John Deere Self-Propelled Windrower 4990 Repair Technical Manual TM1819

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John Deere Self-Propelled Windrower 4990 Repair Technical Manual TM1819
Size: 18.94 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Self-Propelled Windrower
Type of Manual: Repair Technical Manual
Model: John Deere 4990 Self-Propelled Windrower
Part Number: TM1819
Publication Date: 2001
Number of Pages: 521 Pages

Contents:
General

Safety​

Recognize Safety Information​

Understand Signal Words​

Handle Fluids Safely-Avoid Fires​

Prevent Battery Explosions​

Prepare For Emergencies​

Prevent Acid Burns​

Handle Chemical Products Safely​

Avoid High-Pressure Fluids​

Park Windrower Safely​

Stay Clear of Rotating Driveline​

Support Machine Properly​

Wear Protective Clothing​

Work In Clean Area​

Service Machines Safely​

Work In Ventilated Area​

Illuminate Work Area Safely​

Replace Safety Signs​

Use Proper Lifting Equipment​

Remove Paint Before Welding or Heating​

Avoid Heating Near Pressurized Fluid Lines​

Service Tires Safely​

Avoid Harmful Asbestos Dust​

Practice Safe Maintenance​

Use Proper Tools​

Construct Dealer-Made Tools Safely​

Dispose of Waste Properly​

Live With Safety​

Practice Safe Service Procedures​

Specifications​

4990 (S.N. -163100) Self-Propelled Windrower Specifications [Specifications and design subject to change without notice.]​

4990 (S.N. 163101-) Self-Propelled Windrower Specifications [Specifications and design subject to change without notice.]​

Dimensions​

Metric Bolt and Cap Screw Torque Values​

Unified Inch Bolt and Cap Screw Torque Values​

Service Recommendations For O-Ring Boss Fittings​

Service Recommendations For Flat Face O-Ring Seal Fittings​

Service Recommendations For 37° Flare and 30° Cone Seat Connectors​

Service Recommendations For Flare-Type Tube Fittings​

SAE Four Bolt Flange Fitting Torque Chart​

Product Identification Number Plate​

Windrower Product Identification Number Plate Location​

Engine Serial Number​

Fuel Injection Pump Serial Number​

Cab Serial Number​

Fuel, Coolant and Lubricants​

Diesel Fuel​

Diesel Fuel Storage​

Lubricity of Diesel Fuel​

Diesel Engine Coolant​

Supplemental Coolant Additives​

Operating in Warm Temperature Climates​

Diesel Engine Coolants, Supplemental Additive Information​

Testing Diesel Engine Coolant​

Diesel Engine Oil​

Diesel Engine Break-In Oil​

Hydrostatic Drive System and Main Hydraulic System Oil​

Final Drive Oil​

Grease​

Alternative and Synthetic Lubricants​

Lubricant Storage​

Engine

Engine​

John Deere Engine Repair-Use CTM104​

Essential or Recommended Tools​

Service Equipment and Tools​

Specifications​

Remove and Install Engine​

Checking Vibration Damper​

Replace Vibration Damper​

Replace Engine Mount Isolators​

Remove and Install Serpentine Belt​

Cooling System​

Engine Water Pump Repair-Use CTM104​

Essential or Recommended Tools​

Other Material​

Specifications​

Inspect Cooling System​

Remove and Install Radiator​

Disassemble, Inspect and Assemble Radiator Assembly​

Fill Radiator​

Winterize Cooling System​

Flush Out Cooling System​

Fuel and Air Systems

Air Intake and Exhaust​

Turbocharger Repair-Use CTM104​

Cleaning Bowl-Type Air Precleaner​

Cleaning Precleaner Screen​

Cleaning Air Precleaner​

Remove and Install Air Filters​

Clean and Inspect Primary Air Filter​

Remove and Install Air Precleaner and Intake Tube​

Remove and Install Exhaust Tube​

Diesel Fuel System​

Injection Pump, Nozzle, and Governor Repair-Use CTM207​

Specifications​

Shut Off Fuel Supply​

Drain Fuel Tank​

Remove and Install Fuel Tank​

Do Not Modify Fuel System​

Drain Water From Fuel Filter​

Bleed Fuel Filter​

Change Fuel Filter​

Bleed Fuel Injection Pump​

Bleed Fuel Lines to Injectors​

Check and Set Engine Speed​

Electrical

Batteries​

Specifications​

Remove and Install Battery(ies)​

Using Booster Batteries-12 Volt System​

Charging Battery(ies)​

Checking Specific Gravity​

Starter​

Starter Repair-Use CTM77​

Specifications​

Remove and Install Starter Motor​

Alternator​

Alternator Repair-Use CTM77​

Remove and Install Alternator​

Engine Electrical Components​

Other Material​

Replace Fuel Level Sensor​

Replace Air Restriction Switch​

Replace Engine Coolant Temperature Switch​

Replace Engine Coolant Temperature Sensor​

Replace Engine Oil Pressure Switch​

Replace Engine Speed Sensor​

Replace Throttle Motor​

Disassemble and Inspect Throttle Motor​

Remove Rotating Wand Motor​

Rotating Wand Motor-Exploded View​

Install Rotating Wand Motor​

Lighting and Accessory Components​

Service Equipment and Tools​

Specifications​

Halogen Bulb Safety Guidelines​

Replace and Adjust Cab Headlight Bulb​

Replace Flood Light Bulb​

Replace Rear Warning, Tail, and Side Marker Light Bulbs​

Replace Turn Signal Indicator Bulb​

Replace Dome and Console Light Bulb​

Replace Key Switch​

Replace Light Switch, Light Panel Dimmer, and Wiper Switch (S.N. -163100)​

Replace Light Switches and Wiper Switch (S.N. 163101-)​

Replace Turn Signal Switch (S.N. -163100)​

Replace Turn Signal Switch (S.N. 163101-)​

Replace Horn Switch​

Replace Horn​

Replace Overhead Console Horn​

Replace Seat Switch (S.N. -163100)​

Replace Seat Switch (S.N. 163101-)​

Replace Wiper Motor​

Adjust Windshield Wiper-Short Arm​

Adjust Windshield Wiper-Long Arm (Optional)​

Replace Radio (S.N. -163100)​

Replace Radio (S.N. 163101-)​

Replace Radio Speaker​

Replace Radio Antenna​

Mount Communications/CB Radio​

Install FM Radio​

Gauges and Monitors​

Replace Warning Panel or Light Bulbs​

Replace Gauges or Gauge Light Bulbs​

Replace Tachometer​

Program Tachometer​

Platform and Ground Speed Controls​

Essential or Recommended Tools​

Service Equipment and Tools​

Specifications​

Replace Armrest Console Rocker Switches (S.N. -163100)​

Replace Armrest Console Rocker Switches (S.N. 163101-)​

Replace Armrest Console Toggle Switches (S.N. -163100)​

Replace Armrest Console Circuit Board (S.N. -163100)​

Replace Hydro Lever Switch Module​

Replace Hydro Lever Neutral Switch (S.N. -163100)​

Replace Hydro Lever Neutral Switch (S.N. 163101-)​

Remove and Install Hydro Lever (S.N. -163100)​

Remove and Install Hydro Lever (S.N. 163101-)​

Replace Platform Speed Control​

Disassemble and Inspect Platform Speed Control​

Replace Steering Neutral Start Switch​

Replace Hydraulic Filter Restriction Switch​

Replace Hydraulic Charge Pressure Switch​

Replace Hydraulic Oil Temperature Switch​

Replace Hydraulic Float Pressure Transducer​

Replace Ground Speed Sensor​

Adjust Ground Speed Sensor Magnetic Pickup​

Replace Solenoid Coils​

Cab Heat and A/C Electrical Components​

Other Material​

Replace Air Conditioning Switch (S.N. -163100)​

Replace Blower Motor Control Switch (S.N. -163100)​

Replace Blower Motor Control Switch (S.N. 163101-)​

Replace Air Conditioning Temperature Control Switch (S.N. 163101-)​

Replace Blower Motor​

Replace Blower Motor Resistor​

Replace Cab Pressurizer Motor​

Replace Air Conditioning Thermostat​

Replace Air Conditioning Low Pressure Switch​

Replace Air Conditioning High Pressure Switch​

Connector Repair​

Essential or Recommended Tools​

Other Material​

Electrical Connector Handling​

Use Contact Cleaner and Di-electric Grease​

Replace WEATHER PACK Connector​

Install WEATHER PACK Terminal​

Remove Connector Body from Blade Terminals​

Replace METRI-PACK (Push Type) Connectors​

Replace CPC, Large MATE-N-LOK and METRIMATE™ Pin Type Connectors​

Replace DEUTSCH Connectors​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Power Train

Hydrostatic System Flushing and Start-Up​

Specifications​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Flush Hydrostatic Ground Drive System​

Hydrostatic Ground Drive System Start-Up​

Pump Drive Gear Case​

Essential or Recommended Tools​

Service Equipment and Tools​

Other Material​

Remove and Install Pump Drive Gear Case​

Disassemble and Inspect Pump Drive Gear Case​

Assemble Pump Drive Gear Case​

Circulating Pump and Oil Cooler​

Essential or Recommended Tools​

Service Equipment and Tools​

Other Material​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Remove and Install Circulating Pump​

Disassemble Circulating Pump​

Inspect Circulating Pump​

Assemble Circulating Pump​

Clean Pump Drive Gear Case Oil Cooler​

Replace Pump Drive Gear Case Oil Cooler​

Ground Drive Pumps​

Essential or Recommended Tools​

Service Equipment and Tools​

Other Material​

Specifications​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Remove and Install Right-Hand Ground Drive Pump​

Disassemble Ground Drive Pump​

Inspect Ground Drive Pump​

Assemble Ground Drive Pump​

Ground Drive Motor​

Essential or Recommended Tools​

Service Equipment and Tools​

Other Material​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Remove and Install Ground Drive Motor​

Disassemble Ground Drive Motor​

Inspect Ground Drive Motor​

Assemble Ground Drive Motor​

Final Drive (S.N. -163100)​

Essential or Recommended Tools​

Service Equipment and Tools​

Other Material​

Specifications​

Remove and Install Final Drive​

Disassemble and Inspect Final Drive​

Assemble Final Drive​

Final Drive (S.N. 163101-)​

Essential Tools or Recommended Tools​

Service Equipment and Tools​

Other Material​

Specifications​

Remove and Install Final Drive​

Disassemble Final Drive Hub​

Assemble Final Drive Hub​

Ground Drive Linkage (S.N. -163100)​

Remove and Install Ground Drive Control Cables​

Remove and Install Ground Drive Linkage Rods​

Ground Drive Linkage (S.N. 163101-)​

Remove and Install Ground Drive Control Cable​

Remove and Install Ground Drive Linkage Rods​

Steering and Brakes

Steering System (S.N. -163100)​

Service Equipment and Tools​

Other Material​

Specifications​

Remove Steering Mechanism​

Disassemble and Inspect Steering Mechanism​

Assemble Steering Mechanism​

Install Steering Mechanism​

Disassemble and Assemble Steering Column​

Steering System (S.N. 163101-)​

Other Material​

Specifications​

Remove Steering Mechanism​

Disassemble and Inspect Steering Mechanism​

Assemble Steering Mechanism​

Install Steering Mechanism​

Disassemble and Assemble Steering Column​

Brakes​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Specifications​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Remove and Install Brake Disk and Caliper​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Inspect Brake Disk and Caliper Components​

Assemble Brake Disk and Caliper​

Hydraulic System

Auxiliary-Charge Pump​

Essential or Recommended Tools​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Other Material​

Specifications​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Disassemble Auxiliary-Charge Pump​

Inspect Auxiliary-Charge Pump​

Assemble Auxiliary-Charge Pump​

Platform Drive Pump​

Essential or Recommended Tools​

Service Equipment and Tools​

Other Material​

Specifications​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Disassemble Platform Drive Pump​

Inspect Platform Drive Pump​

Assemble Platform Drive Pump​

Repair Control Valve​

Disassemble and Assemble End Cover​

Check and Adjust Platform Drive Speed​

Platform Drive Motor​

Essential or Recommended Tools​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Other Material​

Specifications​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Disassemble Platform Drive Motor​

Inspect Platform Drive Motor​

Assemble Platform Drive Motor​

Main Hydraulic Control Valve​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Specifications​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Remove and Install Main Hydraulic Control Valve​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Replace Solenoid Coils and Valve Cartridges​

Hydraulic Cylinders​

Service Equipment and Tools​

Other Material​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Remove and Install Lift and Tilt Cylinders, and Float Cylinders with Adjusters​

Disassemble and Inspect Float Cylinder​

Assemble Float Cylinder​

Replace Float Cylinder End Block Needle Bearings​

Repair Lift Cylinder​

Disassemble and Inspect Tilt Cylinder​

Assemble Tilt Cylinder​

Repair Steering Lock Cylinder​

Miscellaneous​

Essential or Recommended Tools​

Specifications​

Flat Face O-Ring vs. Flare Hydraulic Fittings (S.N. 151107-)​

Clean Oil Cooler/Condenser​

Replace Oil Cooler/Condenser​

Replace Hydraulic Accumulator​

Drain and Fill Hydraulic Reservoir​

Remove and Install Hydraulic Reservoir​

Miscellaneous

Rear Axle​

Service Equipment and Tools​

Other Material​

Specifications​

Repair Caster Wheel Hub​

Remove and Install Axle Knee​

Remove and Inspect Rear Axle Assembly​

Install Rear Axle Assembly​

Replace Axle Knee Bushings​

Replace Rear Axle Bushings​

Adjust Caster Wheel Track Width​

Drive Wheels​

Specifications​

Remove and Install Drive Wheels​

Lift Arm​

Service Equipment and Tools​

Specifications​

Replace Lift Arm Bearings​

Operator Station

Air Conditioning Service​

Essential or Recommended Tools​

Other Material​

Specifications​

General Information​

R134a Refrigerant Cautions​

Air Conditioning System-Diagram​

Proper Refrigerant Handling​

Refrigerant Hoses and Tubing Inspection​

Recover R134a System​

Flush Air Conditioning System​

Purge Air Conditioning System​

Evacuate R134a System​

Charge R134a System​

Refrigerant Oil Information​

Check Compressor Oil Charge​

Determine Correct Refrigerant Oil Charge​

Add Refrigerant Oil to Pressurized System​

Add Refrigerant Oil to System​

Air Conditioning Repair​

Essential or Recommended Tools​

Service Equipment and Tools​

Other Material​

Service Parts Kits​

Specifications​

Remove and Install Compressor​

Remove and Install Compressor Clutch Assembly​

Check Clutch Hub Clearance​

Inspect Compressor Manifold​

Inspect Compressor Thermal Bypass Valve​

Disassemble and Inspect Compressor​

Assemble Compressor​

Replace Receiver-Dryer​

Remove and Install Compressor Relief Valve​

Remove Evaporator/Heater Core​

Install Evaporator/Heater Core​

Cleaning Condenser​

Repair Condenser​

Heater Controls​

Replace Heater Control Valve (S.N. -163100)​

Replace Heater Control Valve (S.N. 163101-)​

Cab (S.N. -163100)​

Service Equipment and Tools​

Specifications​

Remove and Install Windshield​

Replace Rear Window​

Remove and Install Cab Roof​

Remove Operator’s Seat Air Suspension Assembly​

Disassemble Operator’s Seat Air Suspension Assembly​

Inspect Operator′s Seat Air Suspension Assembly​

Assemble Operator’s Seat Air Suspension Assembly​

Install Operator’s Seat Air Suspension Assembly​

Replace Cab Mount Isolators​

Adjust Hydrostatic Ground Drive​

Cab (S.N. 163101- )​

Service Equipment and Tools​

Specifications​

Remove and Install Windshield​

Replace Rear Window​

Remove and Install Cab Roof​

Remove and Install Operator′s Seat​

Operator Seat Exploded View​

Operator Seat Air Suspension Assembly-Exploded View​

Disassemble Operator′s Seat Air Suspension Assembly​

Assemble Operator′s Seat Air Suspension Assembly​

Replace Cab Mount Isolators​

Check Hydrostatic Ground Drive​

Adjust Hydrostatic Ground Drive​

Dealer Fabricated Tools

Dealer Fabricated Tools​

DFEX1819A Spindle Retaining Tool (S.N. -163100)​

DFEX1819B Rolling Drag Torque Bar (S.N. -163100)​

DFEX1819C Guide​

DFEX1819D Compressor Holding Fixture​

DFEX1819E Support Plate​

Page Number