cylinder In tor.Manual adjustment of this valve determines the
this position no oil is allowed to enter or leave the amount of seat cushioning.

270-15-4 Miscellaneous Hydraulic Components Hydraulic Operation and Tests
p; z: :zz
/
/
/
/
/
/
/
/
/
/
/
/
/
AmÂ
ryyyy y~/_ R 31161
APressure Regulating Valve ECylinder

B Height Adjustment Valve F Dampening Adjustment Valve
C He ight
Adjustment Lever GSeat
DAccumulator .Pressure Free Oil
Fig. 4-Seat In Down Position
When the engine is shut off, pressure oil is no longer height control valve (B) the pin in the manifold unseats
supplied to the pressure regulating valve (A, Fig. 4). Oil the check ball in the valve. This allows the piston to
leakage past the height adjustment valve (B) allows the travel down the center of the valve. This movement
seat to descend. When the piston in the hydraulic compensates for cylinder travel without losing the
cylinder (E, Fig. 4) travels beyond the stroke of the height adjustment lever (C) position.

Hydraulic Operation and Tests Miscellaneous Hydraulic Components 270-15-5
DIAGNOSING MALFUNCTIONS Testing Pressure Regulating Valve
Low Lube Pressure fk CAUTION: Before removing plug from test

Check seal on the pressure regulating valve port in seat valve housing, sit on tractor
Check Discharge flow rate seat and move height adjustment lever up and
Examine ball check and spring down several times to make sure all pressure oil
has been discharged from housing.
Noise From Pressure Regulating Valve
Housing 1 . Remove plug from test port in seat valve housing,
Ch ^ck that pressure line is connected to orifice at

att< nuator
Ex imine input ball check and spring
Check that Identification mark on pressure regulat-
ing vafve is aligned with inlet port
Firm Ride
Check for proper rotation and stopping of ride con-
trol lever
Check for material under or in suspension linkage
Check accumulator pre-charge
Loss of Power or Slow Response

Check pressure regulating valve pressure
Check for plugged filter in infet valve
Checking Discharge Flow Rate

Excessive discharge oil flow from the seat valve
housing may indicate worn O-rings, valves, or an im-
properly adjusted pressure regulating valve. When Fig, 5-Testing Pressure Regulating Valve
discharge flow exceeds 1 pint/min. (473 cmVmin.) the
housing should be disassembled and inspected.
2. Install a 600 psi (34.5 bar) (35.2 kg/cm2 ) gauge in
test port (Fig. 5).
1. Disconnect discharge hose from top of clutch
housing.
3. Start tractor and note gauge reading. Pressure
should be 290 to 320 psi (20.0 to 21 A bar) (20.4 to
2. Place end of hose in a suitable container.
21.8 kg/cm*).
3. Start tractor, and do not allow anyone to sit in

seat or operate the seat control levers. Measure leak-
age over a 1 minute period.
If discharge flow exceeds 1 pint/min. (473 cm 3 /

min.), disassemble valve housing and inspect valves
and O-rings.
TM-1181 (Feth78) Lhho in U.S.A. Tractors - 4040 and 4240

Continued
*
Regulating Valve Hydraulic Oil Reservoir
Adjusting Pressure Regulating Valve
1. Remove suspension front cover.
Fig. 6-Seat Position Vaive Housing

A Reservoir BCheck Valve
2. Remove cap screw securing valve lock plate to
Frg. 8-Hydraufic Oil Reservoir
top of valve housing (Fig. 6).
3* Remove plug from vaive bore, and add or sub- Additional charge oil is provided to the main pump
tract washers as necessary. Install a new O-ring on from the oil reservoir (A, Fig. 8). An air check valve (B)
plug before final assembly. prevents hydraulic oil from entering the air bleed line.
NOTE: Addition of one washer increases pressure

Hydraulic Oil Filters
15 psi (1,03 bar) (1.05 kg/crrf).
Main Hydraulic OH Reservoir
Fig. 9-Hydraufic Oil Fitter - Quad-Range Transmission
Tractors with a Quad-Range transmission are

equipped with one 10-micron hydraulic oil filter that
filters hydraulic function return oil and transmission
pump charging oil.
Fig. 7-Main Reservoir Filler Tube
The transmission case serves as the main hydraulic

reservoir. A mesh screen in the bottom of the case and
attached to the transmission pump iniet tube partially
filters reservoir oil. The tube with
reservoir filler
breather cap extends through the rocks haft housing at

the rear of the tractor.

Miscellaneous Hydraulic Components 270-1 5-7
Hydraulic Oil Attenuator
AHydraulic Function Return BTransmission Pump

Oil Fitter oil Fitter
Fig. 12-Hydraulic Oil Attenuator
Fig, 10-Hydraulic Oil Filters - Power Shift Transmission
The hydraulic oil attenuator is a small tank used in
Power Transmission equipped tractors are
Shift the pressure oil circuit to baffle and suppress hydraulic
equipped with two 1 0-micron filters; one filters function pressure oil flow sound.
return oil, the other filters transmission pump charging
oil.
Hydraulic Oil Cooler
Fig, 11 -Hydraulic Oil Cooler
Charging circuit oil not needed by the main hydraulic

pump is circulated through the hydraulic oil cooler.
The oil cooler is similar to a radiator and is designed
to maintain hydra uJic oil temperature at not more than
100T (37.7C) above air temperature.
The oil cooler is integral with the air conditioning
condenser on tractors equipped with air conditioning.


Hydraulic Operation and Tests Hydraulic Pumps 270-20-1
Group 20
HYDRAULIC PUMPS
TRANSMISSION PUMPS Since oil is trapped between the pump body and the
How The Pumps Work gear teeth, it is forced into the outiet of the manifold
and into the discharge outiet (B).
The hydraulic system
charged and the power train
is
is lubricated by one of two types of transmission A passage coming off the discharge outiet (C) per-
pumps. mits flow to lubricate the transmission drive shaft (D)

oil
and differential drive shaft (E). Lube ofl to the trans-

Operation of External Gear Pump mission and differential drive shafts is supplied by oil
(Quad-Range Tractors) cooler lube oil (G) when the oil cooler lube oil pressure
exceeds spring pressure (F) and discharge pressure.
A fixed-displacement, external-gear pump is used
on Perma-Clutch equipped tractors. The pump is Pump discharge pressure is 140 psi (9.6 bar) (9,7
mounted in the differential compartment of the trans- kg/cm 2 ) on the 4040 and 160 psi (11,0 bar) (11.2
mission case. kg/cm a ) on the 4240 Tractor.
Operation of Internal Gear Pump

(Power Shift Tractors)
R 26485N
A Pump Body O-CJutch Pack

BClutch Oil Manifold D Pump Housing
R2B481H Fig. 2-trrternai Gear Pump (Power Shift Tractors)
AFrom Reservoir FOil Cooler Lube Check
B Discharge Oil Valve Spring On Power Shift Transmission equipped tractors, the
C Lube Passage G From Oil Cooler interna! gear pump ismounted at the front of the
0 Transmission Drive HOrifices transmission clutch pack and is constantly driven by
Shaft Lube flfllritalre Oil
E Differential Drive SgaLube Oil
the clutch drive shaft. It is a fixed, positive displace-
Shaft Lube HI Discharge Oil ment pump.
Fig. 1 -External Gear Pump (Quad-Range Tractors) The drive gear is a spur gear which meshes with the
The pump drive gear is driven counterclockwise by a
larger diameter, Internal gear on one side of each gear.
long hex. shaft which fits In the drive gear. The hex.
shaft is connected to the engine crankshaft with an
adapter. As the idler gear meshes with the drive gear, it
turns in the opposite direction of the drive gear. Oil is
lifted from the reservoir through the intake tube into the
pump manifold (A, Fig. 1)
TM-1181 (Feb-78) L'ttho in USA, Tractors - 4040 and 4240

.
270-20-2 Hydraulic Pumps Hydraulic Operation and Tests
Internal Gear Pump Operation Continued Testing the External Gear Transmission
separated by a
each gear
Pump (Quad-Range)
The opposite side of is
crescent. Since the spur gear is driven by the clutch

shaft, and the larger diameter internal gear is free to
rotate; the outer gear is driven in the same direction as
the spur gear (counterclockwise).
Fig. 4-Testing Lubrication Pressure (Quad-Range)
1 a 0-60 psi {0-5 bar) (0-5 kg/cm 2 ) pressure

Install
X28505IS
gauge at the lube pressure test plug which is located
AInlet FTo C1
on the oil filter relief valve housing (Fig. 4).
B Oil to Filter GTo C2
CTo PTO HN Operating Pressure
D Priority Oil (to F Oil 2. Check lubrication pressure with the engine run-
and 1} Charge Oil ning at 1500 and at 2000 rpm. Specifications are given
E From Cooler to Trans- %$& Lubrication OH in the following chart.
mission Shafts IBS. Pressure Free Inlet
Oil
Fig. 3-Transmission Pump Flow (Power Shift Tractors)
Engine Speed 110 p F{43C)Oil 150F {66C> Oil
As the gear teeth come out of mesh, oil lifted out of (1.7 bar) (1.1 bar)
the reservoir is forced out the pump outlet and through (1.8 kg/cm 2 ) (1.1 kg/cm 2 )
the oil filter to the oil pressure regulating valve housing 2000 rpm 43 psi 28 psi
(Fig. 3). (3.0 bar) (1.9 bar)
The pump supplies oil to operate the transmission, (3,0 kg/cm 2 ) (1.9 kg/cm2)
charge the main hydraulic pump, and to lubricate the
transmission gears and bearings. Priority lubrication is
built into the pump for the transmission.
Testing and Diagnosis

See Group 10 of this section for proper test pro-
cedure, special equipment required for testing, and
diagnosis for any hydraulic problem prior to attempt-
ing to isolatea hydraulic charge problem.
Perform the following test procedures after high
pressure system has been checked. Standby pressure
should have been checked and the pressure control
valve should be operating properly. There should be no
high pressure or return circuit leakage and clutch
pressure should have been adjusted to proper specifi-
cations.

Hydraulic Pumps 270*20-3
Jfc#1 Fig. 6-Flow Meter Outlet to Main Pump
AClutch Pressure Gauge D2102 Fitting

BLube Pressure Gauge E0094 Hose
C2106 Hose with F0017 Elbow
Disconnect
Fig. 5-Ffow Meter and Gauge inlet Connections (Quad-Range)
/t CAUTION: Escaping fluid under pressure

* can have sufficient force to penetrate the
connecting lines, be sure to relieve afl pressure.
Fluid escaping from a very small hole can almost
rather than hands, to search for suspected teaks.
ff injured by escaping fluid, see a doctor at once.

ft 2g3afc
ly.
Fig, 7-Opening Hydra-Analyzer Flow Control Valve
3. a pressure gauge in the clutch pressure
Install
test port which is located on the oil pressure regulating 5, Open the flow meter flow control valve all the
valve housing. way.
Connect a flow meter between the oil pressure

4.
regulating valve housingand the main hydraulic pump
(Figs. 5 and 6).

.
270-20-4 Hydraulic Pumps Hydrauiic Operation and Tests
Testing the External Gear Transmission

Pu m p Co nti n ued
Fig. Âdjusting Selective Control Metering Lever
13. Adjust the left-hand selective control valve me-

8-Jumper Hose Connections tering lever to obtain 4-6 psi (0.27-0,41 bar) (0.26 to
Fig.
0.40 kg/cm*) lubrication pressure. (This step prevents
the cooler relief valve from opening to the lube circuit or
6. Install a jumper hose in both sides of the lower
right-hand selective control valve. Place the selective to the reservoir.
control valve metering lever at maximum flow.
7. Install a jumper hose in the left-hand side of the

left-hand selective control valve and tie its open end
securely into the oil filler tube.
8. Place the left-hand selective control valve me-

tering lever at minimum flow.
9. With ail control valves in neutral and the engine

running at 1000 rpm, turn the flow meter flow control
valve in until the pressure increase hesitates.
1 0. The hesitation indicates cooler relief flow to the

main hydraulic reservoir. If this relief pressure is not
within 115-135 psi (8.7-9.3 bar) (8.9-9.5 kg/cm 2 ), in-
spect and repair the cooler relief valve as necessary to
obtain proper operating specifications,
1 1 Operate the engine at 2000 rpm. Minimum flow

is 10.5 gpm (39.7 1/min) at 110F (43C), and 12.5
gpm (37.9 1/min) at 150T (66C).
A PTO Lever Released BClutch Pedal Released
CControl Levers in Neutral
12. Move the left-hand selective control valve con-
trol lever rearward and adjust engine speed to 2000 Fig, 10-Control Levers In Neutral Position (PST Shown)
rpm.
14. With engine running at 1000 rpm, engage and
disengage the PTO clutch (A, Fig. 10) noting any lube
pressure or ffow change.

.

Hydraulic Pumps 270-20-5
15. Engage the clutch (B) very slowly.

Note any dip 21. Move the left-hand selective control lever rear-
in lubrication pressure
10-20 psr (0.7-1.4 bar) (0.7-
at
ward to route some high pressure oil to the reservoir
1.4 kg/cm 2 ) on the clutch pressure gauge.
and adjust engine speed to 2000 rpm.
a) If the lubrication pressure dips during
dutch 22. Adjust the left-hand selective control valve
engagement, the fube reduction valve is me-
tering lever to obtain 4-6 psi (0.27-0.41 bar) (0.26-0.40
operating property.
kg/cm2) lubrication pressure. Flow should be at least
b) If lubrication pressure did not dip during 12 gpm (45.7 l/min) with oil at 150F (66 D C)
dutch engagement (at 10-20 psi clutch 23. If flow is iow:
pressure), the lube reduction valve is stuck a) Inspect filter relief valve housing and gasket
and should be repaired.
and repair as necessary.
16. Depress and release the dutch pedal (B) noting b) If filter relief area is normal, see External
any flow change.
Gear Transmission Pump Repair. Be sure to
17.With the tractor in "TOW", note any pressure or
inspect inlet and outlet pipes.
flow change as the Quad-Range hf-lo is
shifted from 24. If flow is normal, but flow and lube pressure
1-2.
were low prior to moving flow meter to filter relief
18. An engaged element (in steps 13-15) has ex- housing;
cessive circuit leakage if;
a) Inspect clutch-to-pressure regulating valve
a) Lubrication pressure changes more than 3 gasket and repair as necessary.
psi (0.2 bar) (0.2 kg/cm 2 ) after the control
b) On Quad-Range Tractors, inspect and re-
lever is moved to engage another element.
place two-speed planetary adapter O-rings.
b) Flow changes more than 1 gpm (3.6 l/min)
Also inspect plug on low brake housing for
after the control lever moved
is to engage possible leakage.
another element.
NOTE: important that the following steps be
it is
Testing the Internal Gear Transmission
performed be sure that a iow pressure and flow
to
Pump (Power Shift)
condition is not caused by interna/ ieakage rather
than
a faulty transmission oil pump.
Fig. 12-Testing Lubrication PressurePower Shift

Fig. 11-Fiow Meter inlet At Oil Fitter Relief Valve (System Pressure Gauge also Installed)
19. Connect the flow meter inlet hose to the oil filter 1 install a 0-60 psi (0-5 bar) (0-5 kg/cm 2 pressure
)
relief valve housing outlet. gauge at the lube pressure test plug which \s located at
20. With engine running at 2000 rpm, turn the upper right-hand corner of the clutch housing.
flow Plug
meter flow control valve to obtain specified clutch is made accessible by removing
the footrest panel and
pressure: it is located just to the right of the oil return line.
4040 clutch pressure should be 140 psi (9.6 2. Check lube pressure for the following specifica-
bar) (9.7 kg/cm a ). 4240 clutch pressure should tions:
be 160 psi (11.0 bar) (11.2 kg/cm 2 ).
TM-1181 (Sep-77) Litho in US, A Tractors - 4040 and 4240


Engine Speed 110 D F (43C) Oil 150F (66C) Oil
(1 ,0 bar) (0.7 bar)
(1.1 kg/cm 2 ) (0.8 kg/cm 2 )

(1.9 bar) (1.5 bar)
(2.0 kg/cm*) (1.6 kg/cm 2 )
Fig. 15-Qpening Hydra-Analyzer Flow Control Valve
4. Open the flow meter flow control valve all the

ARegulating Valve Housing B0094 Hose C0760 Adapter way.
D0757 Coupling E0017 Elbow
Fig. 13-Power Shift Flow Meter inlet Connection
3. Connect a flow meter between the oil pressure

regulating valve housing (A, Fig. 14) and main hy-
draulic pump (Fig. 1 5).
TWiirrr'-
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tr -"-:'
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7
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i
"ixOnxr:; il-
Fig. 16-Jumper Hose Connections

PHESBî: !|Hlll:i!:::;jg|
" n~nn;: :
;;::(i BKttiiui] v22iiMi~SHKiiiiliSj iWfe:.

5. Install a jumper hose in both sides of the lower
fig. 14-Fiow Meter Outlet to Main Pump right-hand selective control valve. Place the selective
control valve metering lever at maximum flow.
6. Install a jumper hose in the left-hand side of the

left-hand selective control valve and tie its open end
securely into the oil filler tube.
7. Place the left-hand selective control valve me-

tering lever at minimum flow.
8. With all control valves in neutral and the engine

running at 1000 rpm, turn the flow meter flow control in
until the pressure increase hesitates.
TM-1181 (Sep-77) Litho in U.S. A Tractors - 4040 and 4240

.
9. The hesitation indicates cooler relief flow to the b) Minimum flow 11.5 gpm
is (43.5 l/min) at
hydraulic reservoir, If this pressure is not within 1 15 to 150F (66 C C).
135 psi {8.7-9.3 bar) (8,9-9.5 kg/cm 2), repair the cooler
12. With engine running at 1000 rpm, engage and
relief valve to obtain proper relief pressure.
disengage the PTO dutch noting any pressure or flow
change.
13. Depress and release the inching pedal, noting

any pressure or flow change.
14. With tractor in tow, note any pressure or flow

change as the transmission is shifted through each
gear.
15. An engaged element (of steps 12-14) has ex-

cessive leakage if;
a) Lubrication pressure changes more than 3

psi (0.2 bar) (0.2 kg/cm 2) after the control
lever is moved to engage another element.
b) Flow changes more than one gpm (3.8
Fig. 17-Adjusting Selective Control Metering Lever l/min) after the control lever is moved to
10. Move the left-hand selective control lever rear- engage another element.
ward to routesome pressure oil to sump and adjust 16. See Diagnosing -Malfunctions following, to in-
engine speed to 2000 rpm. terpret test results.
1 1 Adjust the left-hand selective control metering
lever to obtain 10 psi (0.7 bar) (0.7 kg/cm 2) lubrication
pressure. This step prevents the cooler relief vafve
from opening to the lube circuit.
a) Minimum flow is 12 gpm (45.4 l/min) at
110F (43C).
TRANSMISSION OIL PUMP REPAIR
Low or No Pump Output
Possible Cause Remedy Reference
Restricted Oil Filter Replace filter and recheck pressure (See 70-20-5)
Restricted Reservoir Screen Remove plug and check for oil drainage
Broken or damaged hex. shaft or adapter
(Perma-Clutch) Remove and inspect (See 70-15-8)
Discharge pipe or O-ring leaking Remove plug atupper right-rear of transmission case
and look into case with tractor running.
Manifold leaking (See 70-15-8) or (70-15-10)
Oil Filter Relief vafve leaking Remove and plug lube line at valve housing. Run hose
into a bucket to inspect for flow (270-10).
Pressure regulating valve malfunction Test (270-10).
Air leak in inlet pipe or O-ring Remove oil line from oil filter relief valve housing outlet.
Disconnect main pump drive. Attach hose. Run tractor
checking for air in the oil flow.
Pressure regulating-to-clutch valve housing
gasket leak Test and Inspect (See 270-20-5),
Filter relief valve housing gasket leak
(Perma-Clutch) Inspect and repair as necessary
Transmission pump inlet or outlet plugged (See 70-15-8)
Transmission pump worn (See 70-15-8) or (70-15-10)
Transmission pump lubrication priority valve (See 70-15-8)
spring weak or broken (Perma-Clutch)
Leaking pump seal (Power Shift) (See 70-15-10)
TM-1181 (Sep-77) Litho in USA Tractors .
4040 and 424Q
MAIN HYDRAULIC PUMP

How The Main Pump Works Ports oonnect the inlet valve bores through each
piston bore to the outlet gallery valve bores (L).
The main hydraulic pump is a variable displacement,
radial piston pump (Fig. 18). It ismounted in front of the The center section of the pump housing (A) contains
tractor engine. The pump camshaft is driven by the an integral eccentric and race (with needle bearings)
engine crankshaft through a special drive coupler. on the pump shaft. Each of the eight pistons is exposed
The pump is capable of variable displacement be- to the race (B).
cause of a stroke control valve assembly (M) located at demand
When the hydraulic functions oil, oil pres-
the front of the pump. crankcase
sure drops in the outlet gallery (L), at the
Both the 4640 and 4840 use a 3 cu. in. (49 ml) valve (M) in
outlet valve (O), and at the stroke control
displacement pump. On tractors with power front-
the stroke control valve housing. (The outlet gallery is
wheel drive, a 4 cu. in. (66 ml) pump is used. Both
ported to the stroke oontroi valve housing through a
pumps have eight pistons and operate in an identical bore at the lower area of the pump housing and stroke
manner. control valve housing.)
Charge from the transmission
oil pump and pressure
on An outlet gallery pressure drop to approximately
regulating valve housing enters the inlet port (Q) the
rear left-hand side of the pump housing. The annular 1 300 psi (31 .3 bar) (31 .9 kg/cm2 allows the crankcase
)
inlet gallery (G) allows oil to surround each of the eight outlet valve (O) to open.
inlet valves in the rear portion of the housing.
R2B483N
APump Crankcase GInlet Gallery MStroke Control Valve OInlet

H Piston Spring N0.060-Inch (1.52 mm) ROutlet
CCam I Piston Bleed Hole High Pressure Oil
DPump Shaft JDischarge Valve Spring OCrankcase Outlet Valve gUg Low Pressure Crankcase Oil
EInlet Valve Spring K Discharge Valve P Crankcase Outlet Valve Low Pressure Inlet Oil
Finlet Valve LOutlet Gallery Spring
Fig. 18-Main Hydraulic Pump Operation
TM-1181 (Sep-77) Litho in L/.S.A Tractors - 4040 and 4240

When the crankcase outlet valve (0) opens, oil flows DIAGNOSING MALFUNCTIONS
from the pump crankcase through a bore in the right-
hand area of the pump housing and stroke control No Pump Output
valve housing to the inlet gallery (G). Broken pump drive shaft (See 70-15-32)
When pressure is above approximately 1300 psi
Stroke control \/a\\/e open
(31.3 bar) (31.9 kg/cm 2 ), crankcase pressure is bled Improper stroke control valve adjustment
through orifice (N) to put the pump Transmission pump failure or charge leakage (See
"into stroke".
270-20-5)
With the pump "in stroke" and the pistons at the fully
inward position of the eccentric (C), the inlet stroke Low Pump Output
ends and the discharge stroke begins.
Low standby pressure
The pressure on both sides of the infet valves
oil
Stroke control vafve, seat, spring, or packing failure
equalizes and inlet valve spring force closes the inlet Worn or scored pistons and bores
valves (F). Oil is trapped in the piston bores. Broken discharge valve or spring
As the eccentric continues to revoive the piston is Leaking inlet valve
forced outward. The oil in the piston bore forces the
discharge valve open against discharge spring force, Hydraulic Functions Slow
allowing the oil to flow into the outlet gallery (L). Low standby pressure
When the pistonat the top of its outward stroke,
is
Stroke control valve, seat, spring, or packing failure
the discharge valve spring (J) closes the discharge Crankcase outlet valve sleeve packing failure
valve blocking the flow of discharged oil back into the Crankcase outlet valve stuck closed
piston bore.The stroke starts again, beginning a

in/et
new pumping cycle. As the cam rotates each piston Excessive Pump Pressure
has a separate cycle in rapid sequence, producing a Crankcase outlet valve filter plugged (Inspect)
constant oil flow.
If the demand for oil is not great

enough to decrease Slow Pump Response
the pressure below 1300 psi (31.3 bar) (31.9 kg/cm 2
), Crankcase outlet valve set too low
the crankcase outlet valve will move downward to
Crankcase outlet valve stuck closed
dose the passage from the crankcase to the inlet
gallery.
Function Chatter
The pump continues pumping oil until the increased Low standby pressure
pressure forces the stroke control vafve downward, Stroke control valve, seat, spring, or packing failure
opening the valve through the upper passage from the Sticking pump pistons
crankcase outlet valve bore in the stroke control valve Broken discharge valve or spring
housing. Oil is then free to flow into the main pump Broken inlet valve
crankcase. Insufficient inlet oil (cavitation)
The eccentric moves each piston outward in its bore Pressure control valve malfunction (Check by ad-
against piston spring force. The increased oil pressure justing SCV metering valve to lower flow)
in the crankcase holds the pistons away from the

can
race. The pump is "out of stroke" (or in the standby Pump and Oil Line Vibration
position).
Crankcase outlet valve set too high
OH feakage from the crankcase past the pistons and Broken discharge valve or spring
stroke control valve re-enters the inlet gallery via a Leaking inlet valve
bleed passage (N) below the stroke control valve, Broken inlet valve
through the crankcase outlet valve bore, to the inlet
passage. This circulation cools and lubricates the
pump.
Adjustment of the stroke control valve changes its

spring load, thereby changing oil pressure at the outlet
gallery. Adjusting the screw changes the system pres-
sure at which oil is released into the pump crankcase
by the stroke control valve to build standby pressure.

Pump
Continued
Shaft Seal Failure
Broken discharge valve

Quad ring sea! failure (See 70-15-21)
Steering motor packing failure (See 70-20)
Pump Noise or Squeal

Loose drive coupler or worn parts (See 70-15-32)
Low standby pressure
Stroke control valve, seat, spring, or packing failure
Crankcase outlet valve set too high
Leaking inlet valve
Air leak at inlet connection (Inspect)
Insufficient inlet oil (cavitation)

Hydraulic Operation and Tests Rockshaft and Implement Hitches 270-25-1
Group 25
ROCKSHAFT AND IMPLEMENT HITCHES
HOW THE ROCKSHAFT WORKS A thermal relief valve (located in the control valve
housing) relieves excess oil pressure due to thermal
expansion of the trapped oil in the rockshaft cylinder
and valve housing.
Due to the extra supply of oil used when the

tractor is equipped with a lift-assist cylinder, a surge
relief vaWe (F, Fig. 1) is added to protect the rockshaft
from excessive pressure surges, due to a sudden load
on the lift arms.
Load signals from the draft links are sensed by the

mechanism. These signals are transmitted
load control
through mechanical linkage to the control valves.
The degree of load sensing is set by the Joad selec-

tor lever. This lever can be moved from "MIN" to
"MAX."
With the load selector lever in the "MIN" position,

the load sensing mechanism operates at minimum
A Piston Cover D Lift-Assist Cylinder
BThrottle Valve sensitivitywhich allows the rockshaft control lever to
ELift Link
C Lift Arm FSurge Valve control working depth regardless of the amount of pull
required.
Fig. 1 -Rockshaft with Lift-Assist
With the load selector lever in the "MAX" position,

The rockshaft assembly contains a singte-acting the load sensing mechanism operates at maximum
cylinder and piston, rockshaft,lift arms (C, Fig. 1), sensitivity, allowingthe rockshaft to automatically raise
control valves, and load sensing mechanism. or lower the hitch to maintain constant load through
variations in soil density or ground contour.
Pressure oil moves the piston, rod, and crank arm
(which is splined to the rockshaft) to rotate the rock- When the load selector lever is in the "MIN" position;
shaft and raise the
arms. The weight of the imple-
lift or when the load selector is in the "MAX" position and
ment or hitch lowers the lift arms when rockshaft no change in sensed, both the pressure and
load is
pressure oil is released from the cylinder to the crank return valves are closed; the rockshaft is in a neutral
arm cavity. position.
Control valves direct oil to and from the rockshaft Oil is trapped in the rockshaft cylinder holding the
piston cylinder. A flow control valve controls the rate of piston and rockshaft in a set position.
lift, and the throttle valve (B) controls the lowering rate.

270-25-2 Rockshaft and Implement Hitches Hydraulic Operation and Tests
Lower ("MIN" load sensing)
R34875
AThrottfe Valve
G Crank Arm OOperating Arm X Spring
B Lift Arm HNegative Signal Limit Cam P Load Control Shaft Y Return Valve
C Rockshaft Piston I Load Selector Control Arm OLoad Control Arm Z Pressure Valve
DCheck Ball J Rockshaft R Servo Cam Follower AAThermal Relief Valve
E Row Control Valve K Lower Load Selector Arm S Load Selector Link B8 Negative Signal Limit Link
F From Pressure L Load Selector Lever T Valve Operating Shaft CCSurge Relief Valve*
Control Valve MServo Cam UOperating Link ggg Pressure Oil
NConsole Lever Guide V Valve Adjusting Link }gm Return Oil
W Valve Operating Cam : %I Pressure-Free Oil
*Used with fift-assist cylinder only.
Fig. 2-Rockshaft Operation Lower, f

'MIN" Load Sensing
Lower "MIN" Load Sensing Since the load selector lever (L) is in the "MIN"
position, the lower load selector arm (K) is rotated
Moving the console lever (N, Fig. 2) forward, lowers
upward (clockwise) as is the load selector link (S).
the rockshaft. Lever action rotates the control valve
This moves operating link (BB) upward on the rock-
operating arm and shaft (T) counterclockwise. The
shaft servo cam follower (R) which is located on the
valve operating spring (X) moves the valve operating
load control arm (Q).
cam (W) counterclockwise.
Since movement ol the rockshaft load control arm
The valve operating earn opens the upper (return)
(Q) has no effect on valve linkage in this position,
valve (Y) to allow oil in the rockshaft cylinder to flow
deflection of the load control shaft (?) does not affect
through the throttle valve (A) to the return passage and
valve movement
the crank arm cavity.
As the rockshaft lowers, the servo cam (M) rotates
The weight of the hitch and implement moves the
counterclockwise to rotate the operating cam (W)
rockshaft piston (C) rearward lowering the rockshaft
(through the linkage) and allow the return valve (Y) to
The rate of this flow is controlled by an adjustable
(J).
seat. The lowering movement stops.
passage in the throttle valve thereby governing the
lowering rate.

Lower ("MIN" load sensing)
R34876
AThrottle Valve GCrank Arm 0Operating Arm X

Spring
B Lift Ann H Negative Signal Limit Cam P Load Control Shaft Y Return Valve
C Rockshaft Piston I Load Selector Control Arm QLoad Control Arm Z Pressure Valve
OCheck Ball J Rockshaft RServo Cam Follower AAThermal Relief Valve
E Flow Control Valve KLower Load Selector Arm S Load Selector Link BB Negative Signal Limit Link
F From Pressure LLoad Selector Lever T Valve Operating Shaft CCSurge Relief Valve*
Control Valve MServo Cam UOperating Link $? Pressure Oil
N Console Lever Guide VValve Adjusting Link v>.i" Return Oil
WValve Operating Cam :: ^ Pressure-Free Oil
*Used with fift-assist cylinder only.
Fig. 3-Rockshaft Operation Raise, "MfN" Load Sensing
To raise the rockshaft, the console lever (N, Fig, 3) As the servo cam rotates, the cam follower
is moves
pulled to the rear. toward the rockshaft (J) pulling link (BB) with it. This
link movement (caused by cam spring (X) force) moves
The operating arm and shaft (T) rotate cfockwise to the valve operating cam (W) to rotate to close the
open the pressure vaive (Y). Pressure oil from the flow pressure valve (Z).
control vaive (E) flows through the pressure valve into
the rockshaft cylinder. When the piston (C) reaches the end of its selected
intermediate stroke, the pressure valve is closed.
Pressure oil in the rear of the cylinder moves the
piston (C) forward to rotate the rockshaft (J) clockwise When the console lever is in the fully raised (rear-
and raise the lift arms (B). ward position, the pressure vafve is always open
(maintaining system pressure in the rockshaft).
The load selector link (S) and operating link (BB)
ride on the rockshaft servo cam follower (R) which
rides on the servo cam (M).

Raise ("MAX" load sensing)
R34877
AThrottle Valve GCrank Ann OOperating Arm X Spring

B lift Arm HNegative Signal Limit Cam p Load Control Shaft Y Return Valve
C Rockshaft Piston I Load Selector Control Arm Q Load Control Arm Z Pressure Valve
a-CheckBall JRockshaft RServo Cam Follower AAThermal Relief Valve
E~~ How Control Valve KLower Load Selector Arm SLoad Selector Link BBNegative Signal Limit Link
F From pressure LLoad Selector Lever T Valve Operating Shaft CCSurge Relief Valve*
Control Valve MServo Cam U Operating Link gp Pressure Oil
NConsole Lever Guide VValve Adjusting Link ^&i- Return Oil
WValve Operating Cam Ht Pressure-Free Oil
*Lfeed with lift-assist cylinder onfy t
Fig. 4-Rockshaft OperationRaise, "MAX" Load Sensing
Raise "MAX" Load Sensing If the load on the draft links increases, the load
control shaft deflects causing the load control arm to
"MAX" sensing, the rockshaft is lowered in the
In
move rearward. This moves the negative signal limit
same manner as previously described. After the rock- link(BB) to move the operating cam clockwise opening
shaft lowered to the point set by the console lever,
is
the pressure valve (Z), raising the rockshaft.
the pressure and return valves (Y, Z, Fig. 4) are closed.
When the load on the draft links decreases, the
reduced load control arm movement permits the valve
By placing the load selector control lever (L) in operating cam spring (X) to move the valve operating
"MAX," the load selector link (S) and valve operating counterclockwise and open the return valve (Y).
cam
link (BB) are moved downward to locate on the lower
The rockshaft lowers.
portion of the servo cam follower.
Varying Load Response

In this position, load on the draft links is sensed
through the load control shaft (P) causing movement of ifthe load selector lever is placed anywhere be-
U
the load control arm (Q). Load sensed is transmitted to tween MIN" and "MAX," signals from both the load
the valve operating cam (W) moving it from its neutral (draft) and rockshaft console lever, affect rockshaft
position. valve action.

Reverse Load Operation Neutral
R34878
R34S79
AOperating Cam G Return VaJve AOperating Cam

BNegative G Return Valve
Signal H Pressure Valve B Negative Signal H Pressure Valve
Limit Link I Hockshaft Piston Limit Link Rockshaft Piston
CNegative Signal JFlow Control Valve CNegative Signal
I
JFlow Control Valve

Cam
Limit KSurge Relief Valve* Limit Cam K Surge Relief Valve*
DServo Cam
E
F
Foffower
Load Control Arm
$r Pressure Oil
^; Return Oil
DServo Cam Follower
ELoad Control Arm
^
:
Pressure
Vg. Return Oil
Oil
Load Control Shaft Trapped Oil F Load Control Shaft Trapped

^^ Return to Sump
l OiJ
Used with trft-assist cylinder only.

#S Return to Sump
Used with lift-assist cylinder only.
Fig. 5-Negative Signal Stop Operation

Fig. 6-Neutrai
Reverse loads on the draft links through Joad control Neutral (hitch not in full raised or fuff lowered posi-
shaft (F, Fig. 5) movethe load control arm (E) and tion).
servo cam follower (D) forward.
When the load selector lever is in "MIN" and there is

Since negative signal limit link (B) moves with the no movement console lever or when the load
of the
follower, the valve operating cam (A) rotates counter-
selector is in "MAX" and there is no change in Joad
clockwise to open the return valve (G).
sensed, both pressure (H, Fig. 6) and return valves (G)
are closed.
However, the negative signal limit link riding against
the surface of the limit cam <C) prevents the link <B)
Oil is trapped in the rockshaft cylinder, holding the
from moving too far with the follower (D). This keeps
piston (I) and rockshaft in a set position.
the return valve closed. The load contro/ arm and
follower are stili able to move forward under reverse
loads.
The rockshaft can still be raised or lowered with the

console lever.
TM-1181 (Jun-80) Litho in US, A Tractors - 4040 and 4240

270-25-6 Rockshaft and implement Hitches Hydraulic Operation and Tests
IMPORTANT: Before attempting to isolate a rockshaft problem, be sure none of the following general
hydraulic problems are causing the rockshaft malfunction. To eliminate other systems as the cause, see
Diagnosis in Group 10 of this Section. After all these other possible causes are eliminated, then investigate

the rockshaft system for malfunctions.
General Hydraulic System Malfunctions
Rockshaft Slow, Won't Lift Rated Load, Poor Hitch Response, or Chatter When Raising
Low oil level Replenish

Oil filter restricted Replace filter
Operating single-acting cylinder improperly Instruct operator

Low standby pressure Test and repair (See 270-20)
Throttle valve adjustment Adjust (See 70-15)
Flow control valve adjustment Adjust (See 270-10-14)
A
skin,
CAUTION: Escaping fluid under pressure
causing serious personal injury. Before dis-
hoses are not damaged. Fluid escaping from a very
small hole can almost be invisible. Use a piece of
cardboard or wood, rather than hands, to search
for suspected leaks.
K injured by escaping fluid, see a doctor at once.

ly-

Rockshaft System Malfunctions
IMPORTANT; When diagnosing malfunctions, the technician should be aware of and

recoanize anv
^^JSS^ T ht affeCt
; Ckshaft <**>* As an example: with the
MAX posôn; front and rear weights, type of Implement being Li^S^n'Z
pulled, wheel slippage, and operator error
could create a problem which would incorrectly
indicate a rockshaft maffunctio^
Hitch Will Not Raise Or Raises Slowly
Excessive load on hitch

Reduce load or install lift assist
Operating linkage malfunction or maladjusted
Check adjustment (See 270-25-9)
Return valve stuck open or leaking
See Testing (See 270-25-9)
Flow control valve improperly adjusted
See Testing (See 270-25-14)
Thermal relief valve leaking
Test and repair (See 270-25-15)
Rockshaft piston sea) failure
Inspect and replace (See 70-15-2)
Rear inlet adapter O-rings leaking
Rockshaft piston cylinder wall scored or damaged Inspect and repair (See 70-15-2)
Pressure valve stuck dosed
See Testing (See 270-25-9}
Improper engine rpm
Adjust
Hitch Fails To Lower

Operating linkage out of adjustment
Check adjustment (See 270-9)
Weak or broken valve cam operating spring
Inspect and replace (See 70-15-8)
Broken lowering valve spring (\m assist, only) Inspect
Throttle valve
Inspect
Hitch Lowers Slowly
Control linkage out of adjustment

Throttle valve adjusted too near
its seat
Adjust (See 270-25-14)
Weak or broken valve cam operating spring Inspect and replace (See 70-15-8)
Hitch Chatter ("MAX" position)
Load selector adjusted too sensitive Adjust

Operating valves adjusted too tight Check adjustment (See 270-25-9)
Improper engine rpm
Adjust
Incomplete Rockshaft Rotation
Incorrect control rod adjustment

Check adjustment (270-25-9)
Load control arm extension out of adjustment
(MAX)
Load control shaft worn at contact points
(MAX)
Inspect and repair (See 70-15-14)

Working Depth Changes
Control lever friction adjustment too loose

Pressure valve stuck open or leaking
Check and adjust (See 270-25-13)
See Testing (270-25-14)

Excessive Settling (Implement raised, engine stopped)
NOTE: One degree (1) per minute is considered

excessive settling of the impfement with the engine
stopped.
Operating valve clearance too tight Check adjustment (See 270-25-9)

Weak or broken return valve spring Inspect and replace (See 70-15-8)
Return valve leaking Test and repair (See 270-25-14)
Thermal relief valve leaking Test (See 270-25-15)
Press valve metering shaft or guide worn Inspect and repair (See 70-15-12)
Porous or failed rockshaft control valve
housing or rockshaft housing inspect
Rockshaft piston seal failure Inspect and replace (See 70-15-2}
Rockshaft piston cylinder scored or damaged inspect and repair (See 70-15-2)
Lift assist surge relief valve leaking inspect and repair (See 270-25-16)
Valve housing rear inlet adapter 0-rings
leaking Repair (See 70-15-13)
Insufficient Load Response
Rockshaft control lever position incorrect Position lever to the rear

Position of load sensing lever incorrect Position toward "MAX"
Load control arm extension adjustment incorrect Check adjustment (See 270-25-10)
Operating valves adjusted too wide Check adjustment (See 270-25-9)
Return or pressure valve leaking Inspect and repair (See 270-25-14)
Loose or worn operating parts or linkage Inspect and repair (See 70-15-7)
Thermal relief valve leaking Test and repair (See 270-25-15)
Throttle valve too tight (also lowers slowly at "MINT) Adjust throttle valve (See 270-25-14}
Piston seal failure inspect and replace (See 70-15-2)
Valve housing rear inlet adapter O-rings leaking Repair (See 70-15-13)
Load control shaft worn at contact points Inspect and repair (See 70-15-14)
Surge relief valve leaking (Lift Assist, only) inspect and repair (See 270-25-16)
Oil Heating Bypassing of High Pressure Oil
Valve clearance adjusted too tight Check adjustment (See 270-25-9)

Thermal relief valve leaking Test and repair (See 270-25-15)
Porous valve housing Inspect
Vafve housing front inlet adapter O-rings leaking Repair (See 70-15-13)
Piston seal leaking Inspect and repair (See 70-15-2)
Return and pressure valve leaking or open Test (See 270-25-14)
lty-1181 (Sep-77) Litho in USA. Tractors - 4040 and 4240

. .
CHECKS AND ADJUSTMENTS
NOTE: Refer
liminary checks,
to Group 10 of this Section for pre-
and test procedures for isolating the
hydraulic problem to a specific system,
prior to at-
tempting to diagnose a specific rockshaft malfunction.
Rockshaft Checks and Adjustments

Conditions required before making any checks
and
adjustments are:
1. The tractor and rockshaft must be operational.
2. No bad on hitch except for the Rockshaft Con-

sole Lever Adjustment Check.
3. Free from air in system (cycle rockshaft several

times.)
4. Make checks and adjustments only in the follow-

ing sequence.
Load Selector Lever Adjustment Check

A Extended Arm BAdjusting Hole
move the console load selector knob from U MIN" to
"MAX" position. Fig. 7-Checking Rockshaft Valve Clearance (4040 shown)
2. The load selector lever on the rockshaft valve Rockshaft Console Lever Rod Check
housing should reach either end of its travel before
the 1 a heavy implement can be raised with the load
If
console knob reaches either end of the slot in
the selector leverin "MIN", but cannot be raised in
console. "MAX",
adjust console lever as instructed on page
12.
3. If necessary, adjust as instructed in 270-25-11. 2. Check load control arm extension as follows.
Rockshaft Valve Clearance Check

Valve clearance should not need to be
checked
unless a specific complaint is received such
as:
1 Lack of sensitivity (valves set too loose),

2. By passing of oil or noisy valves (valves set
too
tight), then, adjust per adjusting procedure
given on
page 270-25-11.

CHECKSContinued Operational Check
Load Control Arm Extension Adjustment Check NOTE: if any of the following requirements are not
met, the rockshaft should be completely adjusted
Then "MIN" operation should be rechecked.
<^> \
n MAXj
8
n n n
-7
-b
-5
F -
-
'8
-7
-
4
11= - -5
-3
MIN -
-2
-
-4
-3

MIN ^-^
8\ &
h- <*
E2S138H V j
8-Checking Load Control Arm

R2S139N
Ffc.
Extension Adjustment Fig. 9-Checking "MIN" Operation
1.Place load selector lever in "MAX" slot and run 1.Place load selector in "MIN" position and run
engine at slow idle. engine at slow idle.
2. (Not Illustrated) Move rockshaft lever forward to 2. (Not Illustrated) Move console lever forward to
lower the hitch. lower the hitch.
3. Turn the depth adjusting knob to move the rock- 3. Move the console lever rearward. The rockshaft
shaft adjustable stop and console lever rearward. should be fully raised before front edge of lever enters
the console guide stop.
a) Rockshaft should start to raise when the rear
edge of the lever is 1 /8 in. (3 mm) before to NOTE: To check for the fully raised position, try to
1/8 in. (3 mm) after the "I" position on the raise the lift arms by hand. If no movement occurs, the
console guide. Note that the rockshaft will not rockshaft is in the fully raised position.
necessarily fully raise at this position,
4. Move the rockshaft console lever forward. The

b) If the rockshaft does not raise (as specified in rockshaft shoufd reach its fully lowered position before
a), adjust the load control arm extension as the front edge of the lever contacts the front edge of the
instructed on page 270-25-13. slot,
5. Complete rockshaft rotation should be approxi-

mately 76.

,

Rockshaft and Implement Hitches 270-25-11
Adjustments
NOTE: Perform the following adjustments with
no load on the hitch unless otherwise instructed.
To be
certain there is no air in the system, cycle
the rockshaft
several times. These adjustments should
be performed
in the sequence they appear in this manual.
Load Selector Lever Adjustment

move the console load selector knob from "MIN" to
"MAX" position.
2. The load selector lever on the rockshaft valve

housing should reach either end of its travel
before the
console knob reaches either end of the
slot in the
console.
3. Adjust swivel on linkage at

the hydraulic control
inner support, if necessary.

AExtended Arm BSpecial Plug
NOTE: Before checking or adjusting rockshaft valve
clearance on tractors equipped with lift assist Fig- 10-Rockshaft Operating Vafve Adjustment (4040
cylinders shown)
perform the following steps (a through d).
a) Lower the hitch and disconnect the lift assist 1. Place load selector lever in the "MIN" slot.
cylinder oil line at the rockshaft piston cover.
2. Disconnect linkage from the

b) Disconnect return rockshaft control
line from elbow at the surge valve operating arm.
relief valve in the piston cover.
3. Using an extended arm (A, Fig. 10), extend the

c) Cap
the nipples from which the lines
were rockshaft valve operating arm to 10" (254
removed. To allow free hitch movement, mm) from
assist center of valve operating shaft.
cylinder lines should be left open. Use steel caps
from MASTER Hydraulic Fitting Flow Test Kit.
See page 70-00-12 for instructions on making ex-
tended arm.
d) After checking and adjusting valve clearance,
reconnect lines and operate rockshaft to
remove 4. Run engine at slow idle.
air from system.
A
*
CAUTION: Use care to avoid injury by the
lift arm or hitch in case
valve is operated
too rapidly or unexpectedly.

ADJUSTMENTSContinued
5. At the 10" (254 mm) mark, measure the distance
the arm is moved to change rockshaft rotation direc-
tion. This distance should be:
A. New Tractors (as received from factory) -
3/16 to 3/8" (4.76-9.53 mm)
B. Tractors with rockshaft usage - a measured

distance of less than 3/16" (4.76 mm) is ac-
ceptable due to valve seating. The valve
clearance need not be adjusted as long as
some movement of the extended arm is ob-
served without a change in rockshaft rotation
direction. When required, readjust the valve
to obtain 3/16 to 3/8" (4.76-9.53 mm) move-
ment of the extended arm to obtain a change
in rockshaft rotation direction.
6. If necessary, remove plug (B) from side of control

valve housing and turn adjusting screw counterclock-
wise to increase the distance or clockwise to reduce
the distance.
AHand Throttle CLoad Selector Lever
B Rockshaft Console Lever D Depth Adjusting Knob
7. After checking and adjusting valve clearance, Fig. 12-Console Lever Positions
reconnect lines and operate rockshaft to remove air
from system. 2. Turn load control arm adjusting screw clockwise
to its limit.
Rockshaft Console Lever Rod Adjustment

3. Place load selector lever (C, Fig. 12) in "MAX"
position and run engine at slow idle.
4. Move rockshaft console lever (B) forward to

lower the hitch.
\
& ^
MAX
MIN
u u
Fig. 11 -Load Control Arm Extension 8

1 . Remove bad control arm extension adjustment R8$141tf
hole plug from rear of transmission case.
Ftg. 13-Lever Positions

.
Hydraufic Operation and Tests Rockshaft and Implement Hitches 270-25-13
5. Turn the rockshaft depth adjusting knob to move

the rockshaft adjustable stop and the rockshaft console
lever rearward.
a) Rockshaft should start to raise when the front

edge of the console \ever n
is afigned with 1" on the
console guide,
b) If rockshaft does not raise as specified, adjust

the rockshaft operating rod swivel at the valve operat-
ing arm until adjustment is correct.
NOTE: if rockshaft raises too soon, lengthen the

rod. if rockshaft raises too late, shorten the rod.
Load Control Arm Extension Adjustment
Fig. 15-Adjusting Load Control Arm Extension

$' IAX^
MAX
4. Turn the load control arm extension adjusting
8
7 screw counterclockwise until rockshaft starts to raise.
6
5 5. Move the rockshaft console lever forward to
lower the hitch using depth adjusting knob, move lever

4
rearward. Rockshaft should start to raise when rear
-3
edge of lever is at 'T* on console guide. If not readjust
load control arm adjusting screw.
FINAL ADJUSTMENTS
L U
Friction Device Adjustment
"<
1. (Not illustrated) Disconnect linkage from lower
rockshaft valve operating arm.
329138IJ
]<3)
Fig. U-Lever PositionsExtension Adjustment
1 Place the load selector lever in the "MAX" posi-

tion and run the engine at slow idle.

lower the hitch.
3. Turn the depth adjusting knob to move the rock-

shaft console leverand adjustable stop rearward. Stop
when the rear edge of the lever is at "1 " on the console
guide.
Fig. 16-Adjusting Lever Friction
TM-1181 (Sep-77) L'nho in U.S.A. Tractors - 4040 and 4240

.
FINAL ADJUSTMENTSContinued
2. Loosen Jam nut on adjusting screw on console
cover.
3. Turn Adjusting screw counterclockwise to in-

crease friction, or clockwise to decrease friction on
lever, A 7-8 lb. (31-36 N) force should be required to
move the lever.
4. Tighten jam nut and connect operating arm link-
age.
Flow Control Valve Adjustment

1 To adjust flow control valve add or deduct shims
to obtain proper flow specifications.
2. Test flow as instructed on page 270-25-14.
Throttle Valve Adjustment APiston Cover D0714 SCV Plug

B6724 Fitting E0760 Swivel
1 Loosen lock nut on throttle valve. C0094 Hoses F0761 Connector
G0092 Connector
2, Turn throttle valve screw in to decrease or out to
Fig. 17-Rockshaft Flow Test Connections (4040 shown)
increase rockshaft lowering speed.
TESTS 2. Remove the throttJe valve assembly from the

rockshaft piston cover (A, Fig. 17).
Rockshaft Time Cycle Test

3. Install flow meter inlet hose in the throttle valve
1. Operate engine at 2000 rpm. bore in the piston cover. Use fittings from D- 15022 NU
Master Hydraulic Fitting Flow Test Kit as shown in Fig.
2. Check rockshaft lift cycle time (76* rotation). 17.
4240 Tractor - Lift cycle time should be 2.5 - 2.75
seconds. 4040 Tractor - Lift cycle time should be 2.39 -
4. Install the flow meter outlet hose into the right-
2.68 seconds. hand coupler of the selective control valve, as shown in
Fig. 17. Move appropriate selective control valve lever

3. If rockshaft does not meet specifications, refer to to the rear.
page 7 to diagnose the problem.
5. Open the flow meter flow control valve and
Flow Test operate the engine at 2000 rpm.
1. Lower rockshaft and relieve hydraulic pressure.

6. Move the load selector lever to the "MAX" posi-
tion. Pull the rockshaft console lever to raise the rock-
shaft and lock in slot in rear of console lever guide.

.
Hydraulic Operation and Tests Rockshaft and implement Hitches 270-25-15
^" pgia
1
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F. 18~Adjusting flow Meter Flow Control Valve

Fig. 19-Pemta-autch Rockshaft Return Off Line
Adjust the flow meter flow control valve until a

7.
THERMAL RELIEF VALVE TEST
1000 psi (70 bar) (71.4 kg/cm 2 ) reading Is obtained.
1. Relieve hydraulic pressure and remove right-

8. 4240 tractor - flow should be 10-11 gpm hand selective control valve (if equipped) and rockshaft
(37.85-41.64 L/m), valve housing cover.
4040 tractor - flow should be 8-9 gpm (30 28-
34.07 L/m). 2. Carefully remove O-rings, packings,
and pres-
sure and return valve assemblies.
Tractors with optional iift-assist;
4240 tractor - flow should be 12-13 gpm

(45.42-49.21 L/m},
4040 tractor - flow should be 10-11 gpm
(37.85-41.64 L/m).
9. If flow is low, flow control or operating

valves
could be at fault. See page 270-25-7 to diagnose the
malfunction.
10. Remove flow meter and install throttle valve.
1 1 On tractors not equipped with selective control

valves, remove the rockshaft return line to the filter
relief valve housing and route the return from
the flow
meter into the housing. Route the rockshaft return line
into a clean container. (See Fig. 19,)
AJDH-43 Needle Valve and Pressure Gauge
Fig. 20-Thermal Relief Vaive Test
TM-1181 (Sep-77) Lithe in U.S.A.

.
Thermal Relief Valve TestContinued 1 Lower the rockshaft and relieve hydraulic pres-
sure.
3. Install JDH-43 Rockshaft Thermal Relief Valve
2. Remove surge valve (B, Fig. 22) from rockshaft
Test Kit in pressure valve bore.
piston cover and install in John Deere #T-37190
housing (A).
4. Connect hand pump to needle valve on test kit.
NOTE: Always use clean John Deere Hy-Gard

Transmission and Hydraulic Oil in hand pump,
5. Apply pressure with hand pump, noting gauge

pressure reading just before a rapid drop in pressure is
observed.
a) Pressure should reach 3550-3950 psi (245-

2
272 bar) (250-278 kg/cm ).
b) Perform test several times to be sure valve is
closing and opening properly.
c) Service the thermal relief valve if specifica-

tions are not met. (See page ).
6. Remove test kit and replace rockshaft valves,

x 2??Hh
valve cover, and selective control valve.
A-^John Deere E0753 Fitting

Surge Relief Valve Test (Tractors with Lift T37190 Housing F JDH-43 Needle Vaive
Assist)
B Surge Relief Valve and Pressure Gauge
C0111 Plug G 2106 Hose
D0742 Fitting
Fig. 22-Surge Relief Valve Test
3. From the Pressure Test Kit D-15027 NU, install

bushing and 0753 connector (E); connect hand pump
to this fitting.
4. Install 0742 fitting (D) in top of housing; install a
hose over this fitting and place other end in a clean
container.
5. Plug remaining opening with #0111 (C) plug
from the Master Hydraulic fitting Flow Test Kit D-
15022NU.
NOTE: Always use clean John Deere Hy-Gard
Transmission and Hydraulic Oil in hand pump.
6. Apply pressure with hand pump, noting gauge
pressure reading just before a rapid drop in pressure is
observed.
A) Pressure should reach 2650 to 3000 psi
(182.7-206.8 bar), then rapidly decrease, indicating
ASurge Relief Valve BThrottle valve has opened. Relieve pressure so valve can seat.
Valve
Perform test several times to insure accurate reading is
Fig. 21 -Rockshaft Piston Cover achieved.
B) Add or deduct shims if specifications are not
met.
7. Install surge relief valve in piston cover.

. .
ROCKSHAFT AIR LEAKAGE TESTS

When the hydraulic diagnosis indicates leakage at Remove rockshaft flow control valve
1
and spring.
the rockshaft, perform the following air pressure tests
to check the rockshaft and rockshaft valve housing 2. (No SCV option, go to Step 3). install rubber
separately. plugs (A, Fig. 23) in SCV pressure inlet bore(s) and
secure with a plate(s) (C).
Use air nozzle, adaptors, caps and rubber plugs 3. Apply air (70 psi [4,8 bar] [4.9 kg/cm s ] maximum)
from JDG-85 Air Pressure Test Kit. Obtain four at front pressure inlet bore (B) with plug on nozzle.
R60171 plates from air conditioning compressors. Use
appropriate size rubber plugs that best seals bore 4. There should not be any leakage.
holes. Secure rubber plugs by use of appropriate cap NOTE: The pressure valve would be the most likely
screws and washers. Fasten plates to housing using source of leakage. Put some oil on the pressure valve
an adjacent mounting hole. through the rear bore to rockshaft cylinder and watch
for bubbles.
"
iV CAUTION: These tests require the use of a
TY4345 Air Pressure Regulator (or similar
regulator), adjusted to 70 psi maximum
Rockshaft Valve Housing, Pressure to
(no flow). Return Valve Leak Test (With or Without
SCV Option)
Complaints of rockshaft setting should be checked
with a hydraulic hand pump. Check for feakage at the
following areas:
1 Rockshaft return valve.

2. Rockshaft thermal relief valve.
3. Rockshaft flow control valve.
4. Rockshaft piston, bore and seal.
5. Rockshaft surge relief valve.
Rockshaft Valve Housing Pressure

Passage Leak Test
;
R80112E1 ~
\;^
AWire BTo Rockshaft Cylinder Bore
Fig. 24-Checking Pressure to Return Passage
1. Use a looped wire (A, Fig. 24) to disconnect

the
A Rubber Plugs C Plates return spring from the valve operating cam.
B Pressure inlet Bore
2. Apply air (70 psi [4.8 bar] [4.9 kg/cm 2 ] maximum)
Fig. 23-Checking Rock^hart Housing Pressure Passage at rear bore (to RS cylinder) with a rubber plug on
(Triple SCV Cover Shown) nozzle.
3. There should not be any leakage.
NOTE: The pressure and return valves would be the

most likely source of leakage.

.
Rockshaft Valve Housing, Return Rockshaft Housing, Cylinder Pressure

Passage Leak Test Passage Leak Test
i
RS0172F1
C Rubber Plug RB004901

ARubber Plug
B Plate C Bore
A Rubber Plug from Rockshaft Valve
Fig. 25-Checking Rockshaft Vatve Housing Return B Plate

Fig. 26-Checking Rockshaft Housing Cylinder
Pressure Passage
1. Use a looped wire to reconnect the return spring
to the valve operating cam. 1 Remove the rockshaft piston cover.
2. a rubber plug (A, Fig. 25) in the front return

Install 2. Install rubber plug (A, Fig. 26) in the bore from
outlet bore and secure with plate (B). rockshaft valve at cylinder and secure with plate (B).
3. (No lift assist, go to Step 4). Cap lift assist return

3. Apply air (70 psi [4.8 bar] [4.9 kg/cm ] maximum)
2
sensing fitting with (0026) cap (not shown). at the bore from rockshaft valve with a rubber plug on
nozzle.
4. (No triple SCV option, go to Step 5). Hold rubber
plug (C) in the return bore tor the triple SCV option.
5. Apply air (70 psi [4.8 bar] [4.9 kg/cm 2] maximum)

to the rear pressure bore (to rockshaft cylinder) with a
rubber plug and nozzle.
6. There should be leakage from only the pin of the

return spring to the valve operating cam or linkage lube
orifice.

.
Rockshaft Housing Pressure Passage Rockshaft Housing Return Passage Leak

Leak Test Test
A Rubber Plug D Plate

H80049M1 B Plate E 0-18 Adapter (0725)
C Rubber Plug
ARubber Plug D Plate
B Plate E^D-32 Adapter (0745)
Fig. 28-Checking Rockshaft Housing Return Passage
C Rubber Plug
1. Install a special pressure control valve body
with
Fig. 27-Checking Rockshaft Housing Pressure Passage bleed hole brazed shut and four 0.060 in. (1.5 mm) flat
washers between PCV body and elbow.
1 Install rubber plug (A, Fig. 27) in front pressure
passage for rockshaft and secure with plate (B). 2. Install rubber plug (A, Fig. 28) m the return bore
for rockshaft valve and secure with plate (B).
2. Install rubber plug (C) in left-hand SCV pressure
passage for rockshaft and secure with plate (D). 3. Install rubber plug (C) in the left-hand SCV return
bore and secure with plate (D), (Use washers to shim
3. Install a special pressure control valve body
with in clearance between plug and plate.)
bleed hole brazed shut. See "Making Special Tools,"
page 270-00-2. NOTE: Rockshaft piston cover and bottom cover
must be installed.
4. Apply air (70 psi [4.8 bar] (4.9 kg/cm 2] maximum)
with nozzle, hose and D-32 (0745) adapter (E) at 4. Apply air (70 psi [4.8 bar] [4.9 kg/cm 2] maximum)
pressure control vaJve inlet. with nozzle, hose and D-18 (0725) adapter.
5. There should not be any Jeakage. 5. There should not be any leakage.
NOTE: if a speciat PCVbody is not used, there will

be some leakage past the bleed hole.

270-25-20 Rockshaft and implement Hitches Hydraulic Operation and Tests
Rockshaft Housing, Left-Hand SCV

Return Passage Leak Test
NOTE: If the Rockshaft Return Passage Leak Test

was satisfactory, this check is not necessary.
1. Remove rockshaft housing bottom cover, cam,

shaft and arm.
R80O5OE1
fife?. 30-Checking Left-Hand SCV Return Passage
3. Apply air (70 psi [4.8 bar] [4.9 kg/cm 2] maximum)

at left-hand SCV return (A, Fig. 30) bore with a rubber
plug on nozzle.
Slilfff
R30050P1
A Return Bore
Ftg. 29-Checking Left-Hand SCV Return Passage
2. Hold a rubber plug in the return bore (A, Fig. 29)

of arm cavity.

ROCKSHAFT LIFT ASSIST When the load on the hitch is sufficient to overcome
How The System Works return circuit pressure plus spring force against the
right end of the valve, the valve shifts to the right.
A lift assist option is available using one single-act-
ing cylinder to increase rockshaft capacity. With the valve shifted to the right, the assist cylinder
The cylin-
der mounted on a support which is fastened to the
is is connected directly to the rockshaft cylinder. Oil from
rear axte housing-to-transmission case flange. The the cylinder returns through the lowering valve to the
piston end of the cylinder is fastened to the rockshaft normal rockshaft return circuit.
lift arm.
A special lowering valve is required, due to the
Lower (No Load on Hitch)
inability of an empty hitch to create sufficient hydraulic
pressure in the assist cylinder to return its oil into the
return circuit as the hitch lowers.
As installed, the left-hand end of the lowering valve
isexposed to rockshaft cylinder pressure, the right-
hand end to return circuit pressure plus an additional
50 psi (3.5 bar) created by spring pressure.
Raise
The piston cover has an external line routed to the
lift assist cylinder. During the rockshaft raise cycle, the
lift assist lowering valve moves to the right due to
rockshaft system pressure overcoming the spring
pressure and return circuit pressure sensed on the
right-hand end of the valve. With the valve shifted to
the right, the assist cylinder is directly connected to the
rockshaft cylinder. R34880
Lower A Lift Assist ESurge Relief

Lowering Valve Valve Bore
BSpring F From Rockshaft
C Return Pressure Cylinder
Sensing Line GThrottle Valve Bore
DTo Sump H From Lift Cylinder
*$&$> Return Oil
%gg. Sump Oil
Rg. 32-Lower (No Load on Hitch)
With no load on the hitch, return pressure and spring

force against the right end of the lowering valve shift it
to the left, as these pressures are greater than the
pressure in the rockshaft cylinder.
Return oil from the assist cylinder is directed through

the piston cover to the control valve housing and to
sump. Rockshaft oil returns thru its normal return cir-
cuit into the charge circuit.
R 31246 A pressure surge relief valve (located in the piston

ALift Assist cover) relieves excessive pressures from the rockshaft
E Surge Relief
Lowering Valve Valve Bore and lift assist cylinder through the return line to sump H
B Spring F From Rockshaft The valve protects the tractor, implement and
relief
C Return Pressure Cylinder assist cylinder from excessive shock during transport.
Sensing Line GThrottle Valve Bore
DTo Sump H From Lift Cylinder
&7# Return OU
Fig. 31 -Lower (Load on Hitch)

POWER WEIGHT-TRANSFER HITCH Power Weight-Transfer Operation

How The System Works During weight-transfer operation, the rockshaft is
operated in "MAX" toad sensing. Excessive load on
The power weight-transfer hitch transfers weight the load control shaft and arm causes linkage to open
from a drawn implement and the tractor front end to the the rockshaft pressure valve. Pressure oil flows to the
tractor rear wheels for increased traction. rockshaft piston cover and to the hitch control valve.
Theweight-transfer hitch consists of a pressure The control valve knob (A) is turned inward for
gauge, special rockshaft piston cover, control valve, weight-transfer operation. This forces the control valve
coupler, transfer link, and double-acting cylinder. (The (B) off its upper seat. Pressure oil from the piston cover
double-acting cylinder is used as a single-acting cylin- flows up past the control valve (C) and out to the
der.) remote cylinder (G), causing the cylinder to retract.
As the cylinder retracts, the coupler tilts toward the

A 2-way directional control valve mounted at the
is
The coupler on the transfer
pulls
front of the tractor.
rear of the tractor. This valve and a pressure gauge is shifting weight from the implement and tractor
link,
plumbed into the special rockshaft piston cover. front end to the tractor rear wheels.
uses the load sensing portion of the rock- As the load decreases, the rockshaft pressure valve
The hitch
shaft valve assembly to control weight transfer. closes. Since there no flow to the remote cylinder
is
piston, the implement weight pulls on the coupler to
The coupler connected to the draft links. The

is extend the cylinder.
remote cylinder is connected to the coupler at the
cylinder end and at the center link pivot bracket at the
rod end.
The hose opposite the stop rod bracket is attached

to the control valve. The other hose is connected to a
receptacle in the load control arm adjustment opening.
The telescoping transfer link is attached to the top of

the coupler and to the implement. For most efficient
weight-transfer, unit should be operated with draft links
in a horizontal position.
Rockshaft Operation
Turning the control valve knob (A, Rg. 33) outward
(to the rockshaft position) raises the control valve shaft.
Spring (E) forces the control valve off its lower seat and
onto its upper seat.
Oil flows between the rockshaft valves and piston

cover for normal rockshaft operation.
indicates hydraulic control of RS8338N

The pressure gauge
the implement during rockshaft operation. A constant AControl Valve Knob GTo Remote Cylinder
or intermittent "zero" reading indicates that operation

BControl Valve Shaft | Pressure Oil
CControl Valve mm; Pressure-Free Oil
depth is too great for the implement or soil conditions. DTo Piston Cover Trapped Oil
This situation is corrected by raising the rockshaft to EValve Spring
obtain a constant pressure reading. F From Piston Cover
Fig. 33-Control Valve Operation
Litho in USA. Tractors - 4040 and 4240

TM-1181 (Jun-80)
The oil on the rod side of the remote cylinder piston
returns through the hitch control valve into the rock-

shaft piston cover and through the rockshaft return
valve.
Weight-transfer operation occurs automatically (just

as rockshaft changes depth in "MAX") each time load
increases or decreases.
Pressure Gauge
The pressure gauge senses pressure at the piston

cover.As the rockshaft is lowered, the gauge pointer
moves clockwise in the green band to indicate weight-
transfer.
Relief Valve
The relief valve is set at 2450 psi (169 bar) (172

kg/cm 3 ) to protect the system. If pressure rises exces-
sively in the remote cylinder before the rockshaft return
valve can relieve it, the relief valve routes that oil to
sump.
TM-1181 (Jun-80) Lithe in USA. Tractors - 4040 and 4240

TM-1181 (Jun-80) LHho in U.S.A. Tractors - 4040 and 4240

Hydraulic Operation and Tests Selective Control Valve and Remote Cylinder 270-30-1
Group 30
SELECTIVE CONTROL VALVE AND REMOTE CYLINDER
HOW THE SYSTEM WORKS Directional control valve (D) is located at the rear of
the rockshaft control valve housing cover (or in the
selective control valve manifold on tractors without
rockshaft) in front of the lower right-hand selective
control valve.
The directional control valve (D) directs single-act-

ing cylinder return
oil to the reservoir when operated by
the lower right-hand selective control valve. The valve

allows return oil from a double-acting cylinder or a
hydraulic motor to enter the return circuit.
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*:::::
^^g^^B ^^^^^H^^^y^n
i " " :
A Selective Control Valve C Flow Control Valve ^t.':$5SL;i%:JSâsKa!:::
Assemblies D Directional Control

B Breakaway Couplers Valve
i^BH
Fig. 1-Selective Control Valve Mounting Positions
l^l^jjyjjjjjyiij^J HriSiiSafc:::
The tractor may be equipped with as many as three Ar Float Lockout Stops CRetract
selective control valve assemblies (A, Fig. 1). Each B^Selectrve Control Valve Levers DExtend
valve has an integral pair of breakaway couplers (B),
Fig. 2-Selective Control Levers
Each valve operate either a single or double-

will
Up to three control levers (B, Fig. 2) are mounted in
acting remote independently or simulta-
cylinder,
the console on the right-hand side of the operator's
neously with the other two valves.
seat to cause a selective control valve to extend (D),
retract (C), or place a remote cylinder in a floating
When using two selective control valves simulta- position.
neously (as with a farm loader), an optional inlet check
valve can be added to the system in front of the flow
control valve (C). This will prevent back flow from one
selective control valve to the other.
NOTE: Back flow through a selective control valve

occurs when the pressure valves in both SCV assem-
blies are open, and main pump flow is less than
demand. Oil will flow out of the selective control valve
with the greater load into the valve with the least load.
This could cause a retraction of the heavier load and a
faster reaction of the fighter load.

270-30-2 Selective Control Valve and Remote Cylinder Hydraulic Operation and Tests
OPERATION Neutral
The slotted metering valve (G, Fig. 3) is provided to
maintain a desired flow
control valve to the remote
rate through the selective
The metering
cylinder.
In
moved to center of the

3), the console lever is
the neutral position (D, Fig.
console guide. The rocker
operating arm (D) rotates the center detent cam to
4
valve operating arm is located on the end cap of the align its center detent (B) with the detent follower (C),
selective control valve. The pressure and return poppet valves are seated by
their springs.
Rotating the arm opens the valve slot to
to the right
allow increased flow. Rotating the arm to the left closes No oil allowed to or from the remote cylinder.
is
the metering valve slot to allow Jess flow and slower Therefore trapped between the selective control
oil is
operation. valve and remote cylinder. The cylinder is held in the

position it was in prior to neutral.
The flow control valve (H) compensates for changes

in load to maintain consistent flow through the metering Oil pressure (E) to the selective control valve, is
valve. is shuttled in its bore by counter-acting spring

It allowed to build to maximum system pressure so the
and inlet pressure. This action increases or decreases main hydraulic pump may go out of stroke.
the pressure oil passage to the pressure poppet valves
(I and J) to maintain even flow regardless of load.
Four poppet valves direct oil flow to and from the

remote cylinder. The lower left and upper right poppet
valves {I and J) direct pressure oil. The upper left and
lower right poppet valves (M and O) direct return oil
from the cylinder.
The poppet valves are controlled by rotation of a

rocker assembly (A) which is linked to a console lever.
The rocker is located in the selective control valve

housing toward the front of the tractor. An operating
arm (D) and shaft on the side of the selective control
valve housing links the console lever to the rocker
assembly.
The rocker assembly consists of two valve operating

cams (A) and a detent cam (B) in the center which are
pinned to the rocker. Operating cam adjustment (by
screws (Q) on the rocker) causes the return valves to
open just before the pressure poppet valves.

Selective Control Valve and Remote Cyli nder 270-30*3
R34867
AOperating Cams G-Metering Valve M Lower Return Poppet Valve R Keeper

B Detent Cam (Neutral Detent) H Row Control Valve N Left-Hand Coupler
CDetent Follower Lower Pressure Poppet
SFlow Control
I
Valve Receptacle
D Neutral Position J Upper Pressure Poppet Valve 0 Upper Return Poppet Valve
VaJve Stop
E Inlet KDetent Piston Pin P Return to Function
i Pressure Oil
F Detent Piston and Spring LTo Right-Hand Coupler Return Passage

J Return to
Charge Oil
QCam Adjusting Screw Trapped Oil
Fig. 3-Sefective Control Valve Oil Flow Neutral Position
NOTE: 3 shows the oil conditions in the SCV in

Fig.
pressure and return valves. The right-hand breakaway
neutral. There is no oil flow. High pressure oil is at coupler is closed during single-acting cylinder opera-
standby. OH is trapped between remote cylinder and tion.

OPERATIONContinued Oil Flow

With the rocker arm lever forward and the detent
Extend follower in or near the detent cam extend detent (B,
Console lever movement rearward will cause a re- Fig. 4); the lower-left pressure poppet valve (K) and the
mote cylinder to extend (if the piston-end cylinder hose lower-right return poppet valve (O) will be open.
is connected to the proper receptacle). The console
lever may be held rearward until the desired extension Pressure oil through the metering valve (H) and
is obtained. Or, if the control lever is moved to its rear through the flow control valve bore (I) flows through the
limit in the console guide, the lever will remain rear- open pressure poppet valve (K).
ward until the remote cylinder reaches the end of its
stroke. From the open pressure valve, oil flows through the
breakaway coupler receptacle (L) to extend
left-hand
Detent Operation In Extend the remote cylinder (if the piston-end cylinder hose is
connected in that receptacle [M]).

Moving the console lever to its rear limit aligns the
detent cam's extend detent (B, Fig. 4) with the detent
Return oil from the rod-end of the cylinder (N) is
follower (E).
forced through the right-hand coupler receptacle. The
open return poppet valve (O) allows oil to the return oil
Spring force at the rear of the detent piston (G) plus r
passage (P). The return oil is routed to the hydraulic
a pressure drop across the metering valve (H) moves
return circuit.
the detent piston and pin (R) down to hold the follower
in the detent until the end of the cylinder stroke when
flow stops.
When flow stops, pressure increases. It builds at the

front of the detent piston until pressure at the front
equalizes with the force applied at the spring end of the
piston. Because of the difference in area on the detent
piston pin (R), pressure at the front overcomes the
forces at the inlet and spring end of the piston. Since
no forces are now holding the valves open, the valve
springs close the valves rotating the rocker and con-
sole lever to the neutral positions.

Extend
R34868
AOperating Cams G Detent Piston and Spring MTo Remote Cylinder

B Detent Cam (extend detent) HMetering Valve S Flow Control
CFollowers flower) N From RH Receptacle and Cylinder Valve Stop
| Row Control Valve O Lower Return Poppet Valve
D Followers (upper) J|g Pressure Oil
J Upper Return Poppet Valve P Return to Function Return Passage
E Detent Follower K Lower Pressure Poppet Valve QUpper Pressure Poppet Valve
:::' Return to
F Inlet Charge Oil
l Coupler Receptacle RDetent Piston Pin
Fig. 4~$elective Control Valve Oil FlowExtend Position
NOTE: Fig, 4 shows flow while using a double-act-

ing cylinder. During single-acting cylinder extension,
ail
return oit is routed to the hydraulic reservoir.

OPERATIONContinued Oil Flow

Since the rocker assembly has opened the upper
Retract right-hand pressure poppet valve (K, Rg. 5) and the
Console lever movement forward will cause a re- upper left-hand return poppet valve (Q), pressure oil
mote cylinder to retract The console lever may be held through the metering valve (I) and the flow control
forward until the desired retraction is obtained. Or, if valve (J) is directed out the open pressure poppet
the control leveris moved to its forward limit in the valve (K).
console guide, the lever will remain forward until the
remote cylinder reaches the end of its stroke. Oil is routed out the right-hand coupler receptacle
(M) to the rod-side of the remote cylinder.
Detent Operation In Retract
As the cylinder retracts, return oil from the cylinder
Moving the console lever to its forward limit rotates
(N) is forced through the left-hand receptacle (O).
the rocker lever arm (C, Rg. 5) rearward to align the
detent follower (F) with the top detent of the detent cam
Since the return poppet valve (Q) is open, oil is
(B).
allowed to the return oil passage (R). The return oil is
routed to the hydraulic return circuit.

Spring force at the rear of the detent piston (H), plus
a pressure drop across the metering valve (I) moves
the detent piston and pin to hold the follower (F) in the
detent.
The appropriate pressure and return valves are held

open by their cam followers (E) until the cylinder is fully
retracted and flow stops.
When flow is stopped, pressure builds at the front of

the detent piston to equalize with inlet and spring
pressure at the rear of the detent piston.
Because of the difference in area on the detent

piston pin, the pressure on the front of the detent piston
overcomes inlet and spring pressure to move the fol-
lower (F) out of the detent.
The poppet valve springs can now close their

valves, and the rocker and console lever return to their
neutral positions.

Retract
R34S59
A^-Operating Cams
BDetent Cam (retract detent) JM? MTo Remote Cylinder S Flow Control
H~Detent Piston and Spring N-From Remote
CRocker Arm Retract Position "2etenn9 Varve
Cylinder Varve Stop
DLower Cam Followers O-Coupler Receptacle BB Pressure Ott
J-Flow
r
Control Valve P-Lower Pressure Poppet Valve
EUpper Cam Followers KUpper Pressure Poppet Valve
$;;$ Return to
FDetent Follower Q-Upper Return Poppet Valve Charge Oil
L-Lower Return Poppet Valve R Return to Charge Circuit
Fig. S-Selectrve Control Valve Oil Flow-Retract Portion
NOTE: Fig. 5 shows flow while using a double-act-

ing cylinder. During single-acting cylinder
retraction, all
return oil is routed to the hydraulic
reservoir
A
R34370
A Detent Cam F Detent Piston and Spring KFrom Right-Hand Receptacle P Flow Control
B"Regular" Valve Operating Cam GMetering Valve LLower Return Poppet Valve Valve Stop
C"Float" Valve Operating Cam HFlow Control Valve M Left-Hand Coupler Receptacle ggl Pressure Oil
DRocker Arm I Upper Pressure Poppet Valve NUpper Return Poppet Valve ^5. Return to
EInlet J Lower Pressure Poppet Valve OReturn Oil Passage Charge Oil
Fig. 6~Seiective Control Valve Oil HowFtoaf Position
the appropriate movable stop (A, Fig. 2) in the

If past its retract detent to bypass the detent follower.
console guide is raised, moved forward, and dropped The operating cams open the two return poppet valves
into the guide; the selective control valve console lever (L and N) only in this position. Since return oil is
can be moved further forward to the float position. allowed at both ends of the cylinder, it is free to extend
This further movement forward rotates the rocker or retract according to load without restriction.

Selective Control Valve and Remote Cylinder 270-30-9
Breakaway Couplers
AInlet Passage OStop Hod Arm

B Bleed and Stop Valves E Piston Rod Stop
CStop Rod and Spring FPiston
Fig. 8-Remoie Cylinder Operation - Extend
&&?$%?
When extending, pressure oil enters at the piston
A Valve Housing E Lever end of the cylinder (at the side away from
the stop rod
B Receptacle Balls FCylinder Plug with Guide, assembly). Oil enters at the opposite end on the stop
C Receptacle Spring, and Ball when
DPlug wHh Spring and rod side retracting. On single-acting cylinders the
BaN GCylinder Plug
weight of the implement on the rod side of the cylinder
Fig. 7-8rsakaway Coupler forces oil out the piston side to the selective control
valve to retract.
Before a remote cylinderline plug (G, Fig. 7) is
inserted into the coupler body of the selective control Since the piston rod takes up an area, that area can
valve, the receptacle (C) must be moved rearward not be exposed to pressure to move the piston (F, Fig.
for
the balls (B) to seat As the hose plug (G) is inserted, 8). Therefore the retracting stroke of the cylinder is less
the receptacle assembly is pushed toward the front powerful than the extending stroke. Since the entire
of
the tractor. With tever (E) perpendicular to the side face of the piston is exposed to pressure on the ex-
of
the valve housing, the check balls in the receptacle (D) tending stroke, more oil is used and a slower, more
and hose line plug (F) are unseated to allow oil flow. A powerful stroke occurs. Thus, the double-acting cylin-
passage from the selective control valve to the coupler der is the differential or unbalanced type.
admits pressure oil to the line.
The hydraulic-stop remote cylinder can limit piston
Pulling the line plug (G) to the rear also travel by shutting
the flow of outlet oil. As the piston
off
moves the
coupler assembly to the rear to affow disconnection. retracts, the adjustable rod stop (E) contacts the
stop
This action rotates the coupler operating lever (E) to a valve arm (D). This seats the stop valve and closes the
position oil outlet. The trapped oil resists
perpendicular to the rear of the tractor. piston travel and
Therefore the receptacle plug spring can seat causes pressure to rise on the rod end. This causes
its ball
(D) without oil loss. the selective control valve to return to neutral closing
the poppet valves.
The cylinder plug
is locked in place by a ring of balls
(B) which is a groove on the inserted plug (G) by
held in A spring allows incoming oil to reopen the valve for
an outer sleeve. This arrangement creates an auto- the next cylinder stroke.
matic lock release in case the cylinder lines are ac-
cidentally pulled loose. This is a safeguard to discon- Bleed holes in the stop valve allow a limited amount
nect hose lines when an implement is urhitched. of oilout of the cylinder when the console lever is held
in the retract position. This creates an "override" fea-
Remote Cylinder ture* to further retract a cylinder.
One size of double-acting cylinder is available: 3 * Available as a field kit, only

inch diameter, with an 8-'mch stroke (76 by 203 mm
mm). The double-acting cylinder has more applications
than the single-acting cylinder because force can be
applied in both directions. The remote cylinder is
equipped with a hydraulic stop.
TM-1181 (Sep-77) Lithe in U.S.A.

)
NOTE: Before attempting to diagnose selective Cylinder Will Not Retract

control valve malfunctions, refer to 270-10, Hydraulic Remote cylinder stop valve stuck (See 70-20-11)
System Tests.
Coupler receptacles not opened (Re-install hose)
Rocker to shaft spring pin sheared (See 70-20-3)
System Malfunctions Lower pressure or return poppet valve leaking (See
70-20-4)
Cylinder Won't Extend or Moves Too Slowly Upper pressure or return poppet valve stuck closed
SCV metering valve in low flow position (Adjust) (See 70-20-4)
Low transmission oil level (Replenish) Cylinder piston o-ring failure (See 70-20-11)
Oil filter plugged (Replace)
Filter bypass valve stuck open (See 70-05) Cylinder Creeps Under Load
Cooler relief valve stuck open (See 70-05) Poppet valves leaking (Seat damaged) (See 70-20-
Oil pressure regulating valve stuck closed (See 70-
4)
05) Cylinder piston o-ring failure (See 70-20-11)
Transmission pump failure (See 70-10) Return poppet valve or guide o-rings failure (See
Transmission suction screen plugged (Remove and 70-20-5)
clean) Pressure poppet valve roller-end o-ring failure (See
Low standby pressure (See 70-10) 70-20-5)
Main pump failure (See 70-10) Coupler receptacle o-ring failure (See page 70-20-
Steering system malfunction (See 60-05)
2)
Rockshaft system leakage (See 70-15)
Load on 3-point hitch less than load on cylinder
Contro ijsmf
, Won't Go Into Detent
(Adjust flow control valve)
Pressure control valve malfunction (See 70-05) Coupler receptacles not opened (Re-install hose)
Control lever linkage maladjusted or binding (In-
Selective Control Valve Wont Stay in Detent spect and Repair)
Detent cam installed incorrectly (See 70-20-7)
High standby pressure (See 70-10)
Low standby pressure (See 70-10) Control Lever Won't Return to Neutral
Main pump malfunction (See 70-10)
Pressure contro! valve malfunction (See 70-05) Control lever linkage maladjusted or binding (In-
Load on 3-point hitch less than load on cylinder spect and Repair)
(Adjust flow control valve) Detent piston or pin stuck or binding (See 70-20-5)
Cylinder Will Not Extend Cylinder Operates Slowly
Rocker to shaft spring pin sheared (Replace, See Metering valve incorrectly adjusted or sticking (See
70-20-3) 70-20-5)
Coupler receptacles not opened (Re-install hoses) Return poppet valve leaking (See 70-20-4)
Upper pressure or return poppet valve leaking (See Cylinder stop valve sticking (See 70-20-11)
70-20-4)
Lower pressure or return poppet valve stuck closed
(See 70-20-4)
Cylinder piston o-ring failure (Repair, See 70-20-1 1

TESTING
i 1. Refer to 270-10 for hydraulic

system preliminary
checks, special tools, and test procedure
whenever trouble shooting a hydraulic problem.
to use
2. If standby or operating pressure does not meet

specifications, isolate the faulty component and repair
\tbefore making any further selective control
valve
checks.
A
**
CAUTION: Escaping fluid under pressure
skin, causing serious persona! injury.
Before dis-
connecting lines, be sure to relieve ail pressure.
Before applying pressure to system, be sure
all
Fluid escaping from a very small hole
can almost
be invisible. Use a piece of cardboard or
wood,
rather than hands, to search for suspected
leaks!
If injured by escaping fluid,
see a doctor at once.
Serious infection or reaction can develop if
proper
ly.
Time Cycle Test

Properly connect a 3-inch by 8-\nch A-Selective Control Valve BMetering
1.
(76 by mm Valve Arm
203 mm) remote cylinder to the selective control valve GRemote Cylinder
couplers (A, Fig, 9).
Fig. 9-Checking Remote Cylinder Time Cycle
2. Move the selective control valve metering valve
to the full open position (B).
3. Operate the engine at 2000 rpm.
4. Time required toextend the remote cylinder (C)
from the full retract position should be from 1.5 to 2.0
seconds.
5. If cylinder extends too sJowfy, test flow
as in-
structed on page 12 of this group.
TM-1181 (Sep-77) Utho in U.S.A.

270-30-1 2 Selective Control Valve and Remote Cylinder Hydraulic Operation and Tests
Flow Test
NOTE: The following test result is the flow available

tothe remote cylinder. Therefore, the test does not
check return valve operation. To test for return valve
leakage, see page 13.
Fig. 1 1 -Adjusting Flow Meter Ftow Control Valve
4. Adjust the flow meter flow control valve to obtain

1500 psi (103.4 bar) (105.5 kg/cm 2 ). (See Fig. 11.)
5. Move the metering valve arm (A, Fig. 10) to

obtain maximum and minimum flow. Flow should be
adjustable from at least 3 to 16 gpm (11 to 60 l/min).
6. Move the control lever rearward with the inlet
hose in the left-hand receptacle.

AMetering Valve Arm D0761 Fitting
B0714 Coupler E0092 Adapter 7. Repeat steps 4 and 5. Flow should be the same.
C0760 Swivel F0094 Hose
8. if flow does not meet specifications for each
Fig. 10-FJow Test Connections
selective control valve , complete the valve leakage
test.
1. Insert the inlet hose plug in the right-hand
coupler of the selective control valve and the Flow
Meter outlet hose in the left-hand coupler. (See Fig.
10.)
2. Open the flow meter flow control valve and

operate the engine at 2000 rpm.
3. Move the appropriate selective control valve

console lever forward.

.

Selective Control Valve and Remote Cylinder 270-30-13
Valve Leakage Tests

b) If pressure drops below1 000 psi (69.0 bar)
(70.3 kg/cm 2 ) within

minute, the lower re-
1
Leakage Test Procedure
turn poppet valve seat, O-ring, guide O-ring
may be leaking (L, Fig, 6). Or the upper
pressure vaive front O-ring is leaking (see I
Rg. 6).
Fig. 12-Pressure Gauge in Right-Hand Receptacle
1 Install a 2-foot (610 mm) hose with a

0-3000 psi
(0-200 bar) (0-200 kg/cm 2 ) pressure gauge in a right-
Fig. 13-Pressure Gauge in Left-Hand Receptacle
hand coupfer receptacle. (See Fig. 12.)
4. install the pressure gauge and
2. Operate the engine hose in the left-
at 2000 rpm. hand coupler receptacle and operate the engine at
2000 rpm. (See Fig. 13.)
3.Adjust pressure to 1500 psi (103.4 bar) (105.5
kg/cm E ) by moving console fever forward. Maintain
5. Adjust pressure to 1500 psi (103.4
pressure for 10 seconds, then release lever. bar) (105.5
kg/cm 2 ) by moving console lever rearward. Maintain
pressure for 10 seconds, then release lever.
a) With the lever in neutral,
pressure rises
rf
above 2000 psi (137.9 bar) (140.7 kg/cm 2

) a) Ifpressure rises above 2000 psi (137,9 bar)
within 1 minute, the seat of the upper
pres- (140.7 kg/cm 2 } within 1 minute, the seat of the
sure valve (I, Fig. 6) is leaking.
lower pressure poppet valve (J, Fig, 6) is
leaking,
b) pressure drops below 1000

If
psi (69.0 bar)
(70.3kg/cm 2) within 1 minute, the upper re-
turn poppet valve (N, Fig. 6) seat, O-ring,
guide O-rrng, or front O-rfng on the lower
pressure valve is leaking (see J, Fig. 6).
TM-U81 (Jun-80) Litho in U.SA. Tractors - 4040 and 4240

SELECTIVE CONTROL VALVE AIR LEAKAGE TESTS

When hydraulic diagnosis indicates leakage at SCV, Checking SCV Return Passages
use a TY4345 or similar Air Pressure Regulator ad-
justed to 70 psi maximum (no flow) pressure to check
SCV separately.
h
Nozzle, connector and pressure hose can be ob- I
tained from JDG-85 Air Pressure Test Kit.
Checking SCV Pressure Passage
RS0049C1
A SCV Plug (2104) (D-8) OAir Nozzle

B Coupler Lever D Pressure Hose
Fig. 15-Checking SCV Return Passages
1. Install SCV plug (A, Fig. 15) (2104) (D-8) in

R80049K1 ^
Quik-Coupler.
ARocker Assembly CPlug
2. Position Quik-Coupler lever (B) at flow position.
BAir Nozzle
Fig. 14-Checking SCV Pressure Passage 3. Position valve in neutral.
1. Position valve in neutral. Rocker assembly (A T

4. Apply air (70 psi [4.8 bar] [4.9 kg/cm*] maximum)
Fig. 14) should be nearly level with mounting surface of with nozzle and hose to both right and left-hand sides.
housing, There should not be any leakage.
2. Apply air (70 psi [4.8 bar] [4.9 kg/cm 2 ] maximum) NOTE: leakage is detected, replace valves and
If
with plug on air nozzle at pressure inlet passage. There adjust as described in Section 70, Group 20. Repeat
should not be any leakage. test Grind valve seats only if there is evidence of seat
damage.
NOTE: If leakage is detected, replace valves and
adjust as described in Section 70, Group 20. Repeat
test Grind valve seats only if there is evidence of seat
damage.

Operator Station Operation and Tests
Specifications and Special Tools 290-00-1
Section 290
OPERATOR STATION
OPERATION AND TESTS
Page
Page
GROUP 5 - AIR CONDITIONING GROUP 15 - HEATING SYSTEM
SYSTEM OPERATION OPERATION AND TESTS
How The System Works 290-05-1 How the System Works 290-15-1
Electrical Testing 290-05-3 Diagnosis and Testing
Service Valves 290-05-3 Preliminary Checks 290-15-2
Refrigerant Couplings
Electrical Testing 290-15-2
How the Couplings Work 290-05-6 Diagnosing Malfunctions 290-15-2
Compressor
How the Compressor Works 290-05-7 GROUP 20 - SEAT
Receiver-Dryer
(See Section 270 Hydraulic Operation and Tests for
How the Receiver-Dryer Works 290-05-8 information regarding the
Hydracushioned Seat.)
Regulatory Controls
Hydracushioned Seat Suspension
Expansion Valve
Diagnosis 290-20-1
How the Expansion Valve Works 290-05-8
Thermostatic Temperature Control Switch
How the Switch Works 290-05-8
Compressor Relief Valve
How the Relief Valve Works 290-05-9
GROUP 10 - AIR CONDITIONING

SYSTEM TESTS
General Information 290-1 0-1
Preliminary Checks 290-10-1
How to Use Step-by-Step Air Conditioning
Diagnosis Charts 290-10-1
Safety Instructions 290-10-2
Air Conditioning Diagnosis Charts 290-10-3
Discharging the System 290-10-22
Flushing the System 290-1 0-22
Adding Refrigerant Oil to the System 290-10-23
Purging the System 290-10-24
Evacuating the System 290-10-24
Charging the System 290-10-25
Leak Testing the System 290-10-26
TM-1181 (Jun-80) Litho in U.S. A,

290-00-2 Specifications and Special Tools Operator Station Operation and Tests
Group 00
SPECIFICATIONS
Evacuating System (sea level) 29-29.5 in. (1 bar) vacuum

Refrigerant capacity 4 lb. (1,81 kg) Refrigerant-12
Compressor
Oil charge (new or rebuilt) 11 fluid oz. (312 ml_) Frigidaire 525 oil
Pulley diameter Approx. 5-5/8 in. (142.8 mm)

Discharge pressure at 2000 rpm 100-300 psi (7-20 bar) (690-2070 kPa)
Suction pressure at 2000 rpm 1-0-35 psi (.07-2.4 bar) (7-240 kPa)
Compressor Drive Belt
Size 1/2 in - O2 - 7 mm)
Tension
New belt 130-140 lbs (578-622 N)
After run in 85-94 lbs (378-423 N)
Compressor Clutch Coil
Current draw (at 12 volts) 3.2 amps
Resistance 3.7 ohms at 80F (26.7C)
Condenser
Pressure drop in core 2.3 to 8 psi (138 to 552 mbar) (16-55 kPa)
Evaporator
Pressure drop in core 5 to 12 psi (345 to 827 mbar) (35-83 kPa)
Expansion Valve
Q
Superheat setting Approx. 6 F (14.4C)
Thermostatic Temperature Control Switch Cold Settings
Evaporator refrigerant temperature
Contact points open (lower temp, limit)
C
30 F ( 1 ,1C) 1F ( 17.2C)
Contact points close (upper temp, limit) 37F (2.78C) 1F ( 17.2C)
Compressor Relief Valve
Valve opens 440 psi (30 bar) (3030 kPa)
Pressurizer Motors and Blowers
Maximum current draw (at 12 volts) 9 am PS
Heating System
lte m Specification
Heater Valve
Flow rate (at 5 psi [345 mbar]) Approx. 7 gpm (26.5 L/min)
Heating system flow rate at 2000 rpm 3.5 gpm (13.3 L/min)

Specifications and Special Tools 290-00*3
Hose and Tubing Flare Connection Torques
Metal Tube
Outside Diameter
inches (mm)
Thread and
Fitting Size
inches (mm)
SteeJ Tubing**
Torque
Aluminum or
Copper Tubing*
Torque
Nominal Torque
Wrench Span
ft-lbs (Nm) (kgm) tt-lbs (Nm) (kgm) (inches)
1/4 7/16 10-35 (14-47) (1.4-4.7) 5-7 (7-9) (.7-.9) 5/8

3/8 5/8 30-35 (41-47) (4.1-4.7) 11-13 (15-18) (1.5-1.8) 3/4
1/2 3/4 30-35 (41-47) (4.1-4.7) 11-13 (15-18) (1.5-1.8) 7/8
5/8 7/8 30-35 (41-47) (4.1-4.7) 18-21 (24-29) (2.4-2.9) 1-1/16
3/4 1-1/16 30-35 (41-47) (4.1-4.7) 23-28 (31-38) (3.1-3.8) 1-1/4
*ff a conn cfcn /s macfe ^

*** to aAi/nAwin or copper, use the lower torque
Use steelf tubing torques only when both ends of connection
are steel.
specification
Hose and Tubing O-Ring Connection Torques

Metal Tube Thread and
Outside Diameter Fitting Size Torque
inches (mm) inches (mm) ft-lbs (Nm) (kgm)
1/4 7/16 10-15 (14-20) (1.4-2)

3/8 5/8 10-15 (14-20) (1.4-2)
1/2 3/4 24-29 (33-39) (3.3-3.9)
5/8 7/8 26-31 (35-42) (3.5-4.2)
3/4 1-1/16 30-35 (41-47) (4.1^.7)
CAP SCREW TORQUE CHART ft-lbs (Nm) (kgm) *The types of bolts and cap screws are identified by
head markings as follows:
Three Six
Diameter Plain Head* Radial Dashes* Plain Head: regular machine bolts and cap screws.
Radial Dashes*
3-Dash Head: tempered steel high-strength bolts
1/4 6 (8) (.S) 10 and cap screws,
(14) (1.4) 14 (19) (1.9)
5/16 13 (18) (1.8) 20 (27) 30
(2.7) (41) (4.1) 6-Dash Head: tempered steel extra high-strength
3/8 23 (32) (3.2) 35 (47) (4.7) 50 (66)
7/16 35 (47) (4.7) 55 (75)
(6.8) bofts and cap screws.
(7.5) 80 (106) (10.8)
1/2 55 (75) (7,5) 85 (115) (11,5) 120
**Machine bofts and cap screws 7/8-inch and larger
(163) (16.3)
9/16 75 (102) (10.2) 130 (176) (17.6) 175 are sometimes formed hot rather than cotd which
(237) (23.7) t
5/8 105 (142) (14,2) 170 (230) 240 accounts for the lower torque.
(23) (325) (32.5)
3/4 185 (244) (24.4) 300 (407) (40.7) 425 (576) (57.6)
7/8 **160 (217) (21.7) 445 (603) (80.3) 685 (925) (92.5)
1 **250 (339) (33.9) 70 (908) (90.8) 1030 (1396) (139.6)

A
290-00-4 Specifications and Special Toots Operator Station Operation and Tests
SPECIAL TOOLS
Test Equipment
A D-18019KD Manifold Pressure Gauge Assembly 4

BD-18023KD Refrigerant Can Dispensing Valve*
CD-18032KD Test Plate*
KZS&S'Hi?
Ftg. 1 -Special Test Equipment
A D-18009KD Electronic Leak Detector*

BVacuum Pump*
Materials
RefrigeranM2 (Quantity required depends on amount

of system service performed. See
Charging The System.)
525 viscosity compressor oil (See "When Servicing
Compressor/')
* Order test equipment from:

Service Tools inc.,
?rdS83vHi
Box 31 4, Owatonna MN 55060
Ftg. 2-Spedai Test Equipment
TM-1181 (Feb-79) Utho in U.S. Tractors - 4040 and 4240

Specifications and Special Tools 290-00-5
No. Description
A - 2632 3/4 Tube with 1/4 Tee
B - 2733 Tube Test Plug
C - 2634 3/4 to 1/4 Tube Adapter
D - 2635 7/8 to 7/16 Adapter
- 2636 Union Adapter Assembly
h - 2637 Tube Adapter
G - 6887 5/8 to 7/16 Reducer
H - 6888 3/4 to 7/16 Reducer
1 - 7432 3/4 to 5/8 Reducer Elbow
J - 7436 1/2 to 7/16 Reducer
K - 7426 1/2 to 7/16 Reducer Elbow
L - 7427 7/16 to 5/8 Adapter
M - 7439 7/16 to 5/8 Reducer
N - 7447 Cap (2 used)
- 7509 7/8 to 7/16 Adapter
P - 7510 7/8 to 7/16 Reducer
Q - 7511 3/4 to 7/16 Tee Assembly
D-15038NU Air Conditioning Service Fitting Kft
Above kit is used for flushing and purging

air conditioning components, bench testing
R3G196A1
components, and testing thermal expansion
valves.
Fig 3-Air Conditioning Service Fittings

r
Order From: Service Tools

P.O. Box 314
Owatonna, MN 55060

290-00-6 Specifications and Special Tools Operator Station Operation and Tests

Air Conditioning System Operation 290-05*1
Group 05
AIR CONDITIONING SYSTEM OPERATION
9
, ;
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^^^^^Â^T^^^y^T?? ^T^^TtT^
R 31541C
AMagnetic Clutch HSight Glass

BCompressor O Temperature Control Switch
Expansion Valve
C Condenser
I
SI; High Pressure Liquid
J Sensing Tube
D Heat Transfer "'v High Pressure Gas
From
K Heat Transfer From
BB Low Pressure Liquid
Refrigerant Gas To Cab Air To Refrigerant ^^" Low Pressure Gas
E
F
Outside Air At Condenser
Receiver-Dryer
Gas At Evaporator
L Evaporator I Temperature Sensing
Tube Gas
Desiccant MTemperature Sensing Tube
G Pickup Tube NExternal Equalizer Line
Ftg. 1-Schematic of Air Conditioning System

290-05-2 Air Conditioning System Operation Operator Station Operation and Tests
R327S8
ACompressor E Expansion Valve HTemperature Sensing Tube

BCondenser F Evaporator I Recirculating Air Fitter
CCouplers G Blowers J Fresh Air Fitter
DReceiver-Dryer
Fig, 2-Air Conditioning System
The System Cycle of refrigerant entering the evaporator is regulated by

a diaphragm-type valve, called an expansion vafve (E).
Referring to Fig. 2, the compressor (A) draws low
This valve uses an orifice to reduce the flow of high
pressure refrigerant from the evaporator (F) and com-
pressure liquid refrigerant into the evaporator, causing
presses it to a high pressure, increasing the pressure
the refrigerant pressure and temperature to drop.
of the refrigerant causes its boiling point to rise to a
Warm cab air, pulled over the evaporator by the
temperature higher than that of the outside air. heat to the cooler
pressurizer blowers, gives up its
As the high pressure gas passes through .the con- and causing the
refrigerant, thereby cooling the air
denser (B), heat is removed from the gas and trans- Because the pressure in
refrigerant to boil, or vaporize.
ferred to the cooler outside air being forced through the
the evaporator is low, the boiling point of the refrigerant
condenser core. This permits the refrigerant gas to
is also low.
cool sufficiently to condense into a liquid {stiff under
Moisture (in the air) is collected on the evaporator
high pressure).
core during the cooling process and drained away.
The high pressure liquid then passes through the
With the cab air cooled and dehumidified, the desired
receiver-dryer (D), where contaminants such as mois- now com-
effect has been produced and the cycle is
ture, acids, or solids are removed by a special filter.
plete.
The receiver-dryer also acts as a storage reservoir for
The expansion valve and a thermostatic tempera-
refrigerant until demanded by the evaporator.
ture control switch (O, Fig. 1) are the two controls used
The evaporator where the actual cooling and
Is
in the air conditioning system to maintain the proper
drying of warm, moist cab air takes place. The flow
cooling balance.
Air Conditioning System Operation 2 90-05-3
A temperature sensing bulb (M, Fig. 1) is connected Component Check

to the expansion valve by means of a capillary tube
I filled with a low pressure gas.
The sensing bulb is When an electrically operated component in the
clamped to the evaporator outlet pipe and is well system fails to function, make the following preliminary
insulated from external heat sources. Too little checks:
or too
much refrigerant passing through the expansion valve
1. Determine if adequate voltage is being supplied
intothe evaporator, wilf limit the cooling efficiency of to the air conditioning system.
the system.
2. Visually check for a loose connection or a broken
If too little refrigerant passes through the expansion wire.
valve, the refrigerant gas will become too hot, permit- If, aftermaking the preliminary checks, the source of
ting the gas the sensing bulb to
in expand enough to trouble has not been found, test the system for an open
open the expansion valve.
circuit within each component.
If too much liquid refrigerant passes through the Superheat Shutoff Switch
expansion valve, some of the liquid will still be va-
porizing as it leaves the evaporator. This
lowers the
temperature at the outlet, which in turn lowers the
temperature of the gas in the sensing bulb and allows
the expansion valve to close.
The thermostatic temperature control switch is a

rotary-type switch that is connected to a temperature
sensing tube (H, Fig. 2) inserted in the evaporator core.
The switch end of the gas-filled sensing tube has a
diaphragm which controls two external contacts wired
to the
compressor clutch. When the cab air needs to be
cooled, corresponding to the preselected control
set-
ting, the compressor will turn on.
The compressor will
continue to function until the selected temperature
is
reached.
A superheat shutoff switch on the air conditioning

compressor prevents compressor failures due to loss
of charge or restriction in system. The
switch is sensi-
tive to high temperature and low
pressure. When the
combination of both conditions occurs, or the extreme
of either condition exists the compressor R 31782
is shut off to
prevent damage.
ELECTRICAL TESTING A^-Superheat Shutoff Switch CThermal Fuse

BWiring Harness D Snap Ring
Wiring Diagrams Rg. 3-Superheat Shutoff Switch
Refer to Section 240 for wiring diagrams on the air

1. Disconnect the wiring lead from
conditioning system. the superheat
shutoff switch (A, Fig. 3).
2, Connect one lead of a test fight on the superheat

shutoff switch terminal, and the other lead to a power
supply.
>
TM-1181 (Fett-79) Utho in USA. Tractors - 4040 and 4240

If the bulb lights the superheat shutoff switch is Schrader Valves

defective.
NOTE: When replacing the superheat shutoff

switch, the snap ring (D, Fig. 4) must be installed with
the convex side toward the switch to provide a positive
seat and the electrical ground.
Thermal Fuse
1 . Disconnect the wiring harness (B, Fig. 3) from the
thermal fuse (C). R 27041N
2. Install a continuity tester between terminals Fig. 5-Schrader Valve

marked "B" and "C" on thermal fuse (Fig. 4).
When the fitting In the end of the service hose is
If tester shows continuity, the thermal fuse is good. If screwed onto the Schrader valve (Fig. 5), a pin is
no continuity, the fuse is blown and must be replaced. depressed in the center of the valve allowing pressure
to be read on the gauges. When the fitting is removed,
the valve closes.
R 31783
ArThermal Fuse DResistance-type

B Superheat Shutoff Switch Heater
CAir Conditioning Switch EFuse Link
Fig. 4-Thermal Fuse

A

Operation and Tests 290-05-5
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TM-1181 (Feb-79) Litho in U.S.

290*05-6 Air Conditioning System Operation Operator Station Operation and Tests
HOW THE COUPLINGS WORK
There are two refrigerant couplings, both located on
the pressure side of the air conditioning system (C, Fig.
2). One coupling is near the discharge side of the
compressor and the other is just in front of the Sound-
Gard Body, next to the side frame.
R 31845
A Union Nut and C Poppet Valve Assembly

Body Assembly [>-Body
B Valve and Sleeve EGasket Seat
Assembly
Fig. 9-Refrigerant Coupling Fully Connected
31843
Tightening the union nut (A, Fig. 9) draws the cou-
pling halves together.At the same time, the poppet
Fig, 7-Refngerant Coupling Disconnected
valve assembly (C) and valve and sleeve assembly (B)
are moved to open the fluid passage around the
When the coupling is disconnected (Fig. 7), both
valves. When fully coupled, gasket seal (E) on the
halves seal to prevent loss of refrigerant and admission
recessed face of the body (D) is compressed between
of air or foreign material into the system.
faces of coupling bodies (D) and (A) to form a seal.
During disconnection, the springs automatically return

valves (C) and (B) to their sealing position.
R 31844
AUnion Nut and CPoppet Valve Assembly

Body Assembly DBody
BValve and Sleeve EGasket
Assembly
Ftg. 3-Refrigerant Coupling Partially Connected
As the two coupling halves are partially connected

together by the union nut (A, Fig. 8), the stem valve
head of the valve and sleeve assembly (B) contacts the
face of the poppet valve assembly (C), expelling air.
Body (D) contacts a gasket (E) on the face of sleeve
making a seal during the connection.

Air Conditioning System Operation 290-05-7
COMPRESSOR
R 27Q43N
AO-Ring Seal Oust Cover

B Piston
I
PSwash plate
JHub and Drive QMa shaft Rear
C Drive Ball Plate Assembly
in
DBall Bearing
Shoe K
E Suction Reed Pulley R Oil Pick-Up Tube
F Front Discharge L Clutch Coil S Suction Reed

M Front Head T Rear Discharge
Valve Plate NMain shaft Front Valve Plate
G Shaft Seal
H Pulley Bearing
Bearing U~ Rear Head
OMainshaft Thrust V Relief Valve
Bearing WOil Pump
X Superheat Switch
Fig, 10-CrosS'Section of Deico (Frigidaire) Compressor
HOW THE COMPRESSOR WORKS An oil pump (W) mounted at the rear of the com-
The compressor is a Delco (Frigidaire), horizontal,
pressor picks up from the bottom of the compressor
oil
6-cylinder (3-pistons) f double-acting type (Fig. oil sump and pumps the oil to the internal working parts
10),
and is belt-driven from the engine crankshaft. of the compressor
Pistons (B) are mounted axially around the com- Operation of the compressor is controlled by the
pressor shaft and driven by a swash plate (P). temperature control switch, which electrically controls
the magnetic clutch (J) on the compressor.
Reed-type suction and discharge valves are
mounted in valve plates (S and T) between the cylinder The compressor Is fitted with a high pressure relief
assembly and the head at each end of the compressor. valve (V) which opens whenever the compressor
dis-
The heads are connected by gas-tight passage ways charge pressure exceeds 440 psi (30 bar) (30 kg/cm 2
).
which direct refrigerant gas to a common outlet.

290-05-8 A ir Conditioning System Operation Operator Station Operation and Tests
RECEIVER-DRYER
R 25126K
AInlet From D Outlet To

Condenser Expansion Valve
BDesiccant EPick-Up Tube R 31784
C Sight-Glass F Fitter Pad
A Sensing Bulb EOrifice
Fig, H -Cross-Section of Receiver-Dryer BExternal Equalizer Line F Valve Seat
C Diaphragm G Spring
How The Receiver- Dryer Works D Screen H Valve Outlet
receiver-dryer (Fig. 11), mounted under body
The Fig. 12-Expansion Valve
on left-hand side, has a two-fold function. First, it
receives the high pressure liquid refrigerant from the The expansion valve has an external equalizer line
condenser and stores the liquid until needed by the (B) which allows pressure at the valve outlet (H, or
evaporator. Second, the unit removes harmful mois- evaporator inlet) to be transmitted to the evaporator
ture (and acids), and filters out solid contaminants. side of the diaphragm.
Solid contaminants are filtered by the strainer-fitter THERMOSTATIC TEMPERATURE

pads (F), while moisture and acids are removed by the CONTROL SWITCH
dessicant material (B) filling the chamber between the
fitter pads. How The Switch Works
into the The purpose of the temperature control switch (A,

The sight glass (C) is incorporated re-
checking temperature of the refrigerant
Fig. 13) is to regulate the
ceiver-dryer unit, and should be used for
in the evaporator corresponding to the control knob
refrigerant operation.
setting selected by the operator.
REGULATORY CONTROLS The switch consists of a set of contact points which

EXPANSION VALVE receives its power from the pressurizer motor switch.
Valve Works The current flows from the temperature switch to the
How The Expansion
compressor clutch.
Liquid refrigerant under high pressure is piped to the
expansion valve (B, Fig. 12) from the receiver-dryer. The contact points in the temperature switch are
The function of the expansion valve is to regulate the controlled by a gas-filled temperature sensing tube (B)
amount of liquid refrigerant entering the evaporator having a spring bellows or diaphragm on one end
(now under low pressure), depending upon the desired making contact with the point operating mechanism.
inside temperature. Sensing action which regulates The other end of the sensing tube is inserted into the
valve action takes place in the temperature sensing core of the evaporator.
bulb (A),

Air Conditioning System Operation 290-05-9
R 31144
ATemperature Control Switch B Sensing Tube

Rg t 13-Temperature Control Switch
When the control knob is turned on (clockwise), the COMPRESSOR RELIEF VALVE
contact points dose, thereby activating the compres-
sor. However, the compressor will not operate
unless
the pressurizer motors are turned on. As the tempera-
ture in the evaporator reaches its specified lower limit,
the contact points are allowed to open, which in turn
shuts off the compressor. The compressor will remain
off until the temperature in the evaporator reaches its
specified upper limit. When that limit is reached, the
contact points close and the compressor starts opera-
tion. In this manner, the compressor turns off and
on
automatically to satisfy the demand^ of the evaporator.
Turning the control knob all the way to the left R 2S639N
(counterclockwise) manually opens the contact points
in the switch housing, stopping compressor
operation. AValve Seat CSpring Seat
B Spring DValve Housing
Fig. 14-Compressor Relief Valve
The compressor valve (Fig, 14) is a pressure

relief
regulating control. the system discharge pressure
If
exceeds 440 psi (30 bar) (30.61 kg/cm 2 ), the valve (A)
will open automatically against spring
(B) pressure and
stay open until the pressure recedes. The valve will
then close automatically.
If the relief valve opens, a loud popping noise will be

heard. In addition, some oil may be ejected through the
valve. Correct any condition that would cause this
vafve to open.
TM-1181 (Feb-79) Lftho in U.S.A.


. 1
Operator Station Operation and Tests Air Conditioning System Operation and Tests 290-05-1
3. Open both gauge set manifofd valves.

5. Crack dispensing shut-off valve
to purge air from
4. Start the vacuum pump and operate charging hose.
until the low
side gauge registers at least 29-29.5 inches (1 bar)
6. Tighten charging hose connector
vacuum- Continue to operate pump for 5 minutes after on gauge
manifold and close shutoff valve.
the specified vacuum has been reached.
7. Open high side gauge manifold hand valve (C).
If the specified vacuum cannot be reached, or if the
vacuum not hold, check for leaks in system, leaks
will 8. Open shutoff valve on dispensing valve.
around the gauges, or a faulty vacuum pump. Add 1/2
Invert container to allow refrigerant to enter
9.
lb. (0.23 kg) of Refrigerants 2 to the system, high
and check side of system.
for leaks. (See page 90-05-12.)
NOTE: Capacity of the system is 3-1/2 lbs, (1.59
After the leak
has been corrected (or if no leaks were kg). DO NOT OVERFILL
present), evacuate the system for 30 minutes.
10- Complete charge of system.
CHARGING THE SYSTEM USING 1 1 Close high side gauge manifold hand valve
15-OUNCE CONTAINERS (C).
12. Start engine and operate at 1900

rpm (with
temperature control set for maximum cooling
and
blower speed on high position) for 10-12 minutes.
13. Open tow side gauge manifold hand

valve (D) to
allow refrigerant to be drawn into system.
Hold con-
tainer upright and open valve not to exceed 40 psi (2.7
bar) on low side gauge.
NOTE: If single containers are used, it will be nec-

essary to replace each as it becomes empty.
14. Watch sight glass until bubbles disappear.
NOTE: Excessive head pressure with a normal low

side pressure indicates an overcharge of refrigerant or
air in the system.
ADDING REFRIGERANT-12
TO SYSTEM
Small amounts of refrigerant may have to be added
to the system to replace what was lost by leaks,
or
opening of system for service. If there was a large leak,
or an oi! spot, check compressor oil level (see 90-05-
11) before adding refrigerant.
ADispensing Valve C High Side Hand Valve
BCharging Hose D Low Side Hand Valve NOTE: Do not add additional refrigerant unless the
condenser air temperature is 70F(21.1 C) or higher.
Fig. 8-Charging The System
(Typical Installation) 1. Connect manifold hose to refrigerant source and
bleed from hose.
A CAUTION: If filling on high side engine
air
** MUST be shut off, as refrigerant container 2, Start engine and operate at 1900 rpm (with tem-
could explode. perature control set for maximum cooling and
blower
speed on high position) for f(M2 minutes.
1. Install can dispensing valve (A, Fig. 8) to con-
tainer. 3, Open low side manifold valve (D, Fig. 8}.
2. Close shutoff valve on dispensing valve. 4. Use 15-ounce can as shown and open valve
NOT to exceed 40 psi (2.7 bar) on low side
gauge.
3. Install charging hose (B) to dispensing valve.
4. Loosen charging hose at center connector on

gauge manifold.

.
290-05-12 Air Conditioning System Operation and Tests Operator Station Operation and Tests
LEAK TESTING FLUSHING THE SYSTEM

Several types of leak detectors are available to the it is essential that the system be flushed if there has
service technician. Carefully follow manufacturers in- been an internal failure, regardless of the cause. Oth-
structions when using any detector. erwise, metal particles or other types of contamination
may circulate in the system, and create a restriction at
1. Connect the manifold gauge set.
screen of the expansion valve.
the inlet
2. Close high and low side manifold hand valves.

1. Discharge system (page 290-05-10).
3. Note pressure reading. 50 psi (3.4 bar) (3.46
kg/cm 2 ) is necessary to detect leaks. If pressure is 2. Remove receiver-dryer. Flushing freon will vent
2
lower than 50 psi (3.4 bar) (3.46 kg/cm ) refrigerant
to the atmosphere at this location.
must be added. To do this:
A. Purge hoses of air and attach center manifold
3. Remove and inspect expansion valve.
hose to the refrigerant container.
B. Open
the refrigerant container service valve 4. with Schrader valves, remove
On compressors
and the high side manifold valve until 50 psi (3.4 bar) valve core from high side Schrader valve.
(3.46 kg/cm 2 ) is reached on the low side gauge.
5. Install gauge and manifold set.
C. Close high side hand valve and the refrig-
erant service valve. Remove hose.

6. Open the high side valve and close the low side
valve.
7. Connect a refrigerant supply container to the

hose, and turn can upside down.
8. Fully open the container valve and allow liquid
refrigerant to flow into the system.
9. Repeat with a second can of refrigerant.
A Refrigerant will vent to atmo-

CAUTION:
sphere at receiver-dryer location at -22F
(-30 C). Follow all safety precautions listed at the
beginning of the group.
Fig. 9-Using Electronic Leak Detector D-180O9KD 10. Using blow out line from expansion
refrigerant,
valve to receiver-dryer. Blow from the expansion valve
4. Move sampling end of detector used from point to end.
point and examine all joints and connections and any
other possible leak point. Since Refrigerant- 12 is 1 1 Clean or replace expansion valve and install.
heavier than air, it is best to place the sampling end of

the detector beneath the point being tested (see Fig. 12. Install new receiver-dryer,
9)-
13. Replace schrader valve valve core.

5. After locating the leak, purge the system of re-
frigerant. Repair leak.
6. Check compressor oil and add if necessary

(page 90-05-11).
7. Add refrigerant and recheckfor leaks, if no leaks

are present, evacuate and charge.

Operation and Tests 290-05-13
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TM-1181 (Feb-78) Litho in U.SJ\.

290*05-14 Air Conditioning System Operation and Tests Operator Station Operation and Tests
R 27Q47N
ATubing Adapter EGasket Seal HO-Ring

BO-Ring F Lock Nut I Valve and Sleeve Assembly
CPoppet Valve Assembly G Union Nut and JO-Ring
0Body Body Assembly KTubing Adapter
Fig. 1 1 -Exploded View of Refrigerant Coupling
HOW THE COUPLINGS WORK Tightening the union nut (G) draws the coupling
halves together. At the same time, the poppet valve
The refrigerant coupling (Fig. 1 1 ) is used on both the
assembly (C) and valve and sleeve assembly (!) are
pressure and return sides of the air conditioning sys-
moved to open the fluid passage around the valves.
tem, and are located under the floor panel of the
When fully coupled, gasket seal (E) on the recessed
Sound-Gard Body.
face of the body (D) is compressed between faces of
coupling bodies (D) and (G) to form a seal During
When the coupling is disconnected,
both halves seal
disconnection, the springs automatically return valves
to prevent loss of refrigerant and admission of air or
(C) and (I) to their sealing position.
foreign material into the system.
NOTE: Tubing adapters (A) and (K) are brazed to

As the two coupling halves are connected
partially
their respective pipes, and therefore are serviced only
together by the union nut (G, Fig 11) the stem valve
as an assembly.
head of the valve and sleeve assembly (I) contacts the
face of the poppet valve assembly (C), expelling air.
Body (D) contacts a gasket on the face of sleeve (I)
making a seal during the connection.

Air Conditioning System Operation and Tests 290-05-15
COMPRESSOR
R 27048N
AO-Rfng Sear Dust Cover Swash

BPiston I
JHub and Drive

P Plate
QMainshaft Rear
CDrive Bait Plate Assembly Bearing
D-BallShoe KPulley ROH Pick-Up Tube
ESuction Reed LChitch Coif S Suction Reed

F Front Discharge tt Front Head T Rear Discharge
Valve Plate
N Mainehaft Front Valve Plate
G-*Shaft Seal
H Pulley Bearing
Bearing URear Head
O Mainshaft Thrust VReffef Valve
Bearing W-OII Pump
X Superheat Switch
Fig. 12-Cross-Section of Detco (Frigidaire) Compressor
HOW THE COMPRESSOR WORKS An oil pump (W) mounted at the rear of the com-
The compressor is a Delco pressor picks up from the bottom of the compressor
oil
(Frigidaire), horizontal,
6-cylinder (3-pistons), double-acting type (Fig. oil sump and pumps the oif to the internal working parts
12),
and is belt-driven from the engine crankshaft. of the compressor.
Pistons (B) are mounted Operation of the compressor is controlled by the

axially around the com-
pressor shaft and driven by a swash piate temperature control switch, which electrically controls
(P).
the magnetic clutch (J) on the compressor.
Reed-type suction and discharge valves are
mounted in valve pfates (S and T) between the cylinder The compressor is fitted with a high pressure relief
assembly and the head at each end of the compressor valve (V) whichopens whenever the compressor dis-
The heads are connected by gas-tight passage ways charge pressure exceeds 440 psi (30 bar) (30 kg/cm 2 ).
which direct refrigerant gas to a common outlet.

RECEIVER-DRYER
R 2B638N
A Sensing Bulb CExternal Equalizer Line

B Expansion Valve DValve outlet
ArInlet From DOutlet To
Fig. 14-Expansion Valve
Condenser Expansion Valve

B Desiccant EPick-Up Tube
CSight-Glass F Fitter Pad The expansion valve has an external equalizer line
(C) which allows pressure at the valve outlet (D, or
Fig. 13~Cross-$ection of Receiver-Dryer
evaporator inlet) to be transmitted to the evaporator
side of the diaphragm.
How The Receiver-Dryer Works
The receiver-dryer mounted under body
(Fig. 13), THERMOSTATIC TEMPERATURE
on left-hand side, has a two-fold function. First, it CONTROL SWITCH
receives the high pressure liquid refrigerant from the
condenser and stores the liquid until needed by the How The Switch Works
evaporator. Second, the unit removes harmful mois-
The purpose of the temperature control switch (A,
ture (and acids), and filters out solid contaminants.
Fig. 1 the temperature of the refrigerant
5) is to regulate
in the evaporator corresponding to the control knob
Solid contaminants are filtered by the strainer-filter
setting selected by the operator.
pads (F), while moisture and acids are removed by the
dessrcant material (B) filling the chamber between the
The switch consists of a set of contact points which
filter pads.
receives its power from the pressurizer motor switch.
The current flows from the temperature swrtch to the

The sight glass (C) is incorporated into the re-
compressor clutch.
ceiver-dryer unit, and should be used for checking
refrigerant operation.
The contact points in the temperature switch are
REGULATORY CONTROLS controlled by a gas-filled temperature sensing tube (B)

having a spring bellows or diaphragm on one end
EXPANSION VALVE making contact with the point operating mechanism.
Valve Works The other end of the sensing tube is inserted into the
How The Expansion core of the evaporator.
Liquid refrigerant under high pressure is piped to the
expansion valve (B, Fig. 14) from the receiver-dryer.
The function of the expansion valve is to regulate the
amount of liquid refrigerant entering the evaporator
(now under low pressure), depending upon the desired
inside temperature. Sensing action which regulates
valve action takes place in the temperature sensing
bulb (A).
TM-1181 (Sep-77) Utho in US.A Tractors - 4040 and 4240

Operator Station Operation and Tests Air Conditioning System Operation and Tests 290-05-17
R 3U44
ATemperature Control Switch BSensing Tube

Fig. 15-Temperature Control Switch
When the control knob is turned on (clockwise), the

contact points close, thereby activating the compres-
COMPRESSOR RELIEF VALVE
sor. However, the compressor will not
operate unless
the pressurizer motors are turned on. As the
tempera-
ture in the evaporator reaches its specified
lower limit,
the contact points are allowed to open, which in
turn
shuts off the compressor. The compressor will remain
off until
the temperature in the evaporator reaches its
specified upper limit. When that limit is reached,
the
contact points close and the compressor starts opera-
manner, the compressor turns off and on
tion. In this
automatically to satisfy the demands of the evaporator.
Turning the control knob all the way to the left R 28639N
(counterclockwise) manually opens the contact points
in the switch housing, stopping compressor operation. AValve Seat CSpring Seat
BSpring DValve Housing
Fig. 16-Compre$$or Relief Vatve
The compressor valve (Fig. 16) is a pressure

relief
regulating control. the system discharge pressure
If
exceeds 440 psi (30 bar) (30.61 kg/cm a ), the valve (A)
will open automatically against
spring (B) pressure and
stay open until the pressure recedes. The valve will
then close automatically.
!f the relief valve opens, a loud popping noise will be

heard. In addition, some oil may be ejected through the
valve. Correct any condition that would cause this
valve to open.
TM-1181 (Feb-78) Lrtho in U.S.A.

r~

Air Conditioning System Tests and Diagnosis 290-1 0-1
Group 10
AIR CONDITIONING SYSTEM
TESTS AND DIAGNOSIS
GENERAL INFORMATION Additional Information
When diagnosing
any air conditioning problem
Moisture In System
there are three checks that MUST
be performed:
During the development of the air
conditioning
Preliminary Checks diagnostic procedure, it was determined that
moisture
does not freeze out at the expansion valve.
Any of the minor problems checked here can Depending
pro- upon the ambient temperature and flow through
duce an incorrect pressure temperature relationship the
of evaporator, moisture freezes near the inlet or
the refrigerant entering the evaporator, outlet of
with the ex- the evaporator. There seems to be no
ception of engine coolant flowing through consistent
the heater method of indicating moisture in the system. Therefore
core. Decreasing the air flow through
the condenser if all checks are
increases the system pressure. Decreasing
"NORMAL" and the operator com-
the air flow plained of "lack of cooling" below SOT
through the evaporator does not allow (27C) there is
the operators moisture in the system. Above SOT (27C)
compartment to get cooled to a comfortable tempera- " moisture
will not freeze in the system
ture. Always make the Preliminary because the temperature
Checks before any of the refrigerant coming out
operational checks or testing of the system.
of the expansion valve will
be above 32F (0C), the freezing point of water.
Electrical Operational Checks Restriction In System

An operational check of the electrical system
before When feeling refrigerant lines or components for
actual testing assures the following:
always check for a temperature change in
restriction,
1. Compressor clutch is engaging to circulate re- the direction of normal refrigerant flow
frigerant through the to correctly
system. sense temperature changes.
2. Bfower motor is circulating air across the
evapo-
rator for cooling.
Make these operational checks after the Preliminary
HOW TO USE
Checks, but before pressure checks and system
STEP-BY-STEP CHARTS
checks. These charts are usually divided into three sections
System Pressure Checks STEP SEQUENCE RESULT

A system operational pressure check of the Jow and
Always start at the first step and go through
high sides assures that the correct fie
refrigerant pressure complete sequence from left to right. Each sequence
is maintained when it enters
the condenser and leaves ends with a result and tells you the next step.
the evaporator for a specific ambient Work
temperature. through the appropriate steps as directed
Make this check after performing the two checks until the
malfunction has been corrected. After repair,
above, and before starting the test repeat
sequences which the total diagnosing sequence to be sure
follow. the problem
has been corrected.

2
290-10-2 Air Conditioning System Tests and Diagnosis Operator Station Operation and Tests
Additional Information Continued SAFETY PRECAUTIONS

Throughout the diagnosing sequence, reference is Refrigerant-12 by itself is harmless and nonpoison-
made to the following short procedures which are ous; however, special precautions should be taken
located after step 49 of the diagnosing sequence. As when servicing any refrigerant air conditioning system
you become more familiar with these procedures, fre- or handling refrigerant containers.
quent reviewing will not be necessary.

1. Do not expose eyes or skin to liquid refrigerant.
Page Always wear safety goggles when opening refrigerant
Discharging the System 10-22 lines. Liquid Refrigerant-12 has a boiling temperature
Flushing the System 10-22 of approximately (~29.5*C) -21 F at sea level; there-
Adding Refrigerant Oil to the System 10-23 fore, serious injury could result if liquid refrigerant
10-24 contacts the eyes or skin. If Refrigerant-12 strikes the
Purging the System
Evacuating the System 10-24 eye, call a doctor IMMEDIATELY and:
Charging the System 10-25

Leak Testing the System 10-26 Do not rub the eye. Splash cold water on the eye to
gradually raise the temperature of the contacted area.
ABBREVIATIONS USED IN CHARTS
Obtain treatment from a physician as soon as pos-
TEV Thermal Expansion Valve sible.
TEMP Temperature
F Degrees Fahrenheit If the liquid refrigerant comes
as though
in contact with the
were frozen or frost-
C Degrees Celsius skin, treat the injury it .
R-1 Refrigerant- 12 bitten.
SGB Sound-Gard Body

RPM Revolutions Per Minute 2. not discharge refrigerant into an area where
Do
PSI Pounds Per Square Inch there exposed flame. Heavy concentrations of Re-
is
SPEC Specification frigerant-12 contacting an open flame will produce a
RH Right Hand poisonous gas.

LH Left Hand
M-BAR Milii-bar 3. Do not weld or steam clean near or
system. Excessive pressure could
on an air
be
MM Millimeter conditioning
Ml Milliliters built-up within the system.
OZ Ounce
MIN Minimum 4. Do not subject containers of Refrigerant-12 to
MAX Maximum temperatures above (51.8C) 125T. Also, during the

SHSS Super Heat Shut-off Switch charging process, water for heating the refrigerant
Hg Mercury containers should not exceed (51.8C) 125*. Higher
temperatures will cause excessive container pres-
sures.
5. All charging and leak testing should be per-

formed in a well-ventilated area.
6. Before loosening a refrigerant fitting, cover the

connection with a cloth.
7. When charging system with engine running, be

sure high pressure gauge valve is CLOSED,
8. Observe and stay clear of rotating parts.

Air Conditioning System Tests and Diagnosis 290-10-3
AIR CONDITIONING DIAGNOSIS

Slep Sequence
(T) PRELIMINARY
CHECKS
Check the
following:
A.
ADJUSTING
}T~ STRAP
Fresh air filter dirty?

Side screens dirty? Condensor or radiator
Belt loose? (both sides) dirty? NOTE: If filter re-
quires frequent
cleaning, clean entire
roof area.
F. Result
Correct any ab-

normal condition
Recirculating filter Heater "OFF"?
dirty?
Then.,. | GO TO 2 )
(2) ELECTRICAL OPERATIONAL Observe motor speed

CHECKS: and volume of air from
Key switch "ON". air ducts.
Blower switch
SPEED."
at "SLOW
A A
Repeat check at
"FAST" speed. (Also
"MEDIUM" if equipped.)
NOTE: Low air flow in-
*
dicates
1. Bad lead con nee*
tions.
2. Cages installed back-
wards.
3. Reversed polarity OK: | GO TO 3 I
*(7) (3-speed switch only)

'There will normally be
greater velocity from
Not OK: GOTO
ELECTRICAL
both inner ducts than DIAGNOSIS
outer ducts with single SECTION
motor and 3-speed 240.
R32768 switch.
TM-1181 (Feb-79) Litho in USA, Tractors - 4040 and 4240

(3) Blower Switch at "SLOW 1

',
Listen for audible click
As you turn cooling control Knob of compressor clutch.
Click:
to "MAXIMUM COOLING" . NOTE: Clutch will not OK. | GO TO 4 I
engage below 35F
(2C).
No Click:
Not OK. GOTO
ELECTRICAL
DIAGNOSIS
SECTION
240
-CLUTCH
(4} Install test equipment as shown:
My
'M ^W*wv!r'"> ^ r If
Thermometer in shade.
Connect blue or green hose to suction (LH side);
connect red hose to discharge (RH side). I GO TO 5 }
NOTE: Purge air from hoses.
Compressor "OFF".
Connect R-12 can valve to
Compare gauge readings
chart.
to
gauge manifold as shown. Temp. Min. Pressure

F
6
C PSI BAR
"OPEN" low and high side
60 15 45 3.1
valves to stabilize pressures.
65 18 50 3.3
70 21 55 3.7
75 24 6C 4.0
HIGH 80 27 65 4.3
tow SIDE 85 29 70 4.7
SIDE VALVE
"OPEN" 90 32 75 5.0
VALVE
"OPEN" 95 35 80 5.3
100 38 85 5.7
SUCTION 105 41 90 6.0 GO TO
Pressure OK: }
8 1
110 43 95 6.3
CAN 115 46 100 6.7 GO TO
No Pressure: \
6 |
VALVE
"CLOSED' CAUTION: "CLOSE" low and
high side valves after Low Pressure: | GO TO 7
pressures stabilize.
R32769
Air Conditioning System Teste and Diagnosis 290-10-5
Step
Check test hoses for missing

damaged Schrader Valve
or
Sequence
Check gauges for

pressure. Compare
Result
depressor reading to chart in

step 5.
Pressure: | GO TO S~)
No Pressure: j GO TO 7 |
Repair and reconnect hoses.
(V) Compressor "OFF". "OPEN" FM2 can valve.

Purge from charging
air Add R-12 until pressure
hose. "OPEN" low and stabilizes.
high side valves.
CAUTION: "CLOSE" manifold
valves before starting
compressor. Check all
components, joints and line
LOW HIGH connections for R-12 leakage
**
side SIDE with a leakage detector. See
VALVE VALVE page 290-10-26.
"OPEN- -OPEN"
No Leaks: | GO TO 8 I
Leaks: ____^_
CAW
Repair* Then... | GO TO 4 ]
UPRIGHT
*Dischargtng, Evacuating and
Charging may be necessary. See
Pages 290-10-22, 24 and 25.
B34792

Sequence Result
Step
Cb) temperature control Operate system for

^^ switch check: 10 minutes. Observe
SGB door and windows compressor clutch for
"CLOSED". Key switch "ON". cycte ttme.
Engine at 2000 rpm, Blower
switch at "HIGH". Temp, control SPEC.: Below 85F
(29C)
switch at "MAXIMUM COOLING".
"Minimum" cycle time Cycle time more r
30 seconds. than 30 seconds: 1GO TO iz |
|
NOTE: The clutch may Cycle time less ____^_j

not cycle when ambient than 30 seconds: JGO TO 9 |
temperature is above
85F (29C)
Causes of frequent clutch cycling are:

A. Blower motor inoperative
B. Fresh air and recirculating filters dirty
Correct condition.
Then, JGOT0 8
.
C. Evaporator dirty
D. Temperature control switch capillary tube incorrectly

located in evaporator.
E. Temperature control switch temperature range set too IGOTO 10 1
cold. (NOTE: First attempt D.)
Raise SGB roof. Place tube vertical between

Remove pressurizer 1st and 2nd refrigerant tubes
M
cover. 15 from LH side of
evaporator. Push tube all the
way to bottom.
roof FRONT
COVER
NOTE: If tube is vertical, GO

TO 11
IMPORTANT: Press urizer
cover must be secured at
NOTE: Reinstall all roof each corner for all checks.
and cover screws after Engine at 2000 rpm. Com*
testing or repair. pressor "OPERATING".
Observe clutch cycle time.
Cycle time more
than 30 seconds: | GO TO 12 |
Cycle time less

than 30 seconds: [GOTO 11 J
clutch
R33770
USA. Tractors - 4040 and 4240

TM-1181 (Jun-80) Litho in
. |

Qj) Move capillary tube at Observe compressor clutch

2" (51mm) intervals (two cycle time.
moves only) from center
of evaporator toward
RH end of evaporator. Cycle time more
than 30 seconds:
2" (51mm)
I
GO TO 12

J3
Cycle time less
than 30 seconds:
CLUTCH [REPEAT 11 I
Unable to obtain
IMPORTANT: Pressurizer correct cycle
cover must be secured at time;
each corner for all checks. [ GO TO 8 l
Replace switch.
Then. .
RECEIVER-DRIER
SIGHT GLASS CHECK:
Engine at 2000 rpm.
Compressor "OPERA- CAUTION: Bubbles
TING". Check receiver- with"HIGH"
drier sight glass for discharge pressure
bubbles. or very slow bub-
NOTE: Word "TOP" bles and a vacuum,
must be at 12 o'clock GO TO 15.
position.
No bubbles:
O.K. GO TO 15 1
SIGHT
GLASS
Bubbles:
Not OK. 1 GO TO 13""j
R33771
TM-1181 (Jan-81) Litho in UL&A Tractors - 4040 and 4240

290*10-8 Air Conditioning System Tests and Diagnosis Operator Station Operation and Tests
Check all
ponents, joints
com-
and line connec-

tions for R-12 GO TO
No leaks; 14 j
leakage with a
leakage detec-
tor.
Leaks: _-^__^_.
Repair.* Then... | GO TO 4 |
NOTE: Check low and * Discharging, Evacuating and

high sides with engine
Charging may be necessary.
"OFF". Repeat check on
high side with compressor See pages 290-10-22, 24 and 25.
operating. Any damp, dus-
ty spot indicates an R-12
leak.
Connect R-12 container

to gauge manifold as
shown: Purge air from
Compressor "OPERATING".
Engine at 2000 rpm. "OPEN"
low side valve not to exceed
charging hose. 275 kPa (2.75 BAR) (40 psi).
Add R-12 until bubbles

disappear in receiver-drier
HlGH sight glass, then add 475 mL
SIDE (\6oz.)rtiore.
VALVE
"CLOSED"
LOW
SIDE
VALVE
CAN
SIGHT GO TO STEP 13. ,
%
UPRIGHT
GLASS Then.. \ GO T0 12 \
RW1553
TM-1181 (Jan-81) Utho in U.SA. Tractors - 4040 and 4240

j1
Operator Station Operation and Tests Air Conditioning System Tests and Diagnosis 290-10-9
Step
SYSTEM PRESSURE
Sequence
Specification Chart
Result
CHECK
Compressor Temp. Suction Discharge
"OPERATING". Engine *C kPa kPa
at 2000 rpm. Blower at
"HIGH'\ SGB door, 11-16 7-70 690-1034
windows and panels 16-21 14-103 827-1171
"CLOSED". Check 22-27 28-138 896^1344
ambient temperature
27-32 34-172 1000-1550
and gauge pressures.
33-38 70-207 1102-1791
>\< 38-43 103-241 1205-2067
Temp Suction Discharge

TEMP, C BAR BAR
11-16 0,07-0.7 6,9-10.3 Suction Discharge
SUCTION DISCHARGE 16-21 0.14-1.03 8.3-11.7
22-27 0,28-1 ,4 9.CM3.4 Normal Normal | GO TO 35 |
27-32 0,35-1 .8 10.0-15.5

Low, High
33-38 0,7 -2.1 11.0-17,9
Normal (Bubbles)
38-43 1,0 -2,4 12.0-20.7 or High GO TO 16
Temp. Suction Discharge High Low [GOTO 17 I
F PSI PSt
Compare temperature and Normal High
pressure readings to
specification chart.
51-60 1-10 10CM50 or High I GOTO 18
61-70 2-15 120-170
NOTE: The lower figures 71-80 4-20 130-195 Low Normal
correspond to humidity near 81-90 or or
5-25 145-225
10%. The higher figures 91-100 10-30
Vacuum Low GO TO 26
160-260 I I
correspond to humidity near 101-110 15-35 175-300

90%.
There
or
is
RESTRICTION
a
between the
following
locations:
1. Compressor and
denser,
2. Condenser
3. Condenser and
coupler
4. Quik-coupler and
Inspect and
drier
5. Receiver-drier
Repair.* Then... 1GOTQ4 1
NOTE: Feeling lines for a temperature change may or may not *May require Discharging,
locate point of restriction.
Flushing, Evacuating and
CAUTION: These lines are normally "HOT", Charging. See pages 290-10-22
RW1554 24 and 25.

(VF) The following are causes of SUCTION HIGH, DISCHARGE

^^ LOW:
1. Clutch Not Engaged
2. Belt Slipping Repair. Then... | GO TO 15^
3. Clutch Slipping (Cover condenser to obtain higher pressure

to check for slippage)
NOTE: Repair requires Discharging, Evacuation and
Charging system. See pages 290-10-22, 24 and 25.
Repair. Then. GO TO 4
4. NOTES: Repair requires Discharging, page 290-10-22,
Replacing Receiver-Drier page 90-05-15, Flushing, page
290-10-22, and Charging system, page 290-10-25. Perform
compressor Voltmetric Efficiency Test after removal and
before installation of compressor on tractor. See page
90-05-2.
(l8) The following are causes of SUCTION NORMAL OR HIGH,

^-^ DISCHARGE HIGH:
1. Restricted Air Flow Through Condensor or Radiator. Clean Then,.. | GO TO 15 |
2. TEV Thermal Bulb is Loose or Corroded at Evaporator Tail

Pipe.
3. System is Over-Charged with R-12.
4. TEV isStuck "OPEN", (or)
5. Air in System. | GOTO 19l
n) Remove recirculating Inspect thermal bulb for cor-

^-^ filter, "OPENT in- rosion and looseness.
sulating tape on
evaporator outlet pipe.
OK: | GO TO 20"
Not OK:
Repair. Then. | GOTO 15 J
R34795
TM-1181 (Jan-81) Utho in U.S.A. Tractors - 4040 and 4240

Step Sequence
w
(2d) Compressor
"OPERATING". Engine
at 2000 RPM. "OPEN"
Observe receiver-drier sight
glass until bubbles appear,
Result
then "CLOSE" low side (LH)

low side (LH) valve to valve.
discharge R-12 at a
slow rate.
SIGHT
GLASS
LOW
SIDE
VALVE
"OPEN"
HIGH
SIDE
VALVE
"CLOSED"
HC
Check gauge pressures and
/
compare to chart at step 15.
Discharge
Pressure
High: j GO TO 22 j
Pressures
Normal: I GO TO 21 1
Connect R-12 container Engine at 2000 RPM. Com-

togauge manifold as pressor "OPERATING' 1
shown; "OPEN" low side valve not

Purge air from charging to exceed 40 psi (2.6 BAR).
hose. Add R-12 until bubbles disap-
pear in receiver sight glass.
Then add 16 oz. (475 mL)
more.
HIGH SIGHT
STDE GLASS
VALVE
"CLOSED"
LOOSEN
TO PURGE
HO^
Recheck gauge pressures
and compare to chart at step Pressures
CAN K
15.
UPRIGHT Normal: [GO TO 35 ~1
Pressures
High: [GO TO 22 ]
R33775
TM-1181 (Jan-81) Utho in US.A.

. .
(2) Connect a hose to a Engine at 2000 RPM.

can of R-12. Tie open Compressor 1
end of hose to thermal -OPERATING", "OPEN'

bulb of TEV as shown: valve on R-12 can IV2
turn. Invert can for 10-15
seconds. Then
"CLOSE" R^12 can
valve.Observe suction
pressure gauge for a
pressure decrease.
VALVES
"CLOSED-
Pressure
Did Not
CAUTION: Stand to RH Decrease: j GOTQ23H
side of SGB to prevent
contact with liquid R-12. Pressure
"j
Wear Your Goggles. Decreased: j GO TO 24
The TEV is sticking. Perform the following:

1 Discharge system. See page 290-1 0-22.
2. Remove TEV Inlet hose and remove screen for inspection:
A, Screen is "DIRTY"
1 Flush line between receiver-drier and TEV
2. Replace receiver-drier
3. Add (22 mL) .75 oz. refrigerant oil. See page
290-10-23
B, Screen is "CLEAN". Do not replace receiver-drier
unless more than two years old.
3. Remove TEV and perform bench test After
as instructed on page 290-1 0-22b. Charging: j GOTOIsH
4. Install a new TEV and connect all components.
5. Evacuate system. See page 290-10-24-
6. Charge system with R-1 2. See page 290-10-25.
RW1555

Step
Sequence
@ The TEV is intermittently sticking

system. Perform the following:
1
"
heCk: C mpressor " op ÂTfNG-.
open or there
the
Engine at 2000
is air in
Result
RPM
A. Remove thermal bulb of Warm bulb with hand for one

TEV from evaporator minute. Check pressure
outlet pipe. gauges for increase in
pressure.
NOTE: Reattach bulb and in-

sulate after testing or repair.
B. Connect a hose to a can "OPEN" valve on R-12 can

of R-12. Tie open end of
1%
turn. Invert can for 10-15
hose to thermal bulb of seconds. Then "CLOSE"
TEV as shown: R-12 can valve. Observe suc-
tion pressure gauge for a
pressure decrease.
valves
"CLOSED"
Pressure
Increases
Itt TURN and
OPEN
Decreases:
CAUTION: Stand to RH side Pressure Does
of SGBto prevent contact
Not Aiways
with liquid R-12, Wear Your
Change: 1 GO TO 23 "]
Goggles.
TM-1181 (Jan-81) Utho in U.S.A.

.
(5?)
Step
There is air in the system. Perform the following:

Sequence Result

2. Evacuate system. See page 290-10-24.
3. Charge system with R-12. See page 290-10-25-
After Charging: [ GO T0 15 |
(26) of SUCTION LOW OR VACUUM,

The following are causes
DISCHARGE NORMAL OR LOW:
1. Blower motor inoperative.
2. Dirty recirculating and fresh air filters. Repair or clean.
(Discharge may be Normal or Low.) Then... I
GO TO 15'
RESTRICTION: (DISCHARGE MAY BE NORMAL OR LOW,)

a. Between condenser and receiver-drier.
b. At receiver-drier
c. Between receiver-drier and TEV
d. At TEV (inletscreen partially clogged)
e.Between evaporator and Quik-coupler (or)
f.Between Quik-coupler and compressor suction side.
TEV stuck "CLOSED" or no gas charge in thermal bulb.
(Discharge will be Low.) I
GO TO 27 I
Moisture in system. (Discharge may be Normal or Low.)
Remove thermal fuse

from clutch lead.
Connect a jumper wire
between power and clutch
terminals as shown;
D P
NOTE: Reinstall thermal fuse | G0T0 28~]

FUSE after testing or repair.
Compressor Check TEV for frost before

"OPERATING". Engine valve outlet connection after
at 2000 RPM. SGB door three minutes of operation.
1
"CLOSED' Blower at .
"HIGH". Remove recir-

culating filter "OPEN"
insulating tape on ther-
mal expansion valve.
No
Frost: [ GOTQ3lH
NOTE: Recover TEV and bulb
and reinstall recirculating Frost: | GOTQ29H
filter after testing or repair.
RW1556
TM-1181 (Jan-81) Utho in U.SA. Tractors - 4040 and 4240

Step
> Sequence Result
(29) Raise SGB roof. Compressor "OPERATING".

Engine at 2000 RPM. Inspect
line from condenser to TEV No Frost
ROOF inlet for frost or or Temp.
a
temperature change. Change: \ GOTO30
Frost or
Temp.
Change:
Repair*
Restriction.
After
Charging,..
I GO TO 15 J
NOTE: *May require Discharging,

Reinstall alt roof and Flushing, Evacuating and
cover screws after testing NOTE: A temperature change
or repair. Charging system. See pages
indicates a restriction.
290-10-22, 24 and 25.
EV
in[et screen is partially clogged or gas charge
( 30) I
thermal bulb.
is low in
Inspect TEV as follows:
1. Discharge system. See page 290-10-22.
2. Remove TEV inlet hose and remove screen for
inspection-
A. Screen is "DIRTY".
(1) Clean screen and reinstall,
(2) Flush line between receiver-drier and TEV.
(3) Replace receiver-drier.
(4) Add (22 mL) .75 oz. of refrigerant oil. See H
paqe
y
290-10-23.
B. Screen is "CLEAN".
(1)Replace TEV.
(2) DO NOT replace receiver-drier unless more than
two years old.
3. Connect all components and purge system. See 290-1 0-24
4. Evacuate system. See page 290-1 -24. After
5. Charge system with R-12. See page 290-1 0-25 Charging: j GOTO 15 !
(3y Compressor "OPEN" insulating tape on

"OPERATING'-'. Engine thermal bulb of TEV. Inspect
at 2000 RPM. SGB door evaporator outlet pipe for
> "CLOSED". Blower at frost.
"HIGH". Recirculating
filter "REMOVED".
No Frost: I GO TO 32 ]
Frost: GO TO 33
I ]
RW1557
>
TM-1181 (Jan-81) Litho in U.S.A.
.
Step Sequence Result <

(S) Raise SGB roof. Inspect line for a point
where frost starts to ac-
ROOF cumulate or a temperature
change:
1 Between evaporator outlet
and Quik-coupier
2. At Quik-coupier (or)
3. Between Quik-coupier and No Frost

compressor suction side. orTemp.
Change: {
GO TO 33 "|
Frost or
Temp.
"OPEN" insulating tape Change:
on evaporator outlet Repair*
through recirculating Restriction.
filter opening. Then,., ]
GO TO 15 I
*May require Discharging,

NOTE: A very slight Flushing, Evacuating and
temperature change usually Charging system. See pages
indicates a restriction. 290-10-22, 24 and 25.
\
^
(55) "STOP" compressor for
3 minutes. "OPEN" SGB
Compressor "OPERATING".
Engine at 2000 RPM. SGB
DOOR "CLOSED".
DOOR.
Compare pressure readings
to chart at step 16 after 2
minutes operation.
Pressures
LOW Normal:
SIDE Moisture in
VALVE system. I GO TO 47
"CLOSED'
Pressures Low: I GO TO 34 j
TEV thermal bulb has lost gas charge, TEV is stuck "CLOSED" <
or 1,
screen is clogged. Inspect TEV as follows:
Discharge system. See page 290-10-22.
2. Remove TEV inlet hose and remove screen for inspection;
A. Screen is "clogged":
(1) Clean and Reinstall screen
(2) Flush line between receiver-drier
and TEV inlet
(3) Replace receiver-drier
(4) Add (22 mL) 75 oz. refrigerant oil. See page
290-10-23
B. Screen is "CLEAN":
(1) Replace TEV
(2) DO NOT change receiver-drier unless more than two
years old.
3. Evacuate system. See page 290-10-24. Alter Charging: I GO TO 15
Charge system with R-12. See page 290-1 0-25.
4.
RW1558 i
USA. Tractors - 4040 and 4240

TM-1181 (Jan-81) Utho in
7

Air Conditioning System Tests and Diagnosis 290-1 <M
Step Sequence
(35)
^^ Compressor
"OPERATING'
Engine at
1
Resuft
2000 RPM
for at least
10 minutes.
Inspect suc-
tion line from
quih-coupJer
to compressor
for frost.
No frost:
T GO TO 37 ~[
Frost:
I
GOTO 36
^
\36j Remove
filter.
recirculating "OPEN" insulating tape on
outlet of evaporator. Check
TEV thermal bulb for
looseness or corrosion.
OK: j GO TO 37 |
Not OK:
Repair. Then... | GO TO 37 |
(3?) TEMPERATURE Compressor AMB. TEMP

^^ DROP CHECK: "OPERATING". Engine below 75F
Record ambient at 2000 RPM. Place then (24*C)
temperature in mometer in LH blower
shade. airduct. Biower switch Spec. (Min.)
at"HIGH". After 20 20*F (12C)
minutes "MINIMUM"
continuous operating time AMB. TEMP,
with SGB door "CLOSED", between 75 and
record air duct 90F (24-32C)
temperature.
Spec. (Min.)
In Spec: | GO TO 43 )
25T (14C) Out of Spec: j G Q TO 38 ~|

AMB. TEMP,
above 90F
(32C)
Spec. (Min.)
30T Q
(16 C)
R33781

H
_
Step Result
\38)Use two flat washers to crimp a heater hose shut with

^"^ locking pliers as shown:
Repeat temperature drop

check as in Step 37.
In Spec: I GO TO 39 |
Out of Spec. GO TO 40
(39) Heater valve is internally leaking or heater hoses are reversed,
REAR HOSE IS
INLET TO HEATER
CORE FROM
WATER MANIFOLD
HOSE
CONNECTION
Repair. Then.., { GO TO 37 1
(40) Check door, windows,

panels and seams of
SGB for air leakage.
No Leaks: \ GO TO 41
Leaks: p-^_
Repair. Then... | TO GO 37 ]
(411Lack of cooling can be caused by dirty components. Check

^"^ the following:
1. Recirculating filter
2. Blower air duct and fan cage
Not Dirty; GO TO 42"
3. Condenser (
4. Radiator (or)
5. Evaporator Dirty;
Clean, Then... GO TO 37
NOTE: Check
radiator
for
and evaporator.
damaged cooling
^
fins of condenser, \
R33782
|
TM-1181 (Jun-80) Utho in USA Tractors - 4040 and 4240

Air Conditioning System Tests and Diagnosis 290-10*19
) Step
Result
Compressor
"OPERATING."
Engine at 2000
RPM. Feel along
entire length of
No Temp.
Change:
high side from
No Restriction, GO TO 43
compressor to expah j |
sion valve for a

Temp. Change:
temperature change.
Repair*
NOTE: Tubing may be Restriction.
dented, kinked or internally Then,.. Cgotois 1
blocked, restricting flow of
R-12. * Discharging, Evacuating and
Charging may be necessary.
CAUTION: High side line is See pages 290-10-22, 24
normally "HOT".
and 25.
@ CLUTCH CYCLE CHECK:

SGB door "OPEN",
Remove recirculating
Place a piece of cellophane
across rear of evaporator.
filter.
windows "CLOSED". Clutch should cycle within

Blower switch at "HIGH".* 20 seconds if AMB. TEMP,
Compressor is below (24C) 75F,
"OPERATING". Engine at 40 seconds if AMB. TEMP.
2000 RPM. Observe is between (24 and 32C)
compressor clutch for 75 and 90F,
cycling within 10 minutes 60 seconds if AMB. TEMP,
of operation. is above (32C) 90F.
NOTE: Allow clutch to
cycle onpe, then time
second cycle. ^ front
I Clutch Cycles; | GO TO 4^1
CLUTCH
5" x 30" CELLOPHANE Clutch Cycle
*PURGE Time
Remove cellophane after
Out of Spec: ) GO TO 44 ^
testing.
Raise
Remove
SGB roof-
pressurizer
Place capillary tube vertical,
(380 mm) 15 in. from LH side
between
cover. 1st and 2nd
refrigerant tubes of
ROOF evaporator.
r
^
J*
CAPILLARY TUBE
^* / ALL WAY
TO BOTTOTV)
NOTE: It tube is vertical, GO Clutch Cycles: GO TO 46 |

TO 45.
|
NOTE: Reinstall all roof and IMPORTANT: Pressurizer Clutch Does Not __^__^^^^
cover screws after testing or cover must be secured at
repair.
Cycle: jGOTQ45~|
> each corner for all checks.
RW1559
TM-1181 (Jan-81) Litho in U.S.A.

(45) Move capillary tube at Observe compressor clutch

^^ (51 mm) 2" intervals for cycling.
(2 moves only) from center
of evaporator toward
LH end. Clutch Cycles: \ GO TO 46~|
mm) 2" Clutch Does Not

|^- (51
j
Cycle: REPEAT 45 \
Unable to Cycle
Clutch:
IMPORTANT: Pressurizer Replace temp,
cover must be secured at switch. Then... GO TO 43
each corner for alt checks.
46) NO THERMAL FUSE GO TO 48 Remove Recirculating Filter. SGB door

and windows "CLOSED." Blower
SUPER HEAT SHUT-OFF switch at "HIGH".* Temp, switch at
SWITCH CHECK: "MAX." Engine at 2000 pm. Place ai
Connect a jumper lead from starter

piece of cellophane across rear of
solenoid battery terminal to a terminal evaporator.
on compressor clutch. Ground other
*PURGE
c GO TO
terminal. FRONT 47
5" x 30" CELLOPHANE
STARTER Remove cellophane after

testing
Connect an ohmmeter or
to SHSS as shown.
test light Observe gauge manifold suction
pressure. After three minutes check
test tight or ohmmeter for continuity.
SHSS No continuity
above 5" Hg:
Norma!.
| GO TO 48 H
Continuity
above 5" Hg:
Replace
REPEAT 47
MANUFACTURER
SPEC. SHSS. Then.
CONTINUITY AT:
psiand 140-1 70 F
OHMMETER 5" Hg at 135 to 150F
10" Hg at 125 to 145T
i
R34800
TM-1181 (Jan-81) Litho in U.S.A. Tractors - 4040 and 4240

.

Air Conditioning System Tests and Diagnosis 29CM0-21
@ If the system checks

out to be NORMAL at this step and any
problem (includes cleaning filters) has been
corrected the
RELEASE
TRACTOR
system Is NORMAL FOR
OPERATION
If the system checks

out to be NORMAL at this step without
finding a problem, but the operator
complains that the Air
Conditioning Does Not Cool Properly during
operation at or
below approximately (27C) 80F ambient
temperatures or the
thermal fuse fails at temperatures below
(27C) 80 F there k
moisture in the system. GO TO 49 1
Remove moisture from system as follows;

2. Purge system with R-12 or dry nitrogen while
changing
receiver-drier. See page 290-1 0-24.
3. Evacuate system. See page 290-10-24.
4. Charge system with R-12. See page 290-10-25.
5. Repeat test sequence. After Charging: | GO TO 15"
I RZ48Q1

. .
DISCHARGING THE SYSTEM 4. system is to be flushed, add a new charge of

If
oil. See Adding Refrigerant Oil to the System, Page

The following sequence will decrease discharging 290-10-23.
time and Wow less oil out of the compressor or system
by discharging from the high side. 5. system is not to be flushed, add same amount
If
of new oil blown out of system. See Adding Oil to

System page 290-10-23.
6. R-12 If or oil leakage was detected, add new oil.
See Adding Refrigerant Oil to the System page 290-
10-23.
Flushing The System

Flushing the system with R-11 (Flushing Solvent) is
recommended whenever there is an internal failure of
the compressor, or a system has been left open and
water or dirt could have been blown into the system.
Flushing with R-1 1 is more effective than flushing

with R-12 for the following reasons:
a) R-1 1 stays in a liquid state up to (24C) 76*F.
b) Will not freeze moisture in system above

R 31790
(0*C) 32T. (R-12 will freeze moisture with zero pres-
A Low Side Valve Closed C-Hold Hose In Quart Jar sure.)
BHigh Side Valve Open DRear View of Compressor
c) Will move moisture and debris out of system
Fig. 1-Discharging The System more rapidly above (0C) 32F.
1. Connect manifold gauge set to compressor test d) R-11 will not freeze your skin when in direct
fittings as shown in Fig. 1 contact. (R-12 will freeze on contact.)
Components can be flushed on tractor (except

compressor) with R-11 as follows:
* j> and ex-
1 Isolate the compressor, receiver-dryer
pansion valve from system.
2. Flush all components individually. Use special

fittings from D-15038NU Air Conditioning Service Fit-
ting Kit. Refer to Fig. 3 on the following page for
location and identification of fittings.
3. Remove compressor, drain oil, add R-1 1 through

drain port, shake compressor and drain.
Add oil. See Adding Refrigerant

4. Oil to the Sys-
tem, page 290-10-23.
5. Purge with R-12 or dry nitrogen before connect-

ing components.
R 31791
6. After flushing with R-1 1 connect all components.
A Low Side Valve Open B-^High Side Valve Open
7. Purge complete system with dry nitrogen or
Fig. 2-Discharging The System R-12, See Purging The System, page 290-10-24.
2. When pressure is below 40 psi (2.76 bar) (2.82

2
kg/cm ) open low side valve.
3. Measure oil blown out of system after completely

(
discharged.
TM-1181 (Jun-80) Litho in US.A. Tractors - 4040 and 4240

Air Conditioning System Tests and Diagnosis 290-1 0-22a
>
>
TM-1181 (Jun-80) Litho In U.S.A.
. 1
290-1 0-22b Air Conditioning System Tests and Diagnosis Operator Station Operation and Tests
BENCH TESTING THERMAL An expansion valve should not be discarded until its
EXPANSION VALVE operation has been checked. Partial blockage in inlet

screen or excessive moisture in the system which
causes icing in the evaporator, can indicate the same
results as a faulty valve. Connect expansion valve as
shown in Fig.4 and use the following procedures to
test the expansion valve:
1 Close low and high gauge manifold valves (A and

B, Fig. 4),and install No. 2636 special tee fitting with
0.020 in. orifice cap to low side manifold connector.
2. Install No. 2632 special fitting (Fig. 4) on outlet of
expansion vaive.
3.Connect test hose from special fitting on outlet of

expansion valve to fitting on low side of manifold
gauge.
4. Install No. 2634 fitting on inlet of expansion valve

and connect test hose to it and high side of manifold
gauge.
5. hose to center fitting on manifold

install test
gauge and connect to R-12 container (C).
6. Place some ice in a container (E) with a small

amount of water and sprinkle some rock salt over ice to
obtain {-4 - 0C) 26 - 32T temperature.
7. Race some hot (43 - 58C) 1 5 - 1 25F water in
a second container (F).
8. Place R-12 can in container of warm water not

exceeding (52C) 125F.
9. Open valve on R-12 can.
10. Open high side manifold gauge valve to main-

tain (483 - 51 7 kPa) (4.8 - 5.0 bar) 70 - 75 psi on high
side gauge.
11. Hold sensing bulb in ice water until low side

gauge stabilizes. Pressure should be (138 - 172 kPa)
(1.4-1.7 bar) 20 -25 psi.
a) If pressure is above (172 kPa) (1.7 bar) 25

psi, valve did not close enough.
R349S2
b) If pressure is less than (1 38 kPa) (1 .4 bar) 20
A Low Side Valve DThermal Expansion Valve much.
psi, valve closed too
B High Side Valve E Container with Ice Water
C R-12 Container FContainer with Hot Water
4-Schematic Diagram for Testing Thermal
Fig.
Expansion Valves
i

Operator Station Operation and Tests Air Conditioning System Tests and Diagnosis 290-10-23
BENCH TESTING THERMAL 2. If R-12 or oil leakage was detected

and repaired,
EXPANSION VALVES Continued remove the compressor and measure oil drained (Fia
12. Hold sensing bulb in hot water until low side 6).
gauge pressure stabilizes.Pressure should be (275 -

380 kPa) (2.7 - 3.8 bar) 40 - 55 psL a) Less than 3 oz. (90 mL) of oil drained, add 8
oz. (240 mL} of new oil through drain port as in Fig. 5.
a) If pressure is above (380 kPa) (3.8 bar) 55
psi, valve is open too far. b) More than 3 oz. (90 mL) of oil drained, add 6.5
oz. (195 mL) of new oil through drain port as in Fig. 5,
b) If pressure is below (275 kPa) (2.7 bar) 40
psi,
valve did not open far enough. 3. When one of the following components is re-
placed add the corresponding volume of oil;
13. If valve does not meet specifications after

com-
pleting test as instructed above, replace thermal a) Compressor; Drain and add 6.5
ex- oil oz. (195
pansion valve. mL) (see above).
Adding Refrigerant Oil to the System b) Condenser; 1.0 oz. (30 mL) (see Fig. 5 and 6).
c) Evaporator: 1 .5 oz. (45 mL) (see below).
d) Receiver-dryer: 0.75 oz. (23 mL) (see below).
e) Any refrigerant line: 0.25 oz. (7 mL) each (see

below).
NOTE: Total oil charge is 1 1 oz. (330 mL).
R 31792
A-Squeeze Bottle B-Drain Port
Fig, 5-Adding Oil To Compressor
To determine oil charge needed: ?

1, After flushing the complete system, add 11 oz.
(330 mL) of oil through drain port of compressor with a
squeeze bottle.
NOTE: Use 525 viscosity oil only.

ft 31794
A^Low Side Vahre CSqueeze Bottfe

BHigh Side Valve Open
Fig, 7-Adding Oif To System
4. Adding a small amount of oil to the system after a

component has been repaired or replaced, (see below)
a) Connect gauge manifold hoses to compres-

sor test fittings as shown in Fig. 7.
R 31793
> b) Add measured amount of oil into suction test
Fig. 6-Draining Oil
hose with a squeeze bottle as shown in Fig. 7.
TM-1181 (Jun-80) Litho in US.A.

.
2. Check all refrigerant line and component fittings
for tightness.
R 31795
Fig. 6-Bfowing Oif into Compressor

R 31796
c) Connect a can of R-12 to suction hose as

shown in Fig. 6.
A Low Side Valve Open DVacuum Pump
B High Side Valve Open EVacuum Port
d) Open FM 2 can vaive for 5 seconds to blow oil
CCompressor
into compressor.
Fig. 7-Evacuating The System
Purging the System
3. Attach test hoses of gauge manifold to compres-
Purging the system decreases the amount of air and
sor test fittings as shown in Fig. 7.
moisture that could migrate into the system.
1 Purge the system with Dry Nitrogen or R-1 2 after
4. Attach a vacuum pump to center hose of gauge
flushing with R-11 or whenever a component is re-
manifold.
placed.
2. Purge the system with 5-20 psi (340-1380 mbar)
NOTE: Pump must be capable of pulling 28.6 in.
flow at point of gas entry as follows:
Hg. vacuum (sea level). Deduct 1 in. Hg. from 29.9 in.
a) Purge replacement components individually
for each 300 meters (1000 feet) elevation.
for 15-30 seconds.
Connect each component after purging.
b)
CAUTION: Do not operate compressor
Purge the total system through compressor
c)
during evacuation!
high side fitting toward condenser, receiver-dryer TEV,
evaporator and discharge from compressor low side
5. vacuum pump with both gauge manifold
Start
fitting.
valves and pump exhaust open.
3. Evacuate the system, below.
6. If pump does not reach deepest vacuum in 6

Evacuating the System
minutes, check system for leakage by slightly pressur-
1 . Always evacuate the system to remove air and ing the system with R-12- Then check the system for
moisture whenever the system has been discharged leakage with a leakage detector.
for the following reasons:
a) When moisture and refrigerant oil combine, 7. Evacuate the system for at least 30 minutes.
sludge is formed. Sludge does not allow moving parts
to be properly lubricated. NOTE: Ambient temperature must be above 29C
b) When moisture and refrigerant combine, hy- (85F) to remove moisture from the system with 28.6
drofluoric and hydrochloric acid is produced. Acids are in. Hg. vacuum at sea level.
highly corrosive to metal surfaces and leakage even-

tually develops.

Evacuating the SystemContinued

8. Before stopping vacuum
pump, close valves on
gauge manifold. There is excessive leakage
If the
vacuum decreases at a rate of 1 1n. Hg. in five
minutes
Locate and repair leakage.
9. Charge the system. See below.
Charging the System

Charging the system can be best
accomplished
(without bypassing the thermal fuse)
by adding FM2
into the discharge test fitting
as follows:
Engine "OFF". System holding a vacuum

1.
of at
least 28.6
in. Hg. (less 1 in. from
29.9 in. for each 300
meters (1000 feet) of elevation ft 31798
ALow Side Valve CR-12 Valve

B High Side Valve Open
Fig. 9-Chargmg The System
5. Fully open R-12 container

or charging station
valve and Invert container (Fig.
9).
6. Open high side valve of gauge manifold to allow

R-12 to enter the
condenser and receiver-dryer tf
charging system with 454
g (15 oz.) cans, close can
valve to change cans.
R 31797
ALow Side Valve Closed CFM2 Valve

BHigh Side Valve Closed DCenter Hose Fitting
Rq, 8-Charging the System
2. Connect R-12 container or charging station to

center hose of gauge manifold (Fig. 8).
3. Loosen fitting between center hose and gauae

manifold set (D, Fig. 8).
4. Open R-12 can valve (C) slightly with can upright A 31797
to purge charging hose. Then tighten center
hose
connection. ALow Side Valve Open C-Close Vah*
BHigh Side Valve Closed
Fig. 10-Charging The System
7. After high side pressure becomes

slow to in-
crease, open low side valve (A, Fig.
10).
TM-1181 (Jun-80) Litho in US. A

.
8. After low side pressure becomes slow to in- 4. Move sampling end of detector used from point to
crease, close high side valve (B). point and examine all joints and connections and any
other possible Since Refrigerant-12 is
leak point.
9. Close R-12 can valve and upright can. heavier than best to place the sampling end of
air, it is
the detector beneath the point being tested (see Fig,

Engine at 2000 RPM. Compressor "engaged".
10. 9). Do not move sampling end of detector faster than
Add R-12 untii system is charged with 4 lbs. (1.81 kg) 25.4 mm (1 in.) per second.
or bubbles disappear in receiver-drier sight glass.
Then add 484 g (16 oz.) to fully charge system, 5. After locating the leak, discharge the system of
refrigerant. Repair leak.

1 1 Check ambient temperature, system pressures,
and temperature from blower air ducts as instructed in 6. Check compressor oil and add if necessary
the diagnosing sequence. (page 290-10-23).
LEAK TESTING 7. Add and recheck for leaks.

refrigerant If no leaks
are present evacuate and charge system.
Several types of leak detectors are available to the
service technician. Carefully follow manufacturers in-
structions when using any detector.
1. Connect the manifold gauge set.
2. Close high and low side manifold hand valves.
Note pressure reading. 345 kPa (3.5 bar) (50 psi)

3.
isnecessary to detect leaks. If pressure is lower than
345 kPa (3.5 bar) (50 psi) refrigerant must be added.
To do this:
A. Attach center manifold hose to the refrigerant

container and purge hoses of air.
B. Open the refrigerant container service valve

and both manifold valves until 345 kPa (3.5 bar) (50
psi) is reached.
C. Close both manifold valves and refrigerant

service valve.
11 -Using Electronic Leak Detector D-1800SKD

Fig.
\

Heating System Operation and Tests 290-15*1
Group 15
HEATING SYSTEM
OPERATION AND TESTS
R 27057N
A Supply Hose (White

B Return Hose
Stripe, From Water
Manifold)
C Heater Core
D Heater Vaive
Fig. 1 -Heating
System
Referring to Fig.
1 coolant from the engine block (A)
,
The blower draws air through the heater core and
is carried byhoses and pipes to the heater core (C),
directs it inside the body. The blower used for heating
and then to the heater valve (D). The purpose
of the is the same one used for pressurizing and air condi-
valve is to permit or restrict flow of coolant
as desired tioning.
by the operator.
When the valve is open, coolant returns to the water

pump by-pass through a return hose (B).

290-15-2 Heating System Operation and Tests Operator Station Operation and Tests
DIAGNOSIS AND TESTING
When
PRELIMINARY CHECKS
experiencing heating system problems, first When an
ELECTRICAL TESTING
operated component in the
electrically
system fails to function properly, make the following
<
perform the following preliminary checks:
preliminary checks:
1. Determine ifthe engine coolant is at the proper
level and sufficiently warm to give the desired heating 1. Determine if adequate voltage is being supplied
results. to the malfunctioning component.
2. Check system air filters for restrictions, 2. Visually check for a loose connection or a broken
wire,
3. Check for drafts around doors and panels.

the source of trouble has not been found, after
!f
4. Check heater hoses for restrictions. making the preliminary checks, test the system for an
open circuit within each component. Use the wiring
Proceed with the below listed symptoms and causes diagrams (Section 240) as a guide for determining
when the preliminary checks have been performed and each circuit location.
the system stili fails to operate properly.
POSSIBLE SUGGESTED
Insufficient Heating
1. Faulty engine thermostat Replace (Section 20)
2. Foreign material in heater core or hoses Clean as required
3. Heater valve not working properly Replace valve (page 90-10-1)
4. Press urizer blowers not working properly Check circuits (Section 240); replace blowers
if required (page 90-05-22)
5. Obstruction in air inlet Clean as required; check filter element (page
90-05-23)
Inadequate Removal of Ice or Fog

1. Redirect air louvers Check effect of louvers in different posi-
tions
2. Press urizers blowers not working properly Check circuits (Section 240); replace blowers
required (page 90-05-22)
if
3. Heater valve not working properly Replace valve (page 90-10-1)
Heater Valve Not Shutting Off Coolant Flow

1. Inlet and outlet hoses reversed hoses as shown in Fig. 1 on previous
Install
page
2. Defective valve Replace valve (page 90-10-1)

Seat 290-20-1
Group 20
SEAT
R 28422IC
AVertical Suspension Assembly CCushions and Seat Beits

BHorizontal Suspension Assembly D Armrest Assembly
Ftg. UHydracushioned Seat Assembly
HYDRACUSHIONED SEAT SUSPENSION DIAGNOSIS

Horizontal Suspension Assembly Vertical Suspension Assembly
Seat Won't Center or Runs Against Ends of Travel Sluggish Position Lever
Broken seat cushion return spring - 90-15-16 Tangs of friction plate not around pin - 90-15-18
Failed shock absorber - 90-15-16 Foreign contaminants between friction plates -
90-15-18
Seat Suspension Seizes (Won't Move)
Failed seat rail bearings - 90-15-16 Suspension Won't Lower
Foreign materials under suspension

290-20-2 Seat Operator Station Operation and Tests
Litho in U.S.A.
TM-1181 (Feb-79)
y^. ^j^WLWN^^^B.TT.y^^^,
l
Lj
'^'"""h:^ , Wf
SAFETY
live with it

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4040 & 4240

Group 15 Lubrication Group 30 Dual-Speed PTO

Group 30 Power Front-Wheel Drive Group 10 Heating System

AH information, illustrations and specifications contained in this technical

TM-1181 (Sep-77) Litho in USA. Tractors - 4040 and 4240

SECTION 250 POWER TRAIN OPERATION AND

TM-1181 (Sep-77) Litho in U.S.A. Tractors - 4040 and 4240

General Specifications and Special Tools 10-00-1

GROUP 05 PREDELIVERY, DELIVERY, GROUP 20 SEPARATION

GROUP 10TUNE-UP Removing Front End 10-20-14

Preliminary Engine Testing 10-10-1 Removing Engine 10-20-18

HORSEPOWER (Factory observed PTO

TM-1181 (Jun-80) Litho in U.S.A. Tractors - 4040 and 4240

POWER SHIFT TRANSMISSION:

POWER FRONT-WHEEL DRIVE:

TM-1181 (Jun-80) Litho in U.S.A. Tractors - 4040 and 4240

Alternator 72-amp with SOUND-GARD body, 72-amp with SOUND-GARD body,

a 4240 Tractor with 18.4-38 tires.

POWER SHIFT TRANSMISSION

Gear 1500 rpm 2200 rpm 1500 rpm 2200 rpm

2 1.6 (2.6) 2.4 (3.9) 1.7 (2.7) 2.5 (4.0)

3 2.5 (4.0) 3.7 (6.0) 2.6 (4.2) 3.8 (6.2)

4 3.2 (5.2) 4.7 (7.6) 3.4 (4.9) 4.9 (7.9)

5 4.2 (6.8) 6.1 (9.8) 4.4(7.1) 6.5 (10.5)

6 5.4 (8.7) 7.9 (12.7) 5.7(9.2) 8.3 (13.4)

7 7.1 (11.4) 10.5(16.9) 7.6 (12.2) 11.2 (18.0)

8 11.9 (19.2) 17.5 (28.2) 12.9 (20.7) 18.9 (30.4)

1R 1.3(2.1) 1.9 (3.1) 1.5 (2.4) 2.2 (3.5)

2R 1.9 (3.1) 2.8 (4.5) 2.1 (3.4) 3.1 (5.0)

3R 2.9 (4.7) 4.3(6.9) 3.2(5.1) 4.7 (7.6)

4R 3.8 (6.1) 5.5 (8.9) 4.1 (6.6) 6.0 (9.7)

TM-1181 (Jun-80) Litho in U.S.A. Tractors - 4040 and 4240

1 1.3 (2.1) 1.9 (3.1) 1.4(2.2) 2.0 (3.2)

With optional Creeper engaged

5 0.9 (1.4) 1.3 (2.1) 1.0 (1.6) 1.3(2.2)

(Specifications and design subject to change without notice.)

TM-1181 (Jun-80) Litho in U.S.A. Tractors - 4040 and 4240

PREDELIVERY, DELIVERY, AND AFTER-SALE SERVICES

SOUND-GARD Body or Four-Post ROLL-GARD mounting bolts 150 200 20

Steel wheel-to-hub bolts 240 325 33

1/4 mm) 6 8 0.8 10 14 1.4 14 19 1.9

3/8 in. (9.53 mm) 23 31 3.1 35 47 4.7 50 70 /.U

7/16 in. (11.11 mm) 35 47 4.7 55 75 7,5 80 110 11

85 115 12 120 160 16

TM-1181 (Jun-80) Litho in U.S.A. Tractors - 4040 and 4240

Compression 370 to 400 psi (25.5 to 27.6 bar)

High pressure cap 14 to 1 7 psi (0.9 to 1 .2 bar)

Power Shift Transmission 1 1 .0 U.S. gal. (41 .6 L)

Power Shift Transmission 1 5.9 U.S. gal. (60.3 L)

TM-1181 (Jun-80) Litho in U.S.A. Tractors - 4040 and 4240

Fan belt tension New Belt

All belts 85-94 lbs. (378-423 N)

TM-1181 (Feb-78) Lhho in U.S.A. Tractors - 4040 and 4240

Fig. 1-JDG-18 Snap Ring Tool"

JDE-S1-1 Engine Rotation Turn engine to TOC to check

A-^JDE-81-1 Engine Rotation Tool*

Fig. 2-Toois Required for Checking Timing

JDE-28 Adapter and Hand Check engine speeds