John Deere 4990 Repair Technical Manual TM1819

Data Size: 18.94 MB 
File Type: PDF 
Language: English 
Manufacturer: John Deere 
Applicable Machine: Self-Propelled Windrower 
Document: Repair Technical Manual 
Machine Model: John Deere 4990 Self-Propelled Windrower 
Book Number: TM1819 
Publication Date: 2001 
Page: 521 Pages

List 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​ 
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